Systems and methods for wire deposited additive manufacturing using titanium

Abstract

A metallic part is disclosed. The part may comprise a functionally graded monolithic structure characterized by a variation between a first material composition of a first structural element and a second material composition of at least one of a second structural element. The first material composition may comprise an alpha-beta titanium alloy. The second material composition may comprise a beta titanium alloy.

What is claimed is: 
     
         1 . A metallic part, comprising:
 a functionally graded monolithic structure characterized by a variation between a first material composition of a first structural element and a second material composition of a second structural element, wherein   the first material composition comprises an alpha-beta titanium alloy and the second material composition comprises a beta titanium alloy,   wherein the second structural element is monolithic with a surface of the first structural element.   
     
     
         2 - 4 . (canceled) 
     
     
         5 . The metallic part of  claim 1 , wherein the second structural element comprises 5% to 6% by weight iron, 0.5% to 2% by weight aluminum, and 6% to 9% by weight vanadium. 
     
     
         6 . The metallic part of  claim 5 , wherein the heat treated wire comprises 0.25% to 0.50% by weight oxygen and 0.001% to 0.015% by weight hydrogen. 
     
     
         7 . The metallic part of  claim 1 , wherein the first structural element comprises a base plate having 5.5% to 6.75% by weight aluminum and 3.5% to 4.5% by weight vanadium. 
     
     
         8 . The metallic part of  claim 7 , wherein the second structural element comprises a flange portion. 
     
     
         9 . The metallic part of  claim 8 , wherein the first structural element and the second structural element defines one of a “C” shaped channel, a “T” shaped beam, an “S” shaped beam, an “I” shaped beam, an “H” shaped beam, or an “L” shaped beam. 
     
     
         10 . An article of manufacture including a metallic component comprising:
 a functionally graded monolithic structure characterized by a variation between a first material composition of a first structural element and a second material composition of a second structural element, wherein   each of the first material composition and the second material composition comprises at least one of a titanium metal or an alloy,   wherein the second structural element is formed of a wire feedstock,   wherein the wire feedstock comprises a heat treated wire drawn from a sintered billet of powdered metals, and   the sintered billet of powdered metals comprise titanium hydride, iron, vanadium, and aluminum.   
     
     
         11 . The article of manufacture of  claim 10  wherein, wherein the first material composition comprises a substantially iron free titanium alloy. 
     
     
         12 . The article of manufacture  claim 11 , wherein the second material composition comprises a titanium alloy with an iron composition 3% by weight or more. 
     
     
         13 . The article of manufacture of  claim 12 , wherein the sintered billet of powdered metals comprise between 4% and 6% by weight iron, between 0.5% to 2% by weight aluminum, and between 6% to 9% by weight vanadium. 
     
     
         14 . The article of manufacture of  claim 12 , wherein the heat treated wire comprises between 0.25% and 0.50% by weight oxygen and between 0.001% and 0.015% by weight hydrogen. 
     
     
         15 . The article of manufacture of  claim 14 , wherein the heat treated wire is heat treated by at least one of annealing, solutionizing, or aging. 
     
     
         16 . The article of manufacture of  claim 15 , wherein the heat treated wire has undergone at least one of a beta phase transformation, a beta anneal, or an alpha beta anneal during the at least one of annealing, solutionizing, or aging. 
     
     
         17 . A method of additive manufacturing, comprising:
 mixing a plurality of powdered metals comprising titanium, iron, vanadium, and aluminum to produce a powder blend;   cold isostatic pressing and sintering the powder blend to form a billet;   performing a wire forming operation on the billet to produce a worked wire;   heat treating the worked wire to produce a heat treated wire;   loading a first structural element into an additive manufacturing machine;   printing a second structural element of the heat treated wire integral to the first structural element to form a part, and   heat treating the part to generate a functionally graded monolithic structure.   
     
     
         18 . The method of  claim 17 , wherein the titanium is a titanium hydride powder and the first structural element comprises a substantially Iron free Titanium alloy. 
     
     
         19 . The method of  claim 18 , wherein the powder blend comprises between 4% and 6% by weight iron, between 0.5% to 2% by weight aluminum, and between 6% to 9% by weight vanadium. 
     
     
         20 . The method of  claim 19 , wherein the sintering is performed between 900° F. and 1600° F. and under a vacuum.