Multi-wire feeder method and system for alloy sample formation and additive manufacturing

Abstract

Systems and methods, comprising a directed heat source coupled to a multi-wire feed-head configured to feed one or more wires having diverse compositions into a heat affected region, are provided for the synthesis of alloy samples having defined compositions, combinatorial alloy sample series and libraries, and shaped alloy components.

1 . A multi-wire integrated feed-head for producing multiple alloy samples, comprising:
 an upper section comprising an entrance opening for receiving heat output from a directional heat source;   a lower section comprising an upward facing surface and a downward facing surface;   an elongated heat delivery channel traversing the upper and lower head sections running between the upper section opening and an exit disposed in the downward-facing surface of the lower section; and   a multiplicity of elongated wire channels traversing the lower head section, each channel running between one of the multiplicity of entrances disposed on the upward facing surface and one of the multiplicity of exits disposed on the downward-facing surface;   wherein at least a two of the multiplicity of entrances are configured to receive each of at least two wire feeds from each of at least a two wire feeders and the corresponding two wire exits are configured to deliver wire towards a common focus.   
     
     
         2 . The feed-head of  claim 1 , wherein
 the heat delivery channel is aligned along a common longitudinal axis of the upper and lower head sections, and   the longitudinal axes of the multiplicity of elongated wire channels are inclined at equal angles to the head longitudinal axis and converge on the common focus disposed on the head longitudinal axis below the downward-facing surface.   
     
     
         3 . The feed-head of  claim 1 , wherein the longitudinal axes of the multiplicity of channels are inclined at around 50 degrees to the longitudinal axis and distributed symmetrically around the longitudinal head axis. 
     
     
         4 . The feed-head of  claim 1 , wherein the multiplicity of channels have essentially cylindrical portions with internal diameters between about 1.5 and 3.0 mm and lengths between about 15 and 50 mm. 
     
     
         5 . The feed-head of  claim 1 , wherein the multiplicity of wire channels comprises twelve or more channels. 
     
     
         6 . The feed-head of  claim 1 , wherein one or more of the multiplicity of wire channels further comprises a constriction at the channel exit. 
     
     
         7 . The feed-head of  claim 1 , wherein the multiplicity of wire channels comprises wire channels of the same length and internal diameter. 
     
     
         8 . The feed-head of  claim 1 , further comprising liner tubes traversing at least a portion of one or more of the wire channels and extending beyond the downward-facing surface. 
     
     
         9 . The feed-head of  claim 1 , wherein the downward-facing surface is essentially flat and disposed perpendicular to the head longitudinal axis. 
     
     
         10 . The feed head of  claim 1 , wherein the downward-facing surface is concave and disposed co-axially with respect to the longitudinal head axis to reflect heat radiation towards the common focus. 
     
     
         11 . The feed head of  claim 10 , wherein the downward-facing surface is substantially hemispherical. 
     
     
         12 . The feed head of  claim 1 , further comprising a second upward-facing surface and one or more elongated powder feed channels, each running between an entrance on the second upward facing surface and an exit on the downward-facing surface. 
     
     
         13 . The feed-head of  claim 12 , wherein the longitudinal axes of the one or more powder channels are inclined at around 20 degrees to the longitudinal axis and have essentially cylindrical portions with internal diameters between about 1.5 and 3.0 mm. 
     
     
         14 . A system for alloy sample formation comprising the feed-head of  claim 1 , and further comprising:
 mechanisms for applying controlled relative displacement and/or rotation of feed-head and work-piece;   at least two wire feeders and controllers for the at least two-wire feeders; and   a directional heat source coupled to the feed-head.   
     
     
         15 . The system of  claim 14 , further comprising a chamber enclosing the multi-wire feed head and work-piece configured to allow back-filling with an inert gas. 
     
     
         16 . The system of  14 , further comprising a flowing inert gas shield configured to enclose at least a fraction of the downward-facing surface and the heat-affected region comprising the sample and/or at least a portion of the work-piece surface.