OBJECT PRODUCTION

Abstract

Methods and apparatus for producing an object, the method comprising: performing an Additive Manufacturing process to produce an intermediate object from provided metal or alloy, whereby the intermediate object comprises regions having a contaminant concentration level above a threshold level; based upon one or more parameters, determining a temperature and a duration; and performing, on the intermediate object, a contaminant dispersion process by, for a duration that is greater than or equal to the determined duration, heating the intermediate object to a temperature that is greater than or equal to the determined temperature and less than the melting point of the metal or alloy, the contaminant dispersion process being performed so as to disperse, within the intermediate object, a contaminant from regions of high contaminant concentration to regions of low contaminant concentration until the intermediate object comprises no regions having a contaminant concentration level above the threshold level.

Description

FIELD OF THE INVENTION

The present invention relates to the production of objects.

BACKGROUND

Additive Manufacturing (AM) (also known as Additive Layer Manufacturing (ALM), 3D printing, etc.) refers to processes that may be used to produce functional, complex objects, layer by layer, without moulds or dies. Typically, AM processes include providing material (e.g. metal, ceramic or plastic) in the form of a powder or a wire, and, using a powerful heat source (such as a laser beam, electron beam or an electric, or plasma welding arc), an amount of that material is melted and deposited upon a base work piece. Subsequent layers are then built up upon each preceding layer so as to form the object.

Example AM processes include, but are not limited to, Laser Blown Powder, Laser Powder Bed, and Wire and Arc technologies.

However, objects produced using AM processes, particularly those made using powder material, may comprise one or more contaminated regions, i.e. regions in which the material that forms the object has been contaminated by a contaminant (e.g. oxygen). Also, objects produced using AM processes, particularly those made using powder material, may comprise micro-pores and other imperfections at or proximate to the surface of the object. The presence of such contaminated regions and other imperfections tend to adversely affect the fatigue performance of an object, especially in high-cycle fatigue situations. For example, the imperfections may act as crack initiators.

SUMMARY OF THE INVENTION

In a first aspect, the present invention provides a method of producing an object, the method comprising: providing some metal or alloy; performing, using an Additive Manufacturing apparatus, an Additive Manufacturing process to produce an intermediate object from the provided metal or alloy, whereby the intermediate object comprises one or more regions having a contaminant concentration level above a threshold level; based upon one or more parameters selected from the group of parameters consisting of: the type of metal or alloy from which the intermediate object has been produced, the shape and/or size of the intermediate object, a contaminant concentration level of a region of the intermediate object, and the threshold level, determining a temperature and a duration; and performing, on the intermediate object, a contaminant dispersion process by, for a duration that is greater than or equal to the determined duration, heating the intermediate object to a temperature that is greater than or equal to the determined temperature and less than the melting point of the metal or alloy from which the intermediate object has been made, the contaminant dispersion process being performed so as to disperse a contaminant from regions of high contaminant concentration within the intermediate object to regions of low contaminant concentration within the intermediate object until the intermediate object comprises no regions having a contaminant concentration level above the threshold level, thereby producing the object.

The contaminant dispersion process may be performed such that the contaminant is substantially uniformly distributed within the bulk of the object.

The contaminant dispersion process may comprise performing, on the intermediate object, a hot isostatic pressing process at a temperature that is greater than or equal to the threshold temperature and for a duration that is greater than or equal to the threshold duration.

The determined temperature may be between 1100° C. and the melting point of the provided metal or alloy.

The determined temperature may be between 1300° C. and the melting point of the provided metal or alloy.

The determined duration may be greater than or equal to one hour.

The determined duration may be greater than or equal to two hours.

The Additive Manufacturing (AM) process may be a process selected from the group of AM processes consisting of: a powder bed fusion AM process, a blown powder AM process, a sheet lamination AM process, a laser blown powder AM process, a laser powder bed AM process, and an AM process that implements wire and arc technology.

The metal or alloy from which the object is made may be selected from a group of metals or alloys consisting of: titanium alloys, steel, nickel superalloys and aluminium alloys.

The metal or alloy may be Ti-6Al-4V.

The metal or alloy may be provided in powder form.

The Additive Manufacturing process may be a powder bed Additive Manufacturing process.

The contaminant may comprise oxygen.

The intermediate object may comprise a plurality of open cavities. The method may further comprise performing a sealing process on the intermediate object to seal the openings of the open cavities, thereby forming a plurality of closed cavities, and reducing the sizes of the closed cavities by performing a consolidation process on the intermediate object having the closed cavities.

The produced object may comprise a plurality of open cavities. The method may further comprise performing a sealing process on the object to seal the openings of the open cavities, thereby forming a plurality of closed cavities, and reducing the sizes of the closed cavities by performing a consolidation process on the object having the closed cavities.

The step of reducing the sizes of the closed cavities may be performed at least until the closed cavities are no longer present.

The step of performing a consolidation process may comprise performing a hot isostatic pressing process.

The step of performing a sealing process may comprise plastically deforming the surface of the object.

Plastically deforming the surface of the object may comprise shot peening the surface of the object.

