U.S. patent application number 11/312731 was filed with the patent office on 2007-06-21 for braze cladding for direct metal laser sintered materials.
Invention is credited to David Edwin Budinger, Ronald Lance Galley, David Allen Kastrup, Ashwin Sreekant Raghavan.
Application Number | 20070141375 11/312731 |
Document ID | / |
Family ID | 38173957 |
Filed Date | 2007-06-21 |
United States Patent
Application |
20070141375 |
Kind Code |
A1 |
Budinger; David Edwin ; et
al. |
June 21, 2007 |
Braze cladding for direct metal laser sintered materials
Abstract
A direct metal laser sintered material including a substrate
formed from a laser sintering process, the substrate having at
least one surface, and a cladding material brazed onto at least a
portion of the surface.
Inventors: |
Budinger; David Edwin;
(Loveland, OH) ; Galley; Ronald Lance; (Mason,
OH) ; Raghavan; Ashwin Sreekant; (Dayton, OH)
; Kastrup; David Allen; (West Chester, OH) |
Correspondence
Address: |
GENERAL ELECTRIC COMPANY
GE AVIATION
ONE NEUMANN WAY MD H17
CINCINNATI
OH
45215
US
|
Family ID: |
38173957 |
Appl. No.: |
11/312731 |
Filed: |
December 20, 2005 |
Current U.S.
Class: |
428/548 ; 419/9;
428/627 |
Current CPC
Class: |
Y10T 428/12965 20150115;
Y10T 428/12063 20150115; B23K 2103/26 20180801; B23K 35/004
20130101; C23C 24/10 20130101; B23K 26/34 20130101; B23K 26/32
20130101; B23K 2103/50 20180801; B23K 2103/18 20180801; Y10T
428/12944 20150115; B33Y 40/00 20141201; B23K 1/0056 20130101; B23K
2103/08 20180801; B23K 35/007 20130101; B23K 2103/04 20180801; Y02P
10/25 20151101; Y10T 428/12028 20150115; B22F 7/08 20130101; Y10T
428/12576 20150115; B22F 2998/10 20130101; B23K 2101/001 20180801;
Y10T 428/12042 20150115; B22F 2998/10 20130101; B22F 10/20
20210101; B22F 7/08 20130101; B22F 2998/10 20130101; B22F 10/20
20210101; B22F 7/08 20130101 |
Class at
Publication: |
428/548 ;
428/627; 419/009 |
International
Class: |
B22F 7/02 20060101
B22F007/02 |
Claims
1. A direct metal laser sintered material comprising: a substrate
formed from a laser sintering process, said substrate having at
least one surface; and a cladding material brazed onto at least a
portion of said surface.
2. The material of claim 1 wherein said substrate includes at least
one of a steel-based material and a bronze-based material.
3. The material of claim 2 wherein said steel-based material and
said bronze-based material are generally non-shrinking.
4. The material of claim 1 wherein said substrate includes is at
least one of DirectSteel 50, DirectSteel 20, DirectSteel H20,
DirectMetal 50 and DirectMetal 20.
5. The material of claim 1 wherein said substrate is formed from a
direct metal laser sintering process.
6. The material of claim 1 wherein said cladding material is
adapted to wet said surface when said cladding material is in a
molten state.
7. The material of claim 1 wherein said cladding material has a
composition selected such that said cladding material is corrosion
resistant.
8. The material of claim 1 wherein said cladding material has the
following composition: about 82 wt % gold and about 18 wt %
nickel.
9. The material of claim 1 wherein said cladding material is an
alloy selected from the group consisting of AMS 4765, AMS 4772, AMS
4777, AMS 4778, AMS 4779, AMS 4782, AMS 4787, AMS 4784, AMS 4785,
AMS 4786, B50TF145 and B50TF198.
10. A method for treating a surface of a laser sintered material
comprising the steps of: applying a cladding material to at least a
portion of said surface of said laser sintered material; and
heating said cladding material such that said cladding material
melts and wets said surface.
11. The method of claim 10 wherein said cladding material is
applied to said surface as a powder.
12. The method of claim 10 wherein said applying step includes
generally evenly distributing said cladding material on said
surface.
13. The method of claim 10 wherein said laser sintered material is
a material formed during a direct metal laser sintering
process.
14. The method of claim 10 wherein said laser sintered material
includes at least one of DirectSteel 50, DirectSteel 20,
DirectSteel H20, DirectMetal 50 and DirectMetal 20.
15. The method of claim 10 wherein said cladding material has a
composition selected such that said cladding material is corrosion
resistant.
16. The method of claim 10 wherein said cladding material has the
following composition: about 82 wt % gold and about 18 wt %
nickel.
