CLAD WIRE FEEDSTOCK FOR DIRECTED ENERGY DEPOSITION ADDITIVE MANUFACTURING

1 . A clad wire feedstock for a directed energy deposition (DED) process, the clad wire feedstock comprising:

a core material defining an outer surface; and

one or more clad metal layers that surround the outer surface of the core material.

2 . The clad wire feedstock of claim 1 , wherein the one or more clad metal layers are configured to persist after a molten bead of clad wire feedstock has been deposited, and the one or more clad metal layers stays separate from the core material during the DED process.

3 . The clad wire feedstock of claim 2 , wherein the one or more clad metal layers includes a melt temperature that is different from a melt temperature of the core material by at least ten degrees Celsius.

4 . The clad wire feedstock of claim 2 , wherein a surface tension of the one or more clad metal layers differs from a surface tension of the core material by a threshold amount, and wherein the threshold amount ensures the one or more clad metal layers remain intact after depositing the molten bead.

5 . The clad wire feedstock of claim 1 , wherein the one or more clad metal layers are constructed of platinum and the core material is constructed of at least one of nickel, copper, stainless steel, and tin.

6 . The clad wire feedstock of claim 1 , wherein the one or more clad metal layers are constructed of aluminum and the core material is constructed of a metal matrix composite.

7 . The clad wire feedstock of claim 1 , wherein the one or more clad metal layers are constructed of a brazing alloy.

8 . The clad wire feedstock of claim 7 , wherein the core material is constructed of a material including a higher melting temperature when compared to the brazing alloy.

9 . The clad wire feedstock of claim 8 , wherein a melting temperature of the core material is at least ten percent higher than the melt temperature of the one or more clad metal layers.

10 . The clad wire feedstock of claim 1 , wherein the one or more clad metal layers are constructed of a grain boundary inhibitor.

11 . The clad wire feedstock of claim 10 , wherein the core material is constructed of a metal that the grain boundary inhibiter controls.

12 . The clad wire feedstock of claim 11 , wherein the grain growth inhibitors are one or more of the following: titanium carbide (TiC), vanadium carbide (VC), molybdenum carbide (Mo 2 C), and tantalum carbide (TaC).

13 . The clad wire feedstock of claim 11 , wherein the core material ( 240 ) is constructed of tungsten carbide (WC) with a metal binder.

14 . The clad wire feedstock of claim 1 , wherein the clad metal layer is constructed of aluminum or an aluminum alloy, and the core material is a metal matrix composite.

15 . The clad wire feedstock of claim 1 , wherein the clad metal layer acts as an optical energy absorber configured to absorb a specific wavelength of light.

16 . The clad wire feedstock of claim 15 , wherein the light is in the ultraviolet, visible, or infrared spectrum.

17 . The clad wire feedstock of claim 15 , wherein the core material is constructed of aluminum and the clad metal layer is constructed of copper.

18 . The clad wire feedstock of claim 1 , wherein the clad wire feedstock includes two or more clad metal layers that surround the core material.

19 . A method for creating an article by a DED process, the method comprising:

melting, by a focused energy beam, a clad wire feedstock; and

depositing the clad wire feedstock onto a substrate that is part of a three-dimensional printer, wherein the clad wire feedstock includes a core material defining an outer surface and one or more clad metal layers that surround the outer surface of the core material.

20 . The method of claim 19 , wherein the one or more clad metal layers are configured to persist after a molten bead of clad wire feedstock has been deposited, and the one or more clad metal layers stays separate from the core material during the DED process.