The step of performing a sealing process may further comprise sintering the object after the surface of the object has been plastically deformed.

The method may further comprise determining a contaminant concentration level of a region of the intermediate object.

The determined temperature and duration may be based upon the determined contaminant concentration level.

The determining of a contaminant concentration level of a region of the intermediate object may comprise determining the maximum contaminant concentration level within the intermediate object.

In a further aspect, the present invention provides a method of producing an object, the method comprising: providing an initial object, the initial object being made of a metal or an alloy, the initial object having been produced by performing an Additive Manufacturing process, the initial object comprising one or more regions having a contaminant concentration above a threshold level; based upon one or more parameters selected from the group of parameters consisting of: the type of metal or alloy from which the initial object has been produced, the shape and/or size of the initial object, a concentration level of a region of the initial object, and the threshold level, determining a temperature and a duration; and performing, on the initial object, a contaminant dispersion process by, for a duration that is greater than or equal to the determined duration, heating the initial object to a temperature that is greater than or equal to the determined temperature and less than the melting point of the metal or alloy from which the initial object has been made, the contaminant dispersion process being performed so as to disperse a contaminant from regions of high contaminant concentration within the initial object to regions of low contaminant concentration within the initial object until the initial object comprises no regions having a contaminant concentration above the threshold level, thereby producing the object.

In a further aspect, the present invention provides an object that has been produced using a method according to any of the above aspects.

In a further aspect, the present invention provides apparatus for producing an object, the apparatus comprising: Additive Manufacturing (AM) apparatus configured to, using some provided metal or alloy, perform an Additive Manufacturing process to produce an intermediate object from the provided metal or alloy, whereby the intermediate object comprises one or more regions having a contaminant concentration level above a threshold level; means for, based upon one or more parameters selected from the group of parameters consisting of: the type of metal or alloy (12) from which the intermediate object has been produced, the shape and/or size of the intermediate object, a contaminant concentration level of a region of the intermediate object, and the threshold level, determine a temperature and a duration; and heating means configured to perform, on the intermediate object, a contaminant dispersion process by, for a duration that is greater than or equal to the determined duration, heating the intermediate object to a temperature that is greater than or equal to the determined temperature and less than the melting point of the metal or alloy from which the intermediate object has been made, the contaminant dispersion process being performed so as to disperse a contaminant from regions of high contaminant concentration within the intermediate object to regions of low contaminant concentration within the intermediate object until the intermediate object comprises no regions having a contaminant concentration level above the threshold level, thereby producing the object.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration (not to scale) showing example Additive Manufacturing apparatus;

FIG. 2 is a process flow chart of an embodiment of a process of producing an object;

FIG. 3 is a schematic illustration (not to scale) showing a stage of an Additive Manufacturing process performed by the Additive Manufacturing apparatus; and

FIG. 4 is a schematic illustration (not to scale) of a cross section of the object at a certain stage of the process of FIG. 2.

DETAILED DESCRIPTION

FIG. 1 is a schematic illustration (not to scale) showing example Additive Manufacturing apparatus 2 that is to be used, in an embodiment, to perform an Additive Manufacturing process so as to create an object 4.

The terminology “Additive Manufacturing” is used herein to refer to all additive processes that may be used to produce functional, complex objects, layer by layer, without moulds or dies e.g. by providing material (e.g. metal or plastic) in the form of a powder or a wire, and, using a powerful heat source such as a laser beam, electron beam or an electric, or plasma welding arc, melting an amount of that material and depositing the melted material (e.g. on a base plate/work piece 6), and subsequently building layers of material upon each preceding layer.

Additive Manufacture (AM) may also be known inter alia as 3D printing, Direct Digital Manufacturing (DDM), Digital Manufacturing (DM), Additive Layer Manufacturing (ALM), Rapid Manufacturing (RM), Laser Engineering Net Shaping (LENS), Direct Metal Deposition, Direct Manufacturing, Electron Beam Melting, Laser Melting, Freeform Fabrication, Laser Cladding, Direct Metal Laser Sintering.

In this embodiment, the AM apparatus 2 is apparatus for performing a powder bed AM processes. Further information on powder bed AM apparatus and processes may be found, for example in Gibson, I. Rosen, D. W. and Stucker, B. (2010) “Additive Manufacturing Technologies: Rapid Prototyping Direct Digital Manufacturing” New York, Heidelberg, Dordrecht, London: Springer, which is included herein by reference. However, in other embodiments, a different type of AM apparatus is used produce the object 4, e.g. by performing a different type of AM process. Examples of other appropriate AM processes that may be used to produce the object 4 include, but are not limited, blown powder AM processes, sheet lamination AM processes, vat photopolymerisation AM processes, laser blown powder AM processes, laser powder bed AM processes, and AM processes that implement wire and arc technology.

In this embodiment, the AM apparatus 2 comprises a heat source in the form of a laser source 8 configured to produce a high powered laser beam 10. The laser source 8 may be any appropriate type of laser source, e.g. a laser source that is configured to have a continuous wave power output of 500 W.