17. The method of claim 10 wherein said cladding material is an
alloy selected from the group consisting of AMS 4765, AMS 4772, AMS
4777, AMS 4778, AMS 4779, AMS 4782, AMS 4787, AMS 4784, AMS 4785,
AMS 4786, B50TF145 and B50TF198.
18. The method of claim 10 wherein said heating step includes
heating said cladding material to a temperature in excess of a
liquidus temperature of said cladding material.
19. The method of claim 10 wherein said heating step is conducted
under a protective atmosphere, said protective atmosphere including
at least one of a vacuum, an argon atmosphere and a hydrogen
atmosphere.
20. A direct metal laser sintered material comprising: a substrate
formed by laser sintering a steel-based powder; and a gold/nickel
alloy cladding material brazed onto at least a portion of said
substrate.
Description
BACKGROUND OF THE INVENTION
[0001] The present application relates to surface treatments for
direct metal laser sintered materials and the like and, more
particularly, to braze claddings for direct metal laser sintered
materials.
[0002] Rapid prototyping techniques, such as direct metal laser
sintering ("DMLS"), have been used to rapidly prototype and
manufacture various mechanical parts, such as fuel nozzles and fuel
circuits for aircraft engines. Rapid prototyping techniques
typically operate by depositing multiple layers of material,
thereby incrementally (i.e., in layers) forming the overall part.
Each layer may be about 5 to about 100 .mu.m thick, depending on
the technique used and the type of material being deposited.
[0003] The DMLS process has been used to form metallic parts using
a laser sintering process. In particular, the DMLS process
precisely deposits metal powders in thin layers and the deposited
powders are sintered by the laser, thereby forming a generally
rigid layer. The metal powders may be steel-based powders,
bronze-based powders or the like.
[0004] Despite the advantages (e.g., prototyping time savings)
achieved by the DMLS process, direct metal laser sintered materials
often are porous and include crevices, ridges, interconnected
channels and other surface defects. The channels may potentially
give rise to leaks (e.g., fuel leaks) and the surface defects may
provide locations where particles and debris may be deposited,
thereby obstructing fluid flow and/or causing turbulent flow. For
example, surface defects may increase the tendency for coke
formation in fuel circuits formed from direct metal laser sintered
materials. Furthermore, direct metal laser sintered materials may
be used in highly corrosive environments (e.g., as fuel nozzles in
direct contact with fuel) and therefore may be subjected to
chemical degradation.
[0005] Accordingly, there is a need for a system and method for
treating the surface of direct metal laser sintered materials to
improve corrosion resistance and reduce surface defects.
BRIEF DESCRIPTION OF THE INVENTION
[0006] In one aspect, a direct metal laser sintered material is
provided, wherein the direct metal laser sintered material includes
a substrate formed from a laser sintering process, the substrate
having at least one surface, and a cladding material brazed onto at
least a portion of the surface.
[0007] In another aspect, a method for treating a surface of a
laser sintered material is provided. The method includes the steps
of applying a cladding material to at least a portion of the
surface of the laser sintered material and heating the cladding
material such that the cladding material melts and wets the
surface.
[0008] In another aspect, a direct metal laser sintered material is
provided, wherein the direct metal laser sintered material includes
a substrate formed by laser sintering a steel-based powder and a
gold/nickel alloy cladding material brazed onto at least a portion
of the substrate.
[0009] Other aspects of the present invention will become apparent
from the following detailed description and the appended
claims.
BRIEF DESCRIPTION OF THE DRAWING
[0010] FIG. 1 is a photograph of the longitudinal cross section of
a direct metal laser sintered material having an untreated outer
(i.e., top) surface and an inner (i.e., bottom) surface treated
according to an aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0011] As used herein, "direct metal laser sintered material"
refers to any material, device, part or component subjected to,
formed from or formed during a laser sintering process. In one
aspect, the direct metal laser sintered material includes generally
non-shrinking metal powders sintered by a laser. In another aspect,
the direct metal laser sintered material includes a bronze-based
matrix including Ni, a steel-based matrix including Ni or a steel
alloy containing Cr, Ni, Mo, Si, V and/or C. For example, direct
metal laser sintered materials may include DirectSteel 50,
DirectSteel 20, DirectSteel H20, DirectMetal 50 and DirectMetal 20.
DirectSteel and DirectMetal are registered trademarks of EOS GmbH
Electro Optical Systems.
