EP4601862A1 - Bornes en cuivre de diborure de titane et de tungstène pour la projection d'aluminium liquide - Google Patents

Bornes en cuivre de diborure de titane et de tungstène pour la projection d'aluminium liquide

Info

Publication number
EP4601862A1
EP4601862A1 EP23877978.9A EP23877978A EP4601862A1 EP 4601862 A1 EP4601862 A1 EP 4601862A1 EP 23877978 A EP23877978 A EP 23877978A EP 4601862 A1 EP4601862 A1 EP 4601862A1
Authority
EP
European Patent Office
Prior art keywords
nozzle
firing chamber
jetting apparatus
electrodes
jetting
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP23877978.9A
Other languages
German (de)
English (en)
Inventor
Graham W. CULLEN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Desktop Metal Inc
Original Assignee
Desktop Metal Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Desktop Metal Inc filed Critical Desktop Metal Inc
Publication of EP4601862A1 publication Critical patent/EP4601862A1/fr
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/22—Direct deposition of molten metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/53—Nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B35/00—Boron; Compounds thereof
    • C01B35/02—Boron; Borides
    • C01B35/04—Metal borides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • Controlled magnetohydrodynamic pulsing may be used to selectively jet individual drops of molten metals and additively build up three-dimensional geometries, in a process known as magnetohydrodynamic printing (here referred to as MHD printing, or MHD).
  • MHD printing magnetohydrodynamic printing
  • a jetting apparatus is employed to heat solid metal feedstock above its liquidus temperature to create molten metal; contain the molten metal; keep the molten metal above its liquidus temperature; position the body of molten metal relative to a magnetic field; enable an electric current to be passed through the molten metal to create a magnetohydrodynamic pulse; and direct the flow of molten metal towards a desired target.
  • FIGs. 2A-C are depictions of the nozzle of the system of Fig. 1.
  • FIGs. 3A-C depict an embodiment jetting apparatus.
  • Figure 1 is a schematic depiction of an additive manufacturing system 100 using MHD printing of liquid metal in which the disclosed improvements may be employed.
  • Additive manufacturing system 100 can include a nozzle 102, a feeder system 104, and a robotic system 106.
  • the robotic system 106 can move the nozzle 102 along a controlled pattern within a working volume 108 of a build chamber 110 as the feeder system 104 moves a solid metal 112 from a metal supply 113 and into the nozzle 102.
  • the solid metal 112 can be melted via heater 122 in or adjacent to the nozzle 102 to form a liquid metal 112’ and, through a combination of a magnetic field and an electric current acting on the liquid metal 112’ in the nozzle 102, MHD forces can eject the liquid metal 112’ from the nozzle 102 in a direction toward a build plate 114 disposed within the build chamber 110.
  • an object 116 e.g., a two-dimensional object or a three-dimensional object
  • the object may be formed based on a model 126 (stored on a sever 128) enacted through a controller 124.
  • the object 116 can be moved under the nozzle 102 (e.g., as the nozzle 102 remains stationary).
  • the liquid metal 112’ can be ejected from the nozzle 102 in successive layers to form the object 116 through additive manufacturing.
  • the feeder system 104 can continuously, or substantially continuously, provide build material to the nozzle 102 as the nozzle 102 ejects the liquid metal 112’, which can facilitate the use of the three-dimensional printer 100 in a variety of manufacturing applications, including high volume manufacturing of metal parts.
  • MHD forces can be controlled in the nozzle 102 to provide drop-on-demand delivery of the liquid metal 112’ at rates ranging from about one liquid metal drop per hour to thousands of liquid metal drops per second and, in certain instances, to deliver a substantially continuous stream of the liquid metal 112’.
  • a sensor or sensors 120 may monitor the printing process as discussed further below.
  • the nozzle can include a housing 202, one or more magnets 204, and electrodes 206.
  • the housing 202 can define at least a portion of a fluid chamber 208 having an inlet region 210 and a discharge region 212.
  • the one or more magnets 204 can be supported on the housing 202 or otherwise in a fixed position relative to the housing 202 with a magnetic field “M” generated by the one or more magnets 204 directed through the housing 202.
  • the magnetic field can be directed through the housing 202 in a direction intersecting the liquid metal 112’ as the liquid metal 112’ moves from the inlet region 210 to the discharge region 212.
  • the electrodes 206 can be supported on the housing 202 to define at least a portion of a firing chamber 216 within the fluid chamber 208, between the inlet region 210 and the discharge region 212.
  • the feeder system 104 can engage the solid metal 112 and, additionally or alternatively, can direct the solid metal 112 into the inlet region 210 of the fluid chamber 208 as the liquid metal 112’ is ejected through the discharge orifice 218 through MHD forces generated using the one or more magnets 204 and the electrodes 206.
  • a heater 226 may be employed to heat the housing 202 and the fluid chamber 208 to melt the solid metal 112.
  • a discard tray 127 is located in proximity to the build plate and the nozzle may deposit droplets in it during a testing or calibration step.
  • an electric power source 118 can be in electrical communication with the electrodes 206 and can be controlled to produce an electric current “I” flowing between the electrodes 206.
  • the electric current “I” can intersect the magnetic field “M” in the liquid metal 112’ in the firing chamber 216. It should be understood that the result of this intersection is an MHD force (also known as a Lorentz force) on the liquid metal 112’ at the intersection of the magnetic field “M” and the electric current “I”.
