Systems and methods for creating nanocrystalline alloy articles using additive manufacturing

Abstract

Embodiments described herein relate generally to systems and methods for using nanocrystalline metal alloy particles or powders to create nanocrystalline and/or microcrystalline metal alloy articles using additive manufacturing. In some embodiments, a manufacturing method for creating articles includes disposing a plurality of nanocrystalline particles and selectively binding the particles together to form the article. In some embodiments, the nanocrystalline particles can be sintered to bind the particles together. In some embodiments, the plurality of nanocrystalline particles can be disposed on a substrate and sintered to form the article. The substrate can be a base or a prior layer of bound particles. In some embodiments, the nanocrystalline particles can be selectively bound together (e.g., sintered) at substantially the same time as they are disposed on the substrate.

1 - 23 . (canceled) 
     
     
         24 . A method, comprising:
 disposing a plurality of nanocrystalline metal microparticles and a binder;   binding at least a portion of the nanocrystalline metal microparticles together to form a green body;   applying heat to the green body during a first time period to substantially vaporize the binder and form a substantially binderless green body; and   applying heat during a second time period to sinter the substantially binderless green body to form an alloy article.   
     
     
         25 . The method of  claim 24 , wherein the nanocrystalline metal microparticles are disposed onto a substrate. 
     
     
         26 . The method of  claim 24 , wherein the nanocrystalline metal microparticles are disposed using an additive manufacturing process. 
     
     
         27 . The method of  claim 26 , wherein the nanocrystalline metal microparticles are disposed on at least one of a substrate and at least a portion of a prior layer from the additive manufacturing process. 
     
     
         28 . The method of  claim 24 , wherein the plurality of nanocrystalline metal microparticles include a first plurality of nanocrystalline microparticles comprising a first metal material, and a second plurality of nanocrystalline microparticles comprising a second metal material. 
     
     
         29 . The method of  claim 24 , wherein the heat is applied via at least one of an electron beam, a high power laser beam, or a plasma transferred arc system. 
     
     
         30 . The method of  claim 24 , wherein the first time period and the second time period do not overlap. 
     
     
         31 . The method of  claim 24 , further comprising:
 combining a plurality of microcrystalline metal particles with the plurality of nanocrystalline metal microparticles and the binder.   
     
     
         32 . A method, comprising:
 combining a plurality of nanocrystalline microparticles and a binder to create an intermediate material;   selectively causing the binder to bind such that a connected network of intermediate material is formed;   applying heat to the connected network of intermediate material during a first time period to vaporize the binder; and   applying heat to the connected network of intermediate material sufficient during a second time period to sinter the connected network of intermediate material to form a sintered article.   
     
     
         33 . The method of  claim 32 , wherein the connected network is a green body. 
     
     
         34 . The method of  claim 33 , wherein the green body is sintered to form the sintered article. 
     
     
         35 . The method of  claim 32 , wherein the plurality of nanocrystalline microparticles include a first plurality of nanocrystalline microparticles comprising a first metal material and a second plurality of nanocrystalline microparticles comprising a second metal material. 
     
     
         36 . The method  claim 32 , wherein the binder includes a wax. 
     
     
         37 . The method  claim 32 , wherein the binder includes a polymer. 
     
     
         38 . The method  claim 32 , wherein the binder includes a metal. 
     
     
         39 . The method of  claim 32 , wherein applying the heat during the first time period and/or the second time period is via an electron beam, a high power laser beam, or a plasma transferred arc system. 
     
     
         40 . The method of  claim 32 , wherein the first time period and the second time period do not overlap. 
     
     
         41 . The method of  claim 32 , further comprising:
 combining a plurality of microcrystalline microparticles with the plurality of nanocrystalline microparticles and the binder to create the intermediate material.   
     
     
         42 . A method, comprising:
 disposing a plurality of nanocrystalline microparticles, the nanocrystalline microparticles including a first metal material, a second metal material, and a binder;   selectively binding the nanocrystalline microparticles and/or the binder;   vaporizing the binder; and   after the binder is substantially vaporized, sintering the nanocrystalline microparticles at a sintering temperature to form an alloy article.   
     
     
         43 . The method of  claim 42 , wherein the nanocrystalline microparticles are disposed onto a substrate. 
     
     
         44 . The method of  claim 42 , wherein the nanocrystalline microparticles are disposed using an additive manufacturing process. 
     
     
         45 . The method of  claim 42 , wherein selectively binding the nanocrystalline microparticles and/or the binder forms a green body. 
     
     
         46 . The method of  claim 42 , wherein sintering the nanocrystalline microparticles is at a higher temperature than vaporizing the binder. 
     
     
         47 . The method of  claim 42 , wherein the nanocrystalline microparticles are coated with the binder. 
     
     
         48 . The method of  claim 42 , wherein selectively binding the nanocrystalline microparticles and/or the binder includes a chemical fusion process. 
     
     
         49 . The method of  claim 42 , wherein the vaporizing is during a first time period and the sintering is during a second time period, and
 wherein the first time period and the second time period do not overlap.