The AM apparatus 2 further comprises a source of metallic material (hereinafter referred to as “metallic powder 12) in the form of a powder repository 14 (or powder bed). In this embodiment, the metallic material is titanium alloy powder (e.g. Ti-6Al-4V). Titanium alloy powder typically has spherical grains with a diameter in the range 0-45 μm.

In other embodiments, a different type of material (e.g. a different type of metallic power, a plastic powder, or a ceramic powder) may be used.

In operation, a first piston 16 (that is located at the bottom of the first repository) is raised (in the direction indicated by an arrow in FIG. 1 and the reference numeral 18) so as to raise an amount of the powder 12 above a top level of the repository 14.

In this embodiment, a roller 20 is rolled (in the direction indicated by an arrow in FIG. 1 and the reference numeral 22) over the upper surface of the repository 14 and across an upper surface of a further repository 24. This is performed so that the metallic powder 12 that was raised above the level of the repository 14 by the raising of the first piston 16 is spread over an upper surface of the further repository 24. Thus, a top surface of the contents of the further repository 24 is covered by a layer of metallic power 12. In other embodiments, a different means of spreading the metallic powder 12 across a top surface of the contents of the further repository 24, such as a wiper, may be used instead of or in addition to the roller 20.

After a layer of metallic power 12 has been spread across a top surface of the contents of the further repository 24, the laser source 8 is controlled by a computer 26 to deliver the laser beam 10 via an optical fibre 28 to focussing optics 30 which focus the laser beam 10 to the focal point 32 on the layer of metallic power 12 has been spread across a top surface of the contents of the further repository 24.

The laser beam 10 produced by the laser source 8 is focused upon the layer of metallic powder 12 has been spread across the top surface of the contents of the further repository 24 so as to melt a portion of the layer of metallic powder 12.

In this embodiment, a portion of the metallic powder 12 on the top surface of the further repository 24 is fully melted, and subsequently allowed to cool so as to form a layer of solid material.

A second piston 34, located at the bottom of the further repository 24 is then lowered (i.e. moved in a direction indicated in FIG. 1 by a solid arrow and the reference numeral 36) to allow for a further layer of metallic powder 12 to be spread by the roller 20 (and subsequently melted and allowed to solidify) across the top surface of the contents of the further repository 24.

Many layers of material are laid on top of one another (in accordance with a digital design model 38 for the object 4 stored by the computer 26) to produce the object 4.

In this embodiment, the laser source 8 and focussing optics 30 are moveable under the control of the computer 26 in an X-Y plane that is parallel to the top surface of the contents of the further repository 24 (i.e. a top surface of the object 4). Thus, the laser focal point 14 may be directed to any point in a working envelope in the X-Y plane so that layers of material of a desired shape may be deposited.

Thus, AM apparatus 2 for performing a process of producing, in accordance with an embodiment, the object 4 is provided.

FIG. 2 is a process flow chart of an embodiment of a process of producing (i.e. manufacturing, building, constructing, etc.) the object 4 using the above described example AM apparatus 2.

The object 4 that is to be produced by the method of FIG. 2 may be any appropriate type of object having any appropriate size and shape. In this embodiment, the produced object 4 is made of titanium or a titanium alloy. However, in other embodiments, the produced object 4 is made of a different material to the object 2 in this embodiment.

At step s2, a three dimensional digital model 38 of the object 4 (that is to be produced) is provided. The digital model 38 of the object 4 is a digital design model for the object 4.

In this embodiment, the digital model 38 is stored by the computer 26. In this embodiment, the digital model 38 can be viewed, manipulated and analysed using the computer 26 e.g. by implementing a suitable software package or tool.

At step s4, a base plate is provided. The base plate provides a parent structure upon which layers of material are to be added (by the AM apparatus 2 performing the AM process) so as to form the object 4. In this embodiment, the base plate may, for example, be secured to the second piston 34 e.g. using any appropriate means.

At step s6, the AM apparatus is calibrated. This calibration process may, for example, include accurately measuring the base plate 6 and/or providing or creating a three dimensional digital model of the base plate 6. These data and the digital model 38 of the object 4 may be used to generate a “tool path” that, during the AM process, will be followed by the AM apparatus 2 so as to produce the object 4.

At step s8, using the AM apparatus 2, an AM process is performed to add layers of material to the base plate 6, and thereby form the object 4. In this embodiment, the AM apparatus 2 is for performing a powder bed AM process and is described in more detail above with reference to FIG. 1. In this embodiment, the AM process is the powder bed AM process described in more detail above with reference to FIG. 1. Further information on powder bed AM apparatus and the powder bed AM process can be found, for example in the above mentioned “Additive Manufacturing Technologies: Rapid Prototyping Direct Digital Manufacturing”, which is incorporated herein by reference. However, in other embodiments, a different type of AM apparatus and/or process is used produce the object 4.

In this embodiment, the AM process is performed in a substantially inert atmosphere (e.g. a chamber that is back-filled with an inert gas e.g. argon).

In this embodiment, the AM process comprises using a laser beam 10 to melt metallic powder 12 at the laser focal point 14. Typically, as this is performed, small droplets of molten material, or powder grains that have been heated by the laser beam 10, are ejected or sprayed (e.g. by the forces created by the heating process) away from the focal point 14 of the laser beam 10.