[0012] According to one aspect of the present invention, a cladding
material may be applied to the surface of a direct metal laser
sintered material and brazed at the appropriate temperature for the
appropriate time, thereby allowing the cladding material to melt,
flow and wet the surface of the direct metal laser sintered
material. As the cladding material wets the surface of the
material, the cladding material may flow through and fills the
crevices, ridges, interconnected channels and/or other surface
defects of the direct metal laser sintered material, leaving a
generally smooth and/or more corrosion resistant surface.
[0013] In another aspect, the composition of the cladding material
may be selected such that the cladding material is corrosion
resistant. For example, corrosion resistance may be achieved by
using a cladding material having a high gold (or other precious
metal) content. In another aspect, the composition of the cladding
material may be selected such that the cladding material is
ductile, thereby preventing cracking during thermal cycling. For
example, ductility may be achieved by using a cladding material
having a high copper content. In another aspect, the composition of
the cladding material may be selected such that the cladding
material has improved wettability. For example, wettability may be
increased by increasing the nickel content of the cladding
material.
[0014] The cladding material according to an aspect of the present
invention may be any material capable of melting, flowing and
wetting the surface of direct metal laser sintered materials. In
one aspect, the cladding material may include silver alloys. In
another aspect, the cladding material may include nickel alloys. In
another aspect, the cladding material may include precious metal
(e.g., gold and/or palladium) alloys. In another aspect, the
cladding material may include cobalt alloys.
[0015] In one aspect, a silver alloy cladding material may include
at most about 93 wt % silver, at most about 43 wt % copper, at most
about 35 wt % zinc, at most about 5 wt % nickel, at most about 10.5
wt % tin, at most about 0.5 wt % lithium and/or at most about 14 wt
% manganese, with at most about 0.15 wt % other elements.
[0016] A first example of a silver alloy cladding material
according to an aspect of the present invention is AMS 4765 or the
like and may include about 47 to about 65 wt % Ag, about 41 to
about 43 wt % Cu and about 1.5 to about 2.5 wt % Ni.
[0017] A second example of a silver alloy cladding material
according to an aspect of the present invention is AMS 4772 or the
like (solidus temperature of about 1325.degree. F. and liquidus
temperature of about 1575.degree. F.) and may include about 53 to
about 55 wt % Ag, about 39 to about 41 wt % Cu, about 4 to about 6
wt % Zn and about 0.5 to about 1.5 wt % Ni, with up to about 0.15
wt % other elements.
[0018] In one aspect, a nickel alloy cladding material may include
at most about 91.5 wt % nickel, at most about 18 wt % chromium, at
most about 3.5 wt % boron, at most about 8 wt % silicon, at most
about 5 wt % iron, at most about 0.9 wt % carbon, at most about 12
wt % phosphorus, at most about 0.02 wt % sulfur, at most about 0.05
wt % aluminum, at most about 0.05 wt % titanium, at most about 24.5
wt % manganese, at most about 5 wt % copper, at most about 0.05 wt
% zirconium, at most about 17 wt % tungsten, at most about 0.1 wt %
cobalt and/or at most about 0.0005 wt % selenium, with at most
about 0.5 wt % other elements.
[0019] A first example of a nickel alloy cladding material
according to an aspect of the present invention is AMS 4777 or the
like (solidus temperature of about 1780.degree. F. and liquidus
temperature of about 1830.degree. F.) and may include about 6 to
about 8 wt % Cr, about 2.75 to about 3.5 wt % B, about 4 to about 5
wt % Si, about 2.5 to about 3.5 wt % Fe, at most about 0.06 wt % C,
at most about 0.02 wt % P, at most about 0.02 wt % S, at most about
0.05 wt % Al, at most about 0.05 wt % Ti, at most about 0.05 wt %
Zr, at most about 0.005 wt % Se, at most about 0.1 wt % Co, at most
about 0.5 wt % other elements and the balance Ni.
[0020] A second example of a nickel alloy cladding material
according to an aspect of the present invention is AMS 4778 or the
like (solidus temperature of about 1796.degree. F. and liquidus
temperature of about 1904.degree. F.) and may include about 2.75 to
about 3.5 wt % B, about 4 to about 5 wt % Si, at most about 0.5 wt
% Fe, at most about 0.06 wt % C, at most about 0.02 wt % P, at most
about 0.02 wt % S, at most about 0.05 wt % Al, at most about 0.05
wt % Ti, at most about 0.05 wt % Zr, at most about 0.005 wt % Se,
at most about 0.1 wt % Co, at most about 0.5 wt % other elements
and the balance Ni.