  • the one or more magnets 204 and the electrodes 206 can be oriented relative to one another to exert the MHD force on the liquid metal 112’ in a predictable direction, such as a direction that can move the liquid metal 112’ toward the discharge region 212.
  • the MHD force on the liquid metal 112’ is of the type known as a body force, as it acts in a distributed manner on the liquid metal 112’ wherever both the electric current “I” is flowing and the magnetic field “M” is present. The aggregation of this body force creates a pressure which can lead to ejection of the liquid metal 112’.
  • the electrical power source 118 can be controlled to pulse the electric current “I” flowing between the electrodes 206.
  • the pulsation can produce a corresponding pulsation in the MHD force applied to the liquid metal 112’ in the firing chamber 216. If the impulse of the pulsation is sufficient, the pulsation of the MHD force on the liquid metal 112’ in the firing chamber 208 can eject a corresponding droplet from the discharge region 212.
  • the electric current “I” can exert a pullback force on the liquid metal 112’ in the fluid chamber 208.
  • Each pulse can be shaped with a pre-charge that applies a small, pullback force (opposite the direction of ejection of the liquid metal 112’ from the discharge region 212) before creating an ejection drive signal to propel one or more droplets of the liquid metal 112’ from the nozzle 102.
  • the liquid metal 112’ can be drawn up slightly with respect to the discharge region 212.
  • Drawing the liquid metal 112’ slightly up toward the discharge orifice in this way can provide numerous advantageous, including providing a path in which a bolus of the liquid metal 112’ can accelerate for cleaner separation from the discharge orifice as the bolus of the liquid metal is expelled from the discharge orifice, resulting in a droplet with a more well-behaved (e.g., stable) shape during travel.
  • the retracting motion can effectively spring load a forward surface of the liquid metal 112’ by drawing against surface tension of the liquid metal 112’ along the discharge region 212.
  • the forces of surface tension can help to accelerate the liquid metal 112’ toward ejection from the discharge region 212.
  • each pulse can be shaped to have a small pullback force following the end of the pulse.
  • the pullback force is opposite a direction of travel of the liquid metal 112’ being ejected from the discharge region 212, the small pullback force following the end of the pulse can facilitate clean separation of the liquid metal 112’ along the discharge region 212 from an exiting droplet of the liquid metal 112’.
  • the drive signal produced by the electrical power source 118 can include a wavelet with a pullback signal to pre-charge the liquid metal 112’, an ejection signal to expel a droplet of the liquid metal, and a pullback signal to separate an exiting droplet of the liquid metal 112’ from the liquid metal 112’ along the discharge region 212. Additionally, or alternatively, the drive signal produced by the electrical power source 118 can include one or more dwells between portions of each pulse.
  • liquid metal shall be understood to include metals and metal alloys in liquid form and, additionally or alternatively, includes any fluid-containing metals and metal alloys in liquid form, unless otherwise specified or made clear by the context.
  • Metals suitable for use with the disclosure include aluminum and aluminum alloys, copper and copper alloys, silver and silver alloys, gold and gold alloys, platinum and platinum alloys, iron and iron alloys, and nickel and nickel alloys.
  • the first requires a highly conductive material with a low thermal expansion coefficient approximately the same as TiB2.
  • a mixture of 60-90% Tungsten and 40-10% Copper met this criteria, and was machined and an interference fit between the TiB2 and WCu was made through the application of heat and pressure.
  • the second option is to use silver solder to bond the TiB2 to a copper terminal end (other conductive materials may also be employed).
  • Tt is advantageous in such setups to include a smaller amount of metal on the TiB2 that makes electrical contacts.
  • Figs. 3A-C are views showing the placement of the TiB2 in an embodiment MHD jetting apparatus 300.
  • Ajetting apparatus body 301 may contain and otherwise dispose further components in their respective working positions.
  • Fig. 3A is a top view
  • Fig. 3B is a side cutaway schematic view
  • Fig. 3C is see-through top view.
  • the MHD jetting apparatus 301 has a nozzle 302 configured to heat and jet a metallic build material.
  • the nozzle 302 is constructed of a nozzle material and includes an entry orifice 303 configured to accept an amount of metallic build material feedstock, an exit orifice 304 from which the metallic build material may be jetted toward the build surface, an internal cavity 305 establishing fluidic communication between the entry office 303 and exit orifice 304, and a firing chamber 306 at least partially disposed within the internal cavity 305.
  • the firing chamber 306 fluidically connects a pair of separated electrodes 307, at least one of which is constructed from or includes a surface that is titanium diboride.
  • Figs. 3A-3C show a type of contact to the TiB2 where the metal end is clamped with a screw.
  • the metal end might be cylindrical or conical and together with a spring load, could allow for pivoting around the axis of the electrodes. This can be useful for alignment of the nozzle, either once after installation of a new nozzle, or even “served” to measurement of drop exit angle.
  • TiB2 electrodes may be formed by certain processes. In certain instances, they may be formed by sintering powder. They may also be formed from diamond grinding, electrical discharge machining (EDM) or wire EDM. TiB2’s properties are attractive in part because it can be advantageous in certain MHD jetting applications to employ high density /low resistance materials.
  • EDM electrical discharge machining
  • TiB2’s properties are attractive in part because it can be advantageous in certain MHD jetting applications to employ high density /low resistance materials.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)