FIG. 3 is a schematic illustration (not to scale) showing small droplets of molten material (hereinafter referred to as the “droplets” and indicated in FIG. 3 by the reference numeral 40) being ejected, expelled or sprayed away from the focal point 14 of the laser beam 10 during the AM process. In some embodiments, instead of or in addition to liquid droplets 40 of molten material being ejected, expelled or sprayed away from the focal point 14 of the laser beam 10 during the AM process, heated solid particles of metallic material may be ejected and may also become contaminated by gasses or vapours present in the chamber atmosphere.

In this embodiment, the droplets 40 (and solid heated particles) have been heated by the laser beam 10. Due to their elevated temperature and high surface area relative to their volume, the droplets 40 (and solid heated particles) tend to be highly reactive. Thus, the droplets 40 (and solid heated particles) tend to react with any contaminants that are present in the chamber atmosphere 42 in which the AM process is being performed. For example, the droplets 40 may absorb oxygen gas that has contaminated the chamber atmosphere 42 and is present in the chamber in which the AM process is being performed. Also for example, the droplets 40 may react with any water vapour that has contaminated the chamber atmosphere 34 and is present in the chamber in which the AM process is being performed.

In this embodiment, a proportion of the droplets 40 (and solid heated particles), that have reacted with the contaminant within the chamber atmosphere 42 and that have been sprayed, or expelled away from the laser focal point 14, land on the surface of the object 4 being formed. Such a droplet 40 (or solid heated particle) of contaminated material may be “welded” into the structure of the object 4 when the laser beam 10 is focused at the location on the surface at which that contaminated material landed.

Also in this embodiment, a proportion of the droplets 40, that have reacted with the contaminant within the chamber atmosphere 42 and that have been sprayed, or expelled away from the laser focal point 14, land in a bed of un-melted titanium powder 12 contained within the further repository 24 and surrounding the object 4 being formed. The unused metallic powder 12 contained within the further repository 24 is recycled (i.e., reused in the AM process that is performed to produce the object 4, or in future AM processes). Thus, recycled powder that has absorbed a contaminant may be bonded, or welded, into the structure of the object 4.

Thus, the object 4 produced using the AM process of step s8 may comprise one or more contaminated regions. In other words, the object 4 may comprise regions in which the material of the object 4 is contaminated (by a contaminant such as oxygen).

At step s10, after the object 4 has been produced by the AM process, the object 4 is allowed to cool and, in this embodiment, the object 4 is removed from the further repository 24. Excess (i.e. unused or unmelted) metallic power 12 may be removed from the object, e.g. using an air jet, or by washing the object.

Thus, the object 4 is formed. The remaining steps of the process of FIG. 2 describe the processing of the object 4 formed at step s10 that is performed, in this embodiment to produce the finished object 4.

FIG. 4 is a schematic illustration (not to scale) of a cross section of a portion of the object 4 produced by performing steps s2 to s10 as described above.

The surface 44 of the object 4 is relatively uneven, i.e. rough.

In this embodiment, proximate to its surface 44, the object 4 comprises a plurality of open cavities 46 (i.e. open pores or voids in the material body). These open cavities 46 are cavities or hollows that are open to the atmosphere, i.e. cavities or hollows that are connected to the surface 44 of the object 4 such that gas can flow from outside the object 4 into the those open cavities 46.

Also, the object 4 further comprises a plurality of closed cavities 48 (i.e. closed pores or voids in the material body). These closed cavities 48 are hollow spaces or pits in the body of the object 4. Furthermore, the closed cavities 48 are not open to the atmosphere, i.e. they are not connected to the surface 44. In other words, gas cannot flow from outside the object 8 into the closed cavities 48 and vice versa.

Also, the object 4 further comprises a plurality of contaminated regions 50 (i.e. regions in which material that has previously absorbed or reacted with a contaminant, such as oxygen, has been incorporated, i.e. bonded or welded). In some embodiments, a contaminated regions 50 may be the result of the titanium powder raw material being contaminated e.g. by an undesired metal such as tungsten, copper or iron or a ceramic material such as an oxide, nitride or carbide. The contaminated regions 50 within the object may have a different chemical structure to the material that forms the rest of the object matrix (i.e. to the uncontaminated titanium object 4). Also, the contaminated regions 50 within the object 4 may have different material properties (e.g. they may be harder, or softer, and may cause degradation of fatigue performance) than the material that forms the rest of the object matrix (i.e. to the uncontaminated titanium object 4).

The presence of micro-pores (i.e. the open and closed cavities 46, 48) and the other imperfections (i.e. the contaminated regions 50) in the object 4 tend to adversely affect the fatigue performance of the object 4, especially in high-cycle fatigue situations. For example, the cavities 46, 48 and contaminated regions 50 may act as crack initiators. Also, the cavities 46, 48 and the contaminated regions 50 tend to adversely affect the load-bearing characteristics of the object 4.

