Additive manufacturing utilizing metallic wire

Abstract

In various embodiments, additive manufacturing is utilized to fabricate three-dimensional metallic parts using metallic alloy wire as a feedstock material.

What is claimed is: 
     
         1 .- 19 . (canceled) 
     
     
         20 . A method of forming a three-dimensional part comprising a high-entropy alloy or a multi-principal element alloy by additive manufacturing, wherein the high-entropy alloy or multi-principal element alloy comprises four or more metallic elements selected from the group consisting of Nb, Ta, Mo, W, Ti, Hf, V, Zr, Al, and Cr, the method comprising:
 (a) providing a wire extending in an axial direction and comprising a substantially homogenous assemblage of (i) one or more first metal powders each comprising one or more of the metallic elements, wherein at least some particles of at least one first metal powder are substantially spherical, and (ii) one or more second metal powders each comprising one or more of the metallic elements, wherein at least some particles of at least one second metal powder are elongated in the axial direction and extend at least partially around particles of the one or more first metal powders;   (b) translating a tip of the wire relative to a platform;   (c) thereduring, melting a tip of the wire with an energy source to form a molten bead comprising the four or more metallic elements, whereby the bead cools to form at least a portion of a layer of a three-dimensional part; and   (d) repeating steps (b) and (c) one or more times to produce the three-dimensional part,   wherein the three-dimensional part comprises the high-entropy alloy or the multi-principal element alloy.   
     
     
         21 . The method of  claim 20 , wherein at least some particles of at least one first metal powder are elongated in the axial direction. 
     
     
         22 . The method of  claim 20 , wherein particles of at least one first metal powder are less ductile than particles of at least one second metal powder. 
     
     
         23 . The method of  claim 20 , wherein particles of all of the first metal powders are less ductile than particles of all of the second metal powders. 
     
     
         24 . The method of  claim 20 , wherein the one or more first metal powders comprise at least one of Mo or W. 
     
     
         25 . The method of  claim 20 , wherein the one or more second metal powders comprise at least one of Ta or Nb. 
     
     
         26 . The method of  claim 20 , wherein at least one of the first metal powders is an elemental powder consisting essentially of one of the metallic elements. 
     
     
         27 . The method of  claim 20 , wherein at least one of the first metal powders is an alloy powder consisting essentially of two or more of the metallic elements. 
     
     
         28 . The method of  claim 20 , at least one of the second metal powders is an elemental powder consisting essentially of one of the metallic elements. 
     
     
         29 . The method of  claim 20 , wherein at least one of the second metal powders is an alloy powder consisting essentially of two or more of the metallic elements. 
     
     
         30 . The method of  claim 20 , wherein the wire comprises one or more metallic tubes surrounding the one or more first metal powders and the one or more second metal powders, each metallic tube comprising at least one of the metallic elements. 
     
     
         31 . The method of  claim 20 , wherein an oxygen concentration of the wire is 300 ppm or less. 
     
     
         32 . A three-dimensional part fabricated by the method of  claim 20 . 
     
     
         33 . A method of forming a three-dimensional part comprising a high-entropy alloy or a multi-principal element alloy by additive manufacturing, wherein the high-entropy alloy or multi-principal element alloy comprises four or more metallic elements selected from the group consisting of Nb, Ta, Mo, W, Ti, Hf, V, Zr, Al, and Cr, the method comprising:
 (a) providing a wire produced, at least in part, by a process comprising (A) combining, within a tube, (i) one or more first metal powders each comprising a plurality of substantially spherical particles, and (ii) one or more second metal powders each comprising a plurality of non-spherical particles, the one or more second metal powders being mixed with the one or more first metal powders, thereby forming a wire preform, and (B) reducing a diameter of the wire preform via one or more mechanical deformation processes;   (b) translating a tip of the wire relative to a platform;   (c) thereduring, melting a tip of the wire with an energy source to form a molten bead comprising the four or more metallic elements, whereby the bead cools to form at least a portion of a layer of a three-dimensional part; and   (d) repeating steps (b) and (c) one or more times to produce the three-dimensional part,   wherein the three-dimensional part comprises the high-entropy alloy or the multi-principal element alloy.   
     
     
         34 . The method of  claim 33 , wherein the process of producing the wire comprises removing at least a portion of the tube after the diameter of the wire preform is reduced. 
     
     
         35 . The method of  claim 33 , wherein the tube consists essentially of one of the metallic elements. 
     
     
         36 . The method of  claim 33 , wherein the tube is an alloy tube consisting essentially of two or more of the metallic elements. 
     
     
         37 . The method of  claim 33 , wherein at least one of the first metal powders is an elemental powder consisting essentially of one of the metallic elements. 
     
     
         38 . The method of  claim 33 , wherein at least one of the first metal powders is an alloy powder consisting essentially of two or more of the metallic elements. 
     
     
         39 . The method of  claim 33 , at least one of the second metal powders is an elemental powder consisting essentially of one of the metallic elements. 
     
     
         40 . The method of  claim 33 , wherein at least one of the second metal powders is an alloy powder consisting essentially of two or more of the metallic elements. 
     
     
         41 . A three-dimensional part fabricated by the method of  claim 33 .