Additive manufacturing of metal matrix composite feedstock
A feedstock for an additive manufacturing process includes a pre-ceramic polymer intermixed with a base material. A method of additive manufacturing includes melting and pyrolizing a feedstock containing metal and a pre-ceramic polymer. An article of manufacture includes an additive manufacturing component including a pyrolized feedstock.
1. A method of additive manufacturing comprising:
providing a plurality of feedstock particles, each feedstock particle of the plurality of feedstock particles comprising an agglomerate of a base material, a pre-ceramic polymer and a binder intermixed with the base material and the pre-ceramic polymer, the base material comprising metal, and the binder comprising a poly vinyl alcohol;
melting and pyrolyzing the plurality of feedstock particles; and
forming a metal matrix composite article from the melted and the pyrolyzed feedstock particles.
2. The method as recited in claim 1 , wherein the melting and the pyrolyzing is effected by at least one of a laser, an electron beam, an arc heat source or a plasma heat source.
3. The method as recited in claim 1 , wherein the plurality of feedstock particles are blown into a heat source.
4. The method of claim 1 , wherein each feedstock particle has a size in a range of 10-200 microns.
5. The method of claim 1 , wherein the pre-ceramic polymer in each feedstock particle has a volumetric ratio of 1% to 50%.
6. The method of claim 1 , wherein the pre-ceramic polymer in each feedstock particle has a volumetric ratio of 1% to 10%.
7. The method of claim 1 , wherein the metal comprises nickel.
8. The method of claim 1 , wherein the pre-ceramic polymer comprises silicon carbide.
9. The method of claim 1 , wherein the pre-ceramic polymer comprises silicon nitride.
10. A method of additive manufacturing comprising:
providing feedstock material, the feedstock material comprising an agglomerate including a base material, a pre-ceramic polymer and a binder intermixed with the base material and the pre-ceramic polymer, and the base material comprising metal; and
melting and pyrolyzing the feedstock material to form a metal matrix composite article.
11. The method of claim 10 , wherein the binder comprises a poly vinyl alcohol.
12. The method of claim 10 , wherein the feedstock material comprises a plurality of particles, and one of the plurality of particles comprises the agglomerate.
13. The method of claim 10 , wherein the melting and the pyrolizing is performed using a laser.
14. The method of claim 10 , wherein the melting and the pyrolizing is performed using an electron beam.
15. The method of claim 10 , wherein the melting and the pyrolizing is performed using an arc heat source.
16. The method of claim 10 , wherein the melting and the pyrolizing is performed using a plasma heat source.