In conventional methods, after the object 4 has been formed at step s8, the object may be further processed so as to smooth the rough surface 44. For example, a machining or polishing process may be performed. However, such processes tend to be inappropriate when attempting to fully remove the open cavities 46. Furthermore, such processes tend not to shrink, or remove, the closed cavities 48 or the contaminated regions 50 from the object 4. Machining the surface 44 of the object 4 to a sufficient depth may be performed to remove surface roughness and cavities connected to the surface 44. Machining may expose internal closed cavities that were originally isolated and machining tends to be relatively expensive and, depending on the complexity of the shape of the object 4, would at least partly negate the cost advantage of using a net-shape-process to form the object 4. Polishing processes also remove material from an object and so, if continued to a sufficient depth, may be performed to remove surface roughness and surface connected cavities. Polishing processes also tend to be relatively expensive to perform. Also, processes such as Hot Isostatic Pressing (HIPing), that may be employed to remove internal pores, tend not to have any effect on surface connected cavities.

Deficiencies of conventional methods of producing objects/parts may be overcome by performing steps s12 to s16 on the object 4, as opposed to just performing a machining/polishing process. Thus, the object formed at step s10 may be thought of as an “intermediate object” that is to be further processed (in accordance with steps s12 to s16) to produce a “final object”.

At step s12, the object 4 produced at step s10 is peened.

A conventional shot peening process may be used. For example, a process in which the surface 44 of the object 4 is impacting with shot (e.g. substantially round particles made of metal, glass or ceramic) with sufficient force such that the object 4 is plastically deformed at its surface 44 may be implemented. Also for example, laser, or ultra-sonic, peening may be performed.

In embodiments in which the surface 44 of the object 4 is impacted with shot, any appropriate shot medium may be used, e.g. S330 (cast steel with an average diameter of 0.8 mm). Also, any appropriate shot peening pressure may be used, e.g. 0.5 bar, 0.75 bar, 1.25 bar, 2 bar and 4 bar. Also, any appropriate Almen intensities may be used, e.g. 0.15 mmA, 0.20 mmA, 0.30 mmA, 0.38 mmA and 0.52 mmA.

After peening, the surface 44 of the peened object is relatively smooth (compared to the surface 44 prior to peening).

Furthermore, the process of shot peening tends to plastically deform the object 4 at its surface 44 such that the openings of the open cavities 46 are either closed such that gas cannot flow from outside the object 4 into an open cavity 46 and vice versa (i.e. such that, in effect, an open cavity 46 becomes a closed cavity 48), or are closed such that the opening of an open cavity 46 to the surface 44 is very small but that gas may still flow from outside the object 4 into an open cavity 46 and vice versa.

In this embodiment, the plastic deformation of the surface 44 of the object 4 is performed by peening. However, in other embodiments a different plastic deformation process is used, for example, a process of burnishing e.g. using a roller. Such finishing methods (e.g. tumbling, burnishing, shot peening etc.) tend not to remove material from an object.

At step s14, the peened object 4 is sintered.

In this embodiment, a temperature at which, and duration for which, the object is sintered is selected or determined.

The value for the sintering temperature is determined based upon any appropriate parameters, such that, when the object is heated to or above that temperature, contaminant is diffused within the object 4 (from region having high contaminant concentration to regions having low contaminant concentration) at or above a desired rate.

The value for the sintering duration is determined based upon any appropriate parameters, such that, when the object is heated to or above the determined sintering temperature for that duration, the maximum contaminant concentration level within the object 4 is below a threshold value. In some embodiments, the sintering duration is determined such that, when the object is heated to or above the determined sintering temperature for that duration, the contaminant concentration level within the object 4 is substantially uniform.

Examples of appropriate parameters that may be used to determine the sintering temperature or duration include, but are not limited to, the type of metal or alloy from which the object has been produced, the shape and/or size of the object, a contaminant concentration level of a region of the object (e.g. a maximum contaminant concentration level within the object 4), and a threshold contaminant concentration level below which the maximum contaminant concentration level within the object 4 is to be reduced.

In this embodiment, the object 4 is sintered at relatively high temperate. For example, the sintering of the peened object may comprise sintering at a temperature in the range 900° C. to the melting point of the object. In this embodiment, the object 4 is made of Ti-6Al-4V, the melting point of which is approximately 1600° C. Preferably, the object 4 is sintered at or above a temperature of 1100° C. More preferably, the object is sintered at or above a temperature of 1300° C.

In this embodiment, the object is sintered for a relatively long period of time, e.g. 1 hour, or 2 hours, or longer. The length of time sintering is to be performed for may depend upon the type of material from which the object 4 is made, or any other appropriate parameter.

In this embodiment, the sintering process is performed for a time period, and at a temperature, that provide the following:

• • the openings of the open cavities 46 (that were either closed or almost closed by the peening process of step s10) are diffusion bonded such that, in effect, the open cavities 46 become closed cavities 48. In other words, the openings of the open cavities 46 are fully sealed by sintering the object 4;
  • the contaminant(s) within the contaminated regions 50 of the object 4 are diffused within the object 4, e.g. throughout the bulk of the object. Preferably, this is performed such that the contaminant is dispersed substantially uniformly throughout the bulk of the object 4, i.e. such that no one region of the object 4 has a substantially higher concentration of contaminant than a different region of the object 4.

