System and Method for Forming Nano-Particles in Additively-Manufactured Metal Alloys

Abstract

In some embodiments, a method of producing a metallic article includes providing a metallic powder, selecting a predetermined concentration for a reactive component, providing a controlled atmosphere including the reactive component at the predetermined concentration, and additively manufacturing the metallic article from the metallic powder under the controlled atmosphere. The metallic powder includes a metallic element or metallic alloy. The reactive component reacts with the metallic powder in a weld pool formed during the additive manufacturing to form a dispersion of nano-particles in the weld pool. The nano-particles are dispersed throughout the metallic article in a substantially uniform manner. In some embodiments, the metallic powder includes the reactive component. Metallic articles formed by the disclosed methods are also disclosed.

What is claimed is: 
     
         1 . A method of producing a metallic article, the method comprising:
 providing a metallic powder, wherein the metallic powder comprises a metallic element or metallic alloy;   selecting a predetermined concentration for a reactive component;   providing a controlled atmosphere comprising the reactive component at the predetermined concentration; and   additively manufacturing the metallic article from the metallic powder under the controlled atmosphere such that the reactive component reacts with the metallic powder in a weld pool formed during the additive manufacturing to form a dispersion of nano-particles in the weld pool;   wherein the nano-particles are dispersed throughout the metallic article in a substantially uniform manner.   
     
     
         2 . The method of  claim 1 , wherein the metallic powder is copper or a copper-based alloy. 
     
     
         3 . The method of  claim 2 , wherein the copper-based alloy is a copper-nickel-silicon alloy or a copper-tin alloy. 
     
     
         4 . The method of  claim 1 , wherein the controlled atmosphere further comprises an inert gas. 
     
     
         5 . The method of  claim 4 , wherein the inert gas is selected from the group consisting of argon, nitrogen, and a combination thereof. 
     
     
         6 . The method of  claim 1 , wherein the controlled atmosphere is a vacuum. 
     
     
         7 . The method of  claim 1 , wherein the reactive component comprises an element selected from the group consisting of oxygen, nitrogen, silicon, carbon, and a combination thereof. 
     
     
         8 . The method of  claim 1 , wherein the nano-particles are nano-oxide particles. 
     
     
         9 . The method of  claim 1  further comprising subjecting the metallic article to a single-step precipitation hardening process, without solutionizing the metallic article between the additive manufacturing and the precipitation hardening, to enhance at least one mechanical property of the metallic article. 
     
     
         10 . The method of  claim 1 , wherein the additive manufacturing comprises selective laser melting or electron beam melting. 
     
     
         11 . A metallic article formed by the method of  claim 1 . 
     
     
         12 . A method of producing a metallic article, the method comprising:
 selecting a predetermined concentration for a reactive component;   providing a metallic powder, wherein the metallic powder comprises a metallic element or metallic alloy and the reactive component at the predetermined concentration;   providing a controlled atmosphere; and   additively manufacturing the metallic article from the metallic powder under the controlled atmosphere such that the reactive component reacts with the metallic powder in a weld pool formed during the additive manufacturing to form a dispersion of nano-particles in the weld pool;   wherein the nano-particles are dispersed throughout the metallic article in a substantially uniform manner.   
     
     
         13 . The method of  claim 12 , wherein the metallic element or metallic alloy is copper, a copper-based alloy, a copper-nickel-silicon alloy or a copper-tin alloy. 
     
     
         14 . The method of  claim 12 , wherein the controlled atmosphere is an inert gas atmosphere. 
     
     
         15 . The method of  claim 14 , wherein the inert gas is selected from the group consisting of argon, nitrogen, and a combination thereof. 
     
     
         16 . The method of  claim 12 , wherein the controlled atmosphere is a vacuum. 
     
     
         17 . The method of  claim 12 , wherein the reactive component comprises an element selected from the group consisting of oxygen, nitrogen, silicon, carbon, and a combination thereof. 
     
     
         18 . The method of  claim 12 , wherein the nano-particles are nano-oxide particles. 
     
     
         19 . The method of  claim 12  further comprising subjecting the metallic article to a single-step precipitation hardening process, without solutionizing the metallic article between the additive manufacturing and the precipitation hardening, to enhance at least one mechanical property of the metallic article. 
     
     
         20 . The method of  claim 12 , wherein the additive manufacturing comprises selective laser melting or electron beam melting.