Methods for 3D printing and additive manufacturing of refractory alloys
A part made from a refractory alloy is manufactured using additive manufacturing or casting. The part is coated with a protective coating prior to the step of hot isostatic pressing the part.
1 . A method of manufacturing a part, the method comprising:
(a) additive manufacturing the part from a high temperature refractory alloy, wherein the high temperature refractory alloy is a niobium (Nb) refractory alloy having a melting point above 2400° C.;
(b) applying a silicide material to at least a portion of an exterior of the part, after the additive manufacturing, to interact with the high temperature refractory alloy to form a permanent, silicide-based protective coating on the at least a portion of the exterior of the part; and
(c) thereafter, hot isostatic pressing the part, wherein the protective coating is permanently retained on the part after the hot isostatic pressing.
2 . The method of claim 1 , wherein the silicide material is applied by using a slurry coating process, chemical vapor deposition process, a physical vapor deposition process or an electrodeposition process.
3 . The method of claim 2 , further comprising: machining an interface on the part prior to applying the silicide material.
4 . The method of claim 3 , further comprising: annealing the part prior to applying the silicide material.
5 . The method of claim 1 wherein the silicide material is a disilicide.
6 . A method of manufacturing a high temperature refractory alloy final part comprising:
(a) forming a high temperature refractory alloy initial part, using an additive manufacturing process, from a high temperature refractory alloy comprising a niobium (Nb) refractory alloy having a melting point above 2400° C.;
(b) applying a silicide material to form a permanent protective coating and to permanently adhere the permanent protective coating to at least a portion of an outer surface of the high temperature refractory alloy initial part, using a process selected from the group consisting of a slurry coating process, a chemical vapor deposition process, a physical vapor deposition process, and a electrodeposition process; and
(c) thereafter, performing a hot isostatic pressing operation on the high temperature refractory alloy initial part thereby creating a high temperature refractory alloy final part, wherein the permanent protective coating protects the high temperature refractory alloy against contamination during the hot isostatic pressing operation to retain ductility of the high temperature refractory alloy, and wherein the permanent protective coating is retained on the high temperature refractory alloy final part after the hot isostatic pressing operation.
7 . The method of claim 6 , further comprising:
machining an interface on the high temperature refractory alloy initial part prior to applying the silicide material.
8 . The method of claim 7 , further comprising:
annealing the high temperature refractory alloy initial part prior to applying the silicide material.
9 . The method of claim 6 , wherein the silicide material is applied using the slurry coating process comprising either immersion or spraying.
10 . The method of claim 9 , wherein the niobium refractory alloy is a niobium C103 alloy.
11 . The method of claim 6 further comprising: conducting finish machining on the high temperature refractory alloy final part after the hot isostatic pressing operation.
12 . The method of claim 6 further comprising: functionally integrating the high temperature refractory alloy final part into a product for high-temperature use, wherein the permanent protective coating is retained on the high temperature refractory alloy final part in the product.
13 . A method of protecting a high temperature refractory alloy part, after additive manufacturing, during hot isostatic pressing without use of a temporary, protective sacrificial foil, the method comprising:
(a) applying a silicide material to at least a portion of an outer surface of the high temperature refractory alloy part to form a permanent, silicide-based protective coating on the at least a portion of the outer surface of the high temperature refractory alloy part, wherein the high temperature refractory alloy part is formed of a niobium (Nb) refractory alloy having a melting point of above 2,400° C.; and
(b) thereafter, performing a hot isostatic pressing operation on the high temperature refractory alloy part, such that the protective coating protects the high temperature refractory alloy against contamination during the hot isostatic pressing operation to retain ductility of the high temperature refractory alloy, and wherein the permanent protective coating is retained on the high temperature refractory alloy part after the hot isostatic pressing operation.
14 . The method of claim 13 wherein the high temperature refractory alloy is a niobium C103 alloy.
15 . The method of claim 13 wherein the protective coating is a disilicide niobium eutectic intermetallic compound.
16 . The method of claim 13 , wherein the silicide material is applied to the high temperature refractory alloy part by using a slurry coating process, a chemical vapor deposition process, a physical vapor deposition process or an electrodeposition process.
17 . The method of claim 13 further comprising: machining an interface on the high temperature refractory alloy part prior to applying the silicide material.
18 . The method of claim 17 , further comprising: annealing the high temperature refractory alloy part prior to applying the silicide material.