In this embodiment, the peened object 4 is sintered at a temperature that is below the melting point of the material from which the object 4 is made.

One advantage of plastically deforming the surface prior to sintering is that recrystallisation and diffusion bonding during high temperature sintering tends to be faster and more effective at smoothing the surface and closing open cavities when compared to an undeformed surface. This may, for example, be due to stored dislocation energy and residual stress within the object 4.

At step s16, a hot isostatic pressing (HIP) process is performed on the sintered object 4.

A conventional HIP process is used to reduce the porosity, and increase the density, of the sintered object 4. In this embodiment, the sintered object 4 is subjected to elevated temperature and elevated isostatic gas pressure by subjecting the sintered object 4 to heated and pressurised argon. A HIP cycle having a duration of approximately 2 hours, a temperature of 920° C., and a pressure of 102 MPa may be used.

The HIP process produces a relatively high pressure at the surface 44 of the sintered object 4, whilst the pressures in the closed cavities 48 (including the open cavities 46 that have been formed into closed cavities 48 as described above) are relatively low. This is due to the closed cavities 48 not being open to the surface 44, i.e. being gas-tight. As a result of plastic deformation, creep, and/or diffusion bonding caused by the elevated temperature and pressure, the closed cavities 48 in the sintered object 4 shrink or vanish completely.

The HIP process performed on the sintered object may cause diffusion of the contaminants within the objects 4. However, at a typical HIP temperature of 920° C., in titanium, the diffusion rates of most contaminants e.g. oxygen, nitrogen, carbon, etc. tend to be relatively low and sufficient to disperse contamination over only small distances, e.g. a few microns. In contrast, at a typical sintering temperature of 1300° C., the diffusion rate of contaminants tends to be several orders of magnitude faster than it is at 920° C., and therefore diffusion distances are correspondingly much greater. The sintering process described above may be thought of as a “contaminant homogenisation process”, i.e. a process of homogenising a concentration of a contaminant within an object produced using an AM process.

The hot isostatic pressing of the sintered object 4 produces the finished object 4. Thus, a process of producing the object 4 is provided.

In the above embodiments, the process of producing the object comprises peening, sintering and subsequently HIPing an object. This process of peening, sintering and subsequently HIPing an object may be performed in accordance with any of the methods described in patent application GB1203359.3, “Processing of Metal or Alloy Objects”, filed at the United Kingdom Intellectual Property Office (UKIPO) on 24 Feb. 2012, and incorporated herein, in its entirety, by reference.

An advantage provided by the above described methods is that pores, pits, or other (e.g. minute) openings, orifices, or interstices in the surface of the object tend to be removed. In other words, defects and/or discontinuities at or proximate to the surface of the object may, in effect, be repaired. These open cavities may act as crack initiators. Thus, removal of these open cavities from the object tends to result in improved fatigue performance, especially in high-cycle fatigue situations. The improved surface finish and microstructure of the object tend to improve its fatigue performance.

The above described methods also tend to remove (or shrink) the closed cavities (or other voids or hollows that are closed to the surface) in the body of the object. This also tends to improve the microstructure of the object, which tends to lead to improved fatigue performance.

A further advantage provided by the above described methods is that regions with relatively high concentrations of contaminants within an object produced using an AM process tends to be removed. Regions with relatively high levels or concentrations of a contaminant within an object (i.e. the contaminated regions 50) tend to have different material properties than the material that forms the rest of the object matrix, and may act as crack initiators or adversely affect the properties of the object. Thus, removal of these relatively contaminated regions (i.e. by more evenly distributing the contaminant throughout the object 4) tends to result in improved fatigue performance and material properties of the object 4.

Conventionally, objects produced using AM processes are not typically treated by sintering those objects at high temperatures. This is partly for cost reasons and partly because high temperature sintering of such an object tends to increase the grain size within the object, thereby reducing the strength of the object. However, the present inventors have realised that, surprisingly, the benefits gained by sintering the object so as to more evenly (e.g. uniformly) distribute contaminants within the object outweigh the disadvantages of performing the sintering process (i.e. the increased grain size).

Objects produced using an above described process tend to be able to withstand a greater maximum stress, and/or withstand a greater number of fatigue load cycles to failure, when compared to objects produced using a conventional AM process.

A further advantage provided by the above described methods is that the surface finish of the object tends to be improved. The object tends to be smoother and shinier than those that are produced using conventional techniques. This increased reflectivity is important in certain applications. For example, if the object is for decorative purposes, the improved aesthetic appearance of the object tends to be important. Also for example, the object tends to be less likely to retain dirt or surface contamination, and be easier to clean and less abrasive.

A further advantage provided by the above described processes is that an object is produced by an AM process. This tends to provide that the object is produced with very little wastage. Furthermore, it tends to be relatively easy to make relatively complex shapes that may be prohibitively expensive to machine.

The above described processes are advantageously applicable to objects of any size. The treatment process (e.g. a process of shot peening, sintering, and hot isostatic pressing) is performed after the formation of the object (i.e. after the performance of the AM process).

