1111111111111111111111111111111111111111111111111111111111111111111111111111 (12) United States Patent Hofmann et al. (54) METHODS FOR FABRICATING GRADIENT ALLOY ARTICLES WITH MULTI - FUNCTIONAL PROPERTIES (71) Applicant: California Institute of Technology, Pasadena, CA (US) (72) Inventors: Douglas C. Hofmann, Altadena, CA (US); John Paul C. Borgonia, Pasadena, CA (US); Robert P. Dillon, Costa Mesa, CA (US); Eric J. Sub, Pasadena, CA (US); Jerry L. Mulder, La Crescenta, CA (US); Paul B. Gardner, Pasadena, CA (US) (73) Assignee: California Institute of Technology, Pasadena, CA (US) (*) Notice: Subject to any disclaimer, the term of this patent is extended or adjusted under 35 U.S.C. 154(b) by 487 days. (21) Appl. No.: 13/664,285 (22) Filed: Oct. 30, 2012 (65) Prior Publication Data US 2015/0044084 Al Feb. 12, 2015 Related U.S. Application Data (60) Provisional application No. 61/553,860, filed on Oct. 31, 2011. (51) Int. Cl. B22F 7102 (2006.01) C22C38108 (2006.01) (Continued) (52) U.S. Cl. CPC ... B22F 7102 (2013.01); B05D 1118 (2013.01); B05D 1136 (2013.01); B05D 7/00 (2013.01); B22F 7104 (2013.01); B23K20110 (2013.01); (Continued) (1o) Patent No.: US 9,101,979 B2 (45) Date of Patent: Aug. 11, 2015 (58) Field of Classification Search CPC ........ B22F 7/02; C22C 38/08; C21D 2251/02 USPC .............................................................. 419/2 See application file for complete search history. (56) References Cited U.S. PATENT DOCUMENTS 5,810,924 A 9/1998 Legoues et al. 2003/0231973 Al 12/2003 Krumpelt et al. (Continued) FOREIGN PATENT DOCUMENTS wo 2013112217 A2 8/2013 wo 2013112217 A3 10/2013 OTHER PUBLICATIONS Griffith et al., "Understanding the microstructure and Properties of Components Fabricated by Laser Engineered Net Shaping (Lens)", Sandia Report, Nov. 2007, SAND2007-7832, 14 pgs. (Continued) Primary Examiner Weiping Zhu (74) Attorney, Agent, or Firm KPPB LLP (57) ABSTRACT Systems and methods for fabricating multi-functional articles comprised of additively formed gradient materials are pro- vided. The fabrication of multi-functional articles using the additive deposition of gradient alloys represents a paradigm shift from the traditional way that metal alloys and metal/ metal alloy parts are fabricated. Since a gradient alloy that transitions from one metal to a different metal cannot be fabricated through any conventional metallurgy techniques, the technique presents many applications. Moreover, the embodiments described identify a broad range of properties and applications. 25 Claims, 16 Drawing Sheets 1. Identify desired L Identify alloys 3. Design the gradient in such multi-functional part that could achieve away as to satisfy the desired Froperty A the desired multi- properties in the final part functionality- 000 Property zr A 000 PropyA P,, p zr+ Fc zr B Property eK S > . 4. Design the graded path using phase 5. Define the manufacturing process or diagrams or other information about 311 combination of processes to fabricate composition the multi-functional part Property A Undesirable .•i•`.• ° •:: • • ti •''::. ...... `• phases Property B
METHODS FOR FABRICATING GRADIENT ALLOY ARTICLES WITH MULTI-FUNCTIONAL PROPERTIES
May 29, 2023
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