[0021] A third example of a nickel alloy cladding material
according to an aspect of the present invention is AMS 4779 or the
like (solidus temperature of about 1800.degree. F. and liquidus
temperature of about 1950.degree. F.) and may include about 1.5 to
about 2.2 wt % B, about 3 to about 4 wt % Si, at most about 1.5 wt
% Fe, at most about 0.06 wt % C, at most about 0.02 wt % P, at most
about 0.02 wt % S, at most about 0.05 wt % Al, at most about 0.05
wt % Ti, at most about 0.05 wt % Zr, at most about 0.005 wt % Se,
at most about 0.1 wt % Co, at most about 0.5 wt % other elements
and the balance Ni.
[0022] A fourth example of a nickel alloy cladding material
according to an aspect of the present invention is AMS 4782 or the
like (solidus temperature of about 1975.degree. F. and liquidus
temperature of about 2075.degree. F.) and may include at most about
0.05 wt % B, about 9.75 to about 10.5 wt % Si, at most about 0.5 wt
% Fe, at most about 0.1 wt % C, at most about 0.02 wt % P, at most
about 0.02 wt % S, at most about 0.05 wt % Al, at most about 0.05
wt % Ti, at most about 0.05 wt % Zr, at most about 0.005 wt % Se,
at most about 0.1 wt % Co, at most about 0.5 wt % other elements
and the balance Ni.
[0023] In one aspect, a precious metal alloy cladding material may
include at most about 82 wt % gold, at most about 62.9 wt % copper,
at most about 60 wt % palladium, at most about 66.5 wt % nickel, at
most about 13 wt % chromium, at most about 2.6 wt % iron, at most
about 3.8 wt % silicon and/or at most about 2.4 wt % boron, with at
most about 0.15 wt % other elements.
[0024] A first example of a precious metal alloy cladding material
according to an aspect of the present invention is AMS 4787 or the
like (solidus and liquidus temperature at about 1740.degree. F.)
and may include about 81.5 to about 82.5 wt % Au and about 17.5 to
about 18.5 wt % Ni.
[0025] A second example of a precious metal alloy cladding material
according to an aspect of the present invention is AMS 4784 or the
like (solidus temperature of about 2015.degree. F. and liquidus
temperature of about 2050.degree. F.) and may include about 49.5 to
about 50.5 wt % Au, about 24.5 to about 25.5 wt % Ni and about 24.5
to about 25.5 wt % palladium.
[0026] A third example of a precious metal alloy cladding material
according to an aspect of the present invention is AMS 4785 or the
like (solidus temperature of about 2075.degree. F. and liquidus
temperature of about 2130.degree. F.) and may include about 29.5 to
about 30.5 wt % Au, about 35.5 to about 36.5 wt % Ni and about 33.5
to about 34.5 wt % palladium.
[0027] A fourth example of a precious metal alloy cladding material
according to an aspect of the present invention is AMS 4786 or the
like (solidus temperature of about 1845.degree. F. and liquidus
temperature of about 1915.degree. F.) and may include about 69.5 to
about 70.5 wt % Au, about 21.5 to about 22.5 wt % Ni and about 7.5
to about 8.5 wt % palladium.
[0028] A fifth example of a precious metal alloy cladding material
according to an aspect of the present invention is B50TF145 (Au 6)
or the like (solidus temperature of about 1845.degree. F. and
liquidus temperature of about 1915.degree. F.) and may include
about 20 to about 21 wt % Au, about 3.0 to about 3.6 wt % Si, about
1.8 to 2.4 wt % B, about 5 to about 6 wt % Cr, about 1.7 to about
2.8 wt % Fe, at most about 0.5 wt % Co, at most about 0.001 wt %
Zn, at most about 0.001 wt % Cd, at most about 0.002 wt % Pb, at
most about 0.002 wt % P, at most about 0.03 wt % C, at most about
0.005 wt % Se, at most about 0.01 wt % S, at most about 0.02 wt % O
and the balance Ni, with at most about 0.1 wt % other elements.
[0029] A sixth example of a precious metal alloy cladding material
according to an aspect of the present invention is B50TF198
(M.sup.385) or the like (solidus temperature of about 1725.degree.
F. and liquidus temperature of about 1780.degree. F.) and may
include about 30 to about 31 wt % Pd, about 2.3 to 2.6 wt % B,
about 10 to about 11 wt % Cr, at most about 0.02 wt % N, at most
about 0.05 wt % Mo, at most about 0.05 wt % Zr, at most about 0.03
wt % C, at most about 0.01 wt % S, at most about 0.002 wt % P, at
most about 0.005 wt % Se, at most about 0.05 wt % W and at most
about 0.02 wt % 0, at most about 0.5 wt % Fe, at most about 0.05 wt
% Ti and at most about 0.1 wt % Mn, with at most about 0.1 wt %
other elements.