A further advantage provided by the above described processes is that the some of them may be performed on a large number of objects simultaneously. Thus, a cost of performing any or all of these operations (per component) may be significantly reduced.

A further advantage provided by the above described method is that a metallic powder that is known to contain contaminants may be used, by performing an AM process, to create an object that has substantially the same or better material/fatigue properties as a different object that has been produced, using the same AM process, from a metallic powder that contains fewer impurities or contaminants. This is because the object created from the relatively more contaminated powder may be treated (using the treatment processes described herein) so as to improve the material/fatigue properties of the object to be the same or better than those of the object formed from the relatively less contaminated powder. Thus, costs of producing an object having given material/fatigue properties may be reduced.

It should be noted that certain of the process steps depicted in the flowcharts of FIG. 2 and described above may be omitted or such process steps may be performed in differing order to that presented above and shown in FIG. 2. Furthermore, although all the process steps have, for convenience and ease of understanding, been depicted as discrete temporally-sequential steps, nevertheless some of the process steps may in fact be performed simultaneously or at least overlapping to some extent temporally.

Apparatus, including the computer, may be provided by configuring or adapting any suitable apparatus, for example one or more computers or other processing apparatus or processors, and/or providing additional modules. The apparatus may comprise a computer, a network of computers, or one or more processors, for implementing instructions and using data, including instructions and data in the form of a computer program or plurality of computer programs stored in or on a machine readable storage medium such as computer memory, a computer disk, ROM, PROM etc., or any combination of these or other storage media.

In the above embodiments, the object is formed using a powder bed AM process. However, in other embodiments the object is formed using a different type of AM process, for example, a blown powder process, a sheet lamination process, a vat photo-polymerisation process, a Laser Powder Bed process, or an ALM process that implements Wire and Arc technologies.

In other embodiments, the treatment process performed on the object produced using an AM process comprises peening, sintering, and hot isostatic pressing.

However, in other embodiments, the treatment process comprises the sintering process, and not the peening or HIPing processes. The high temperature sintering process advantageously tends to provide that the contaminant(s) within the contaminated regions of the object diffuse within the object, e.g. throughout the bulk of the object e.g. such that no one region of the object has a substantially higher concentration of contaminant than a different region of the object. This advantageously tends to result in improved fatigue performance and material properties of the object.

Also, in other embodiments, the treatment process comprises the hot isostatic pressing process, and not the sintering or peening processes. The hot isostatic pressing process advantageously tends to provide that the closed cavities in the object shrink or vanish completely. This advantageously tends to result in improved fatigue performance and material properties of the object. Also, if performed at a suitably high temperature (i.e. >900° C.), and for a suitably long duration, the hot isostatic pressing process advantageously tends to provide that the contaminant(s) within the contaminated regions of the object diffuse within the object, e.g. throughout the bulk of the object e.g. such that no one region of the object has a substantially higher concentration of contaminant than a different region of the object. This advantageously tends to result in improved fatigue performance and material properties of the object.

In some embodiments, the peening process is omitted.

In the above embodiments, the object is formed from a titanium alloy (e.g. an alloy comprising titanium with 6% aluminium and 4% vanadium which is also known as Ti-6Al-4V, or 6-4, 6/4, ASTM B348 Grade 5). However, in other embodiments, the object is formed from a different material. For example, in other embodiments, the object is formed from a pure (i.e. unalloyed) metal or a different type of alloy to that used in the above embodiments, or a ceramic.

In the above embodiments, the treatment process (i.e. a process of peening, sintering, and hot isostatic pressing) is performed on a single object. However, in other embodiments, a treatment process, or part of a treatment process, may be performed on any number of (different or the same) objects. This advantageously tends to reduce the cost of the process per component.

In the above embodiments, the sintering of the object is performed at the above specified temperatures, and for the above specified time-periods. However, in other embodiments sintering of an object is performed at a different appropriate temperature and/or for a different appropriate time period.

In the above embodiments, the HIP process is performed at the above specified temperatures and pressures, and for the above specified time-periods. However, in other embodiments a HIP process is performed at a different appropriate temperature and/or pressure, and/or for a different appropriate time period.

In the above embodiments, the sealing process performed on the object to seal the openings of the open cavities (i.e. the process of shot peening and sintering, or the process of coating and heating) is performed once before the HIP process is performed on the object. However, in other embodiments, before the HIP process is performed, one or both of the sealing processes may be performed multiple times. For example, the sealing process of peening and sintering may be performed more than once. In such an example, the sintering process that follows a shot peening process, tends to soften the work hardened surface formed during shot peening and tends to disperse any surface contamination into the bulk of the object, making the surface of the object more amenable to another shot peening process. Furthermore, the second, and any subsequent, shot peening processes may be performed at a lower intensity than the first shot peening process. This tends to result in a better surface appearance.

