Additive manufacturing of functionally gradient degradable tools
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B33Y-010/00
B33Y-080/00
B22F-003/105
B22F-001/02
출원번호
US-0853977
(2015-09-14)
등록번호
US-10059092
(2018-08-28)
발명자
/ 주소
Welch, John C.
Xu, Zhiyue
Oxford, James Andy
출원인 / 주소
BAKER HUGHES, A GE COMPANY, LLC
대리인 / 주소
Cantor Colburn LLP
인용정보
피인용 횟수 :
0인용 특허 :
14
초록▼
A method of manufacturing an article comprises depositing a metallic powder on a substrate or a worktable; fusing the metallic powder according to a preset pattern; and adjusting a composition of the metallic powder or a condition to fuse the metallic powder or a combination thereof to additively fo
A method of manufacturing an article comprises depositing a metallic powder on a substrate or a worktable; fusing the metallic powder according to a preset pattern; and adjusting a composition of the metallic powder or a condition to fuse the metallic powder or a combination thereof to additively form an article such that the article has a first portion and a second portion, wherein the first portion has one or more of the following properties different than those of the second portion: corrosion rate; tensile strength; compressive strength; modulus; or hardness.
대표청구항▼
1. A method of manufacturing an article, the method comprising: depositing a metallic powder on a substrate or a worktable;fusing the metallic powder according to a preset pattern; andadjusting a composition of the metallic powder or a condition to fuse the metallic powder or a combination thereof t
1. A method of manufacturing an article, the method comprising: depositing a metallic powder on a substrate or a worktable;fusing the metallic powder according to a preset pattern; andadjusting a composition of the metallic powder or a condition to fuse the metallic powder or a combination thereof to additively form an article such that the article has a first portion and a second portion, wherein the first portion has one or more of the following properties different than those of the second portion: corrosion rate; tensile strength; compressive strength; modulus; or hardness,wherein the metallic powder comprises a coated particle having a particle core with a nanoscale coating disposed thereon, the nanoscale coating having a melting point different than a melting point of the particle core. 2. The method of claim 1, wherein the depositing and the fusing are carried out as part of a selective laser sintering process, a laser melting process, or a direct metal deposition process. 3. The method of claim 1, wherein fusing the metallic powder comprises applying an energy beam from an energy source to the metallic powder. 4. The method of claim 1, wherein the metallic powder is at least partially fused before deposited on the substrate or the worktable. 5. The method of claim 1, wherein the metallic powder is fused after deposited on the substrate or the worktable. 6. The method of claim 1, wherein the particle core comprises one or more of the following: Mg; Al; Zn; Mn, or an alloy thereof. 7. The method of claim 1, wherein the nanoscale coating comprises one or more of the following: Al; Zn; Mn; Mg; Mo; W; Cu; Fe; Si; Ca; Co; Ta; Re; or Ni; an oxide thereof; a carbide thereof; or a nitride thereof. 8. The method of claim 1, wherein adjusting a condition to fuse the metallic powder comprises fusing the metallic powder at an energy gradient. 9. The method of claim 1, wherein the metallic powder further comprises a second particle that is compositionally different from the coated particle. 10. The method of claim 9, wherein the second particle comprises one or more of the following: Fe; Ni; Co; W; or Cu; or oxides; nitrides; or carbides thereof. 11. The method of claim 9, wherein adjusting a composition of the metallic powder comprises changing the relative amounts of the coated particle and the second particle. 12. The method of claim 9, wherein adjusting a composition of the metallic powder comprises varying a particle size of the metallic matrix particle, varying a particle size of the second particle, or a combination thereof. 13. A method of using an article, the method comprising: forming an article according to a method of claim 1, the article comprising a first portion that is corrodible in a fluid at a first corrosion rate and a second portion that is corrodible in the fluid at a second corrosion rate, wherein the first corrosion rate is greater than the second corrosion rate;using the article to perform a first operation;exposing the article to the fluid;selectively corroding the first portion of the article to provide a corroded article; andusing the corroded article to perform a second operation that is different from the first operation. 14. The method of claim 13, wherein the article is a downhole article, the fluid is a wellbore fluid, and the first and second operations are wellbore operations. 15. A method of manufacturing an article, the method comprising: depositing a metallic powder on a substrate or a worktable;fusing the metallic powder according to a preset pattern; andadjusting a composition of the metallic powder or a condition to fuse the metallic powder or a combination thereof to additively form an article such that the article has a first portion and a second portion, wherein the first portion has one or more of the following properties different than those of the second portion: corrosion rate; tensile strength; compressive strength; modulus; or hardness;wherein the metallic powder comprises an uncoated metallic matrix particle and a second particle;the metallic matrix particle comprising one or more of the following: a magnesium-based alloy; an aluminum-based alloy; or a zinc-based alloy; andthe second particle comprising one or more of the following: a metal; an oxide of the metal; a nitride of the metal; or a cermet of the metal; wherein the metal is W; Co; Cu; Ni; or Fe. 16. The method of claim 15, wherein adjusting a composition of the metallic powder comprises changing the relative amounts of the metallic matrix particle and the second particle. 17. The method of claim 16, wherein adjusting a composition of the metallic powder comprises varying a particle size of the metallic matrix particle, varying a particle size of the second particle, or a combination thereof. 18. The method of claim 15, wherein the metallic matrix particle comprises a magnesium-based alloy. 19. The method of claim 15, wherein the metallic matrix particle comprises a zinc-based alloy.
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