Abstract

La présente invdention porte sur un appareil de projection magnétohydrodynamique (MHD) à performance améliorée. En particulier, des électrodes sont configurées pour délivrer un courant électrique à une cavité interne d'une buse de l'appareil de projection, et ainsi au métal fondu à l'intérieur. Ces électrodes sont formées à partir d'une surface qui est du diborure de titane ou ont une surface qui est du diborure de titane. Le diborure de titane est connecté à la source de courant électrique par un matériau hautement conducteur ayant un faible coefficient de dilatation thermique par rapport au diborure de titane. Les appareils de projection selon l'invention ont des caractéristiques de projection améliorées, telles que des fréquences de projection stables plus élevées, une croissance d'oxyde inférieure sur la région de buse, conduisant à plus de temps entre des nettoyages de buse, et un courant de projection plus stable à partir du début de la projection par projection à l'état stable.
EP23877978.9A 2022-10-11 2023-10-11 Bornes en cuivre de diborure de titane et de tungstène pour la projection d'aluminium liquide Pending EP4601862A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202263415184P 2022-10-11 2022-10-11
PCT/US2023/034977 WO2024081333A1 (fr) 2022-10-11 2023-10-11 Bornes en cuivre de diborure de titane et de tungstène pour la projection d'aluminium liquide

Publications (1)

Publication Number Publication Date
EP4601862A1 true EP4601862A1 (fr) 2025-08-20

Family

ID=90670093

Family Applications (1)

Application Number Title Priority Date Filing Date
EP23877978.9A Pending EP4601862A1 (fr) 2022-10-11 2023-10-11 Bornes en cuivre de diborure de titane et de tungstène pour la projection d'aluminium liquide

Country Status (2)

Country Link
EP (1) EP4601862A1 (fr)
WO (1) WO2024081333A1 (fr)

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NO822739L (no) * 1981-08-31 1983-03-01 Battelle Memorial Institute Sintringssammensetning paa titanboridbasis og anvendelse derav for fremstilling av sintrede gjenstander
US9943918B2 (en) * 2014-05-16 2018-04-17 Powdermet, Inc. Heterogeneous composite bodies with isolated cermet regions formed by high temperature, rapid consolidation
US10507638B2 (en) * 2015-03-17 2019-12-17 Elementum 3D, Inc. Reactive additive manufacturing
US10315247B2 (en) * 2015-09-24 2019-06-11 Markforged, Inc. Molten metal jetting for additive manufacturing
WO2017136793A1 (fr) * 2016-02-05 2017-08-10 Alphabet Energy, Inc. Structure d'électrode pour matériaux en vrac à base de siliciure de magnésium destinée à empêcher la migration élémentaire en vue d'une fiabilité à long terme

Also Published As

Publication number Publication date
WO2024081333A1 (fr) 2024-04-18

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