[0030] In one aspect, a cobalt alloy cladding material may include
at most about 93 wt % cobalt, at most about 18 wt % nickel, at most
about 20 wt % chromium, at most about 8.5 wt % silicon, at most
about 4 wt % boron, at most about 5 wt % tungsten, at most about
0.5 wt % carbon, at most about 0.05 wt % titanium, at most about
0.05 wt % aluminum, at most about 0.05 wt % zirconium, at most
about 0.005 wt % selenium, at most about 0.02 wt % phosphorus
and/or at most about 0.02 wt % sulfur, with at most about 0.1 wt %
other elements.
[0031] An example of a cobalt alloy cladding material according to
an aspect of the present invention is AMS 4783 or the like (solidus
temperature of about 2050.degree. F. and liquidus temperature of
about 2100.degree. F.) and may include about 16 to about 18 wt %
Ni, about 18 to about 20 wt % Cr, about 7.5 to about 8.5 wt % Si,
about 0.7 to about 0.9 wt % B, about 3.5 to about 4.5 wt % W, about
0.35 to about 0.45 wt % C, at most about 0.05 wt % Ti, at most
about 0.05 wt % Al, at most about 0.05 wt % Zr, at most about 0.005
wt % Se, at most about 0.02 wt % P, at most about 0.02 wt % S and
the balance Co.
[0032] At this point, those skilled in the art will appreciate that
various compositions of cladding materials are useful according to
the present invention. In particular, the compositions of the
cladding material may be selected such that the cladding material
melts, flows and wets the surface of the direct metal laser
sintered material substrate during brazing. Furthermore, the
compositions may be selected such that the cladding materials
provides improved corrosion resistance, ductility and/or
durability.
[0033] The cladding material may be applied to the direct metal
laser sintered material in powdered form. Alternatively, the
cladding material may be a paste, a wire, a film (e.g., a layered
or laminated film) or the like. Those skilled in the art will
appreciate that the physical form of the cladding material may be
selected to facilitate application of the cladding material to the
surface of the direct metal laser sintered material prior to
brazing.
[0034] The direct metal laser sintered material substrate may be
treated according to an aspect of the present invention by applying
an appropriate cladding material to a surface of the substrate. For
example, a powdered cladding material may be randomly applied to a
surface of the substrate. Alternatively, a powdered cladding
material may be evenly distributed over a surface of the substrate.
The substrate and cladding material may be heated to the
appropriate brazing temperature for the appropriate amount of time
under the appropriate conditions (e.g., a vacuum or atmospheric
pressure) such that the cladding material melts, flows an wets the
surface. Any known brazing technique may be used. For example, the
cladding material may be heated by induction heating or,
alternatively, the substrate and cladding material may be heated in
a furnace.
[0035] Accordingly, capillary forces created by the crevices and
other surface defects of the direct metal laser sintered material
may cause the molten cladding material to wet and generally evenly
distribute across the surface of the material. Therefore, complete
coverage of various regular and irregular surfaces having various
geometric configurations (e.g., the internal passage of a fuel
nozzle) may be obtained.
EXAMPLE 1
[0036] A direct metal laser sintered material was formed from
DirectSteel H20 and had a top surface and a bottom surface. The
bottom surface was coated with about 1.4 grams of AMS 4787 (i.e., a
braze powder including about 82 wt % gold and about 18 wt %
nickel), which is generally corrosion resistant. The substrate and
braze powder were brazed at about 1850.degree. F. for about 10
minutes. A photograph of the substrate after brazing is provided at
FIG. 1. In particular, the outer surface (i.e., the top surface in
FIG. 1) of the substrate remained rough and abrasive, while the
inner surface (i.e., the bottom surface in FIG. 1) had a smooth and
protected finish.
EXAMPLE 2
[0037] The cladding material of Example 1 was replaced with AMS
4772, a silver/copper/zinc/nickel cladding material and the
substrate was brazed at about 1700.degree. F. for about 10 minutes.
The resulting substrate had a smooth and treated finish.
[0038] Accordingly, the surface of direct metal laser sintered
materials, including the surface of hard-to-reach internal
passages, may be treated to increase corrosion resistance and
durability and to reduce or eliminate surface defects by treating
the surface of the materials with appropriate cladding
materials.
[0039] At this point, those skilled in the art will appreciate that
channels (e.g., the internal channels of fuel nozzles) having
surfaces treated as described above may provide improved, laminar
fluid flow with a reduced likelihood for leaks.
[0040] Although the present invention is described herein with
respect to certain aspects, modifications may occur to those
skilled in the art upon reading the specification. The present
invention includes all such modifications and is limited only by
the scope of the claims.
* * * * *