Spherical metallic powder blends and methods for manufacturing the same

• US 11,130,175 B2
• Filed: 01/18/2018
• Issued: 09/28/2021
• Est. Priority Date: 01/18/2018
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Parrish, Catherine J., Cotton, James D.
• Primary Examiner(s): Wyszomierski, George
• Application Number:
  US15/874,134
• Publication Number:
  US 20190217389A1
• Time in Patent Office: 1,349 Days
• Field of Search: None
• CPC Class Codes: B22F 1/065 Spherical particles
• CPC Class Codes: B22F 1/09 Mixtures of metallic powders
• CPC Class Codes: B22F 1/14 Treatment of metallic powder mixing with lubricating or binding agents or with organic material B22F1/10
• CPC Class Codes: B22F 2009/001 from scrap particles
• CPC Class Codes: B22F 2009/041 by mechanical alloying, e.g. blending, milling
• CPC Class Codes: B22F 2202/13 Use of plasma
• CPC Class Codes: B22F 2301/205 Titanium, zirconium or hafnium
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 9/04 starting from solid material, e.g. by crushing, grinding or milling C22C1/1084 takes precedence; crushing, grinding or milling, in general, see the relevant subclasses, e.g. B02C
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: C22C 1/0458 Alloys based on titanium, zirconium or hafnium
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A method for manufacturing a spherical metallic powder blend using a metallic starting material, the method including steps of grinding the metallic starting material to yield an intermediate powder, spheroidizing the intermediate powder to yield a first spherical powder component, and mixing the first spherical powder component with a second spherical powder component, wherein the first spherical powder component and the second spherical powder component have substantially the same chemical composition.

Claims

1. A method for manufacturing a spherical metallic powder blend from a metallic starting material, the method comprising:

grinding the metallic starting material to yield an intermediate powder;

spheroidizing the intermediate powder to yield a first spherical powder component; and

mixing a first quantity of the first spherical powder component with a second quantity of a second spherical powder component, wherein the first spherical powder component and the second spherical powder component both comprise titanium, but have different oxygen concentrations, and wherein the mixing the first spherical powder component with the second spherical powder component comprises mixing at a first spherical powder component-to-second spherical powder component ratio that yields a mixture having an oxygen concentration below about 2000 ppm.

2. The method of claim 1 wherein the first spherical powder component has an oxygen concentration greater than 2000 ppm and the second spherical powder component has an oxygen concentration of at most 1800 ppm.

3. The method of claim 2 wherein the first spherical powder component has an oxygen concentration ranging from about 2100 ppm to about 4000 ppm.

4. The method of claim 2 wherein the first spherical powder component has an oxygen concentration ranging from about 2100 ppm to about 2300 ppm.

5. The method of claim 2 wherein the second spherical powder component has an oxygen concentration ranging from about 800 ppm to about 1800 ppm.

6. The method of claim 2 wherein the second spherical powder component has an oxygen concentration ranging from about 900 ppm to about 1100 ppm.

7. The method of claim 1 wherein the metallic starting material comprises swarf.

8. The method of claim 1 wherein the grinding the metallic starting material to yield the intermediate powder comprises grinding to achieve an average particle size between about 10 μ

m and about 100 μ

m.

9. The method of claim 8 wherein at least 80 percent of powder particles of the intermediate powder have a particle size within 20 percent of the average particle size.

10. The method of claim 1 wherein the grinding is performed in a planetary mill, a ball mill or a roller mill.

11. The method of claim 1 further comprising hydriding the metallic starting material prior to the grinding.

12. The method of claim 11 further comprising dehydriding the intermediate powder prior to the spheroidizing.

13. The method of claim 1 wherein the spheroidizing the intermediate powder comprises introducing the intermediate powder to an induction plasma.

14. The method of claim 1 wherein the mixing the first spherical powder component with the second spherical powder component comprises mixing at a first spherical powder component-to-second spherical powder component ratio of at least 1:

1.

15. The method of claim 14 wherein the first spherical powder component-to-second spherical powder component ratio is at least 2:

1.

16. The method of claim 1 wherein the first spherical powder component and the second spherical powder component comprise Ti-6Al-4V.

17. A method for manufacturing a spherical metallic powder blend comprising:

mixing a first quantity of a first spherical powder component with a second quantity of a second spherical powder component, wherein;

the first spherical powder component comprises titanium and has an oxygen concentration ranging from about 2100 ppm to about 4000 ppm,

the second spherical powder component comprises titanium and has an oxygen concentration of at most about 1800 ppm, and

wherein the mixing the first spherical powder component with the second spherical powder component comprises mixing at a first spherical powder component-to-second spherical powder component ratio that yields a mixture having an oxygen concentration below about 2000 ppm.

18. The method of claim 17 wherein both the first spherical powder component and the second spherical powder component comprise Ti-6Al-4V.

19. The method of claim 17 further comprising:

grinding a metallic starting material to yield an intermediate powder; and

spheroidizing the intermediate powder to yield the first spherical powder component.

20. The method of claim 17 wherein the second spherical powder component has an oxygen concentration ranging from about 800 ppm to about 1800 ppm.