Claims

1. A method of producing an object, the method comprising: providing some metal or alloy;performing, using an Additive Manufacturing apparatus, in an environment containing an amount of a reactive contaminant, an Additive Manufacturing process to produce an intermediate object from the provided metal or alloy, wherein the Additive Manufacturing processes includes heating the provided metal or alloy thereby causing at least some of the metal or alloy to react with the reactive contaminant in the environment so as to produce contaminated metal or alloy, the intermediate object comprises the contaminated metal or alloy, and the intermediate object comprises one or more regions in which concentration level of the contaminated metal or alloy is above a threshold level;based upon the threshold level and a concentration level of the contaminated metal or alloy within one or more of the regions, determining a temperature and a duration; andsintering the intermediate object for a duration that is greater than or equal to the determined duration at a temperature that is greater than or equal to the determined temperature and less than the melting point of the metal or alloy so as to disperse the contaminated metal or alloy from the regions to one or more further regions within the intermediate object having a lower concentration level of the contaminated metal or alloy until the intermediate object comprises no regions having a concentration level of the contaminated metal or alloy above the threshold level, thereby producing the object.

2. A method according to claim 1, wherein the sintering is performed such that the contaminated metal or alloy is substantially uniformly distributed within the bulk of the object.

3. A method according to claim 1, wherein the method further comprises, after the sintering process, performing, on the intermediate object, a hot isostatic pressing process.

4. (canceled)

5. A method according to claim 1, wherein the determined temperature is between 1300° C. and the melting point of the provided metal or alloy.

6. A method according to claim 1, wherein the determined duration is greater than or equal to one hour.

7-9. (canceled)

10. A method according to claim 1, wherein the metal or alloy is Ti-6Al-4V.

11. A method according to claim 1 wherein, the metal or alloy is provided in powder form and the Additive Manufacturing process is a powder bed Additive Manufacturing process.

12. A method according to claim 1, wherein the reactive contaminant is oxygen.

13. A method according to claim 1, wherein the intermediate object comprises a plurality of open cavities, and the method further comprises: performing a sealing process on the intermediate object to seal the openings of the open cavities, thereby forming a plurality of closed cavities; andreducing the sizes of the closed cavities by performing a consolidation process on the intermediate object having the closed cavities.

14. A method according to claim 1, wherein the produced object comprises a plurality of open cavities, and the method further comprises: performing a sealing process on the object to seal the openings of the open cavities, thereby forming a plurality of closed cavities; andreducing the sizes of the closed cavities by performing a consolidation process on the object having the closed cavities.

15. A method according to claim 13, wherein the step of reducing the sizes of the closed cavities is performed until the closed cavities are no longer present.

16. A method according to claim 13, wherein the step of performing a consolidation process comprises performing a hot isostatic pressing process.

17. A method according to claim 13, wherein the step of performing a sealing process comprises plastically deforming the surface of the object.

18. A method according to claim 17, wherein plastically deforming the surface of the object comprises shot peening the surface of the object.

19. A method according to claim 17, wherein the step of performing a sealing process further comprises sintering the object after the surface of the object has been plastically deformed.

20. A method according to claim 1, wherein: the method further comprises determining a concentration level of the contaminated metal or alloy within a region of the intermediate object; andthe determined temperature and duration are determined using the determined contaminant concentration level.

21. A method according to claim 20, wherein the determining of a concentration level of the contaminated metal or alloy within a region of the intermediate object comprises determining the maximum concentration level of the contaminated metal or alloy within the intermediate object.

22. (canceled)

23. Apparatus for producing an object, the apparatus comprising: Additive Manufacturing apparatus configured to, using some provided metal or alloy, in an environment containing an amount of a reactive contaminant, perform an Additive Manufacturing process to produce an intermediate object from the provided metal or alloy, wherein the Additive Manufacturing process include heating the provided metal or alloy thereby causing at least some of the metal or alloy to react with the reactive contaminant in the environment so as to produce a contaminated metal or alloy, and the intermediate object comprises one or more regions in which a concentration level of the contaminated metal or alloy is above a threshold level;means for, based upon the threshold level and the concentration level of the contaminated metal or alloy within one or more of the regions, determine a temperature and a duration; andsintering means configured to sinter the intermediate object for a duration that is greater than or equal to the determined duration at a temperature that is greater than or equal to the determined temperature and less than the melting point of the metal or alloy so as to disperse the contaminated metal or alloy from the regions to one or more further regions within the intermediate object having a lower concentration level of the contaminated metal or alloy until the intermediate object comprises no regions having a concentration level of the contaminated metal or alloy above the threshold level, thereby producing the object.

24. An object that has been produced using a method according to claim 1.

25-26. (canceled)

27. A method according to claim 1, wherein the step of performing comprises: performing, using the Additive Manufacturing apparatus, in the environment containing an amount of the reactive contaminant, an initial Additive Manufacturing process, the initial Additive Manufacturing processes including heating the provided metal or alloy, thereby causing at least some of the metal or alloy to react with the reactive contaminant in the environment so as to produce the contaminated metal or alloy; andperforming, using the Additive Manufacturing apparatus, a further Additive Manufacturing process, to produce the intermediate object from metal or alloy recycled from the initial Additive Manufacturing process, the metal or alloy recycled from the initial Additive Manufacturing process including the contaminated metal or alloy.