Grain boundary engineering for additive manufacturing
First Claim
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1. A metal part, comprising:
- a material, wherein at least a portion of the material is formed by melting metal powder with a laser or electron beam during a powder bed additive manufacturing process, wherein the portion receives an effective amount of energy from the laser or electron beam during the powder bed additive manufacturing process to introduce an amount of residual strain, and wherein the portion is configured to substantially release the residual strain and transform into a grain boundary engineered material having substantially distributed coincidence site lattice (CSL) grain boundaries, low angle grain boundaries, or both upon heat treatment.
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Abstract
In one embodiment, a method of manufacturing a metal part using a laser or electron beam during a powder bed additive manufacturing process includes melting each of a number of layers of metal powder of the metal part with an effective amount of energy using the laser or electron beam to form the metal part such that at least one or more portions of the metal part have a critical amount of residual strain. The method also includes performing a heat treatment on the metal part that transforms the residual strain into substantially distributed coincidence site lattice (CSL) grain boundaries, low angle grain boundaries, or both in the metal part.
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Citations
20 Claims
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1. A metal part, comprising:
a material, wherein at least a portion of the material is formed by melting metal powder with a laser or electron beam during a powder bed additive manufacturing process, wherein the portion receives an effective amount of energy from the laser or electron beam during the powder bed additive manufacturing process to introduce an amount of residual strain, and wherein the portion is configured to substantially release the residual strain and transform into a grain boundary engineered material having substantially distributed coincidence site lattice (CSL) grain boundaries, low angle grain boundaries, or both upon heat treatment. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method of manufacturing a metal part using a laser or electron beam powder bed additive manufacturing process, comprising:
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melting each of a plurality of layers of metal powder of the metal part with an effective amount of energy using a laser or electron beam to form the metal part such that at least one or more portions of the metal part have a critical amount of residual strain; and performing a heat treatment on the metal part that transforms the residual strain into substantially distributed coincidence site lattice (CSL) grain boundaries, low angle grain boundaries, or both in the metal part. - View Dependent Claims (13, 14, 15, 16)
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17. A metal part, comprising:
a metal microstructure, wherein at least a portion of the metal microstructure comprises substantially distributed coincidence site lattice (CSL) grain boundaries, low angle grain boundaries, or both that improve hold time fatigue and resistance to stress corrosion cracking, wherein the metal microstructure is formed using a laser or electron beam powder bed additive manufacturing process that delivers an effective amount of energy to introduce an amount of residual strain, and wherein the metal part subsequently undergoes a heat treatment that converts the residual strain into the substantially distributed CSL grain boundaries, low angle grain boundaries, or both in the portion. - View Dependent Claims (18, 19, 20)
Specification