System and method for producing superalloys utilizing electro-metallurgy

Abstract

A system and method for producing a rigid, heat-resistant part, such as a superalloy, via electrodeposition. The method can include the steps of coating a secondary alloy particulate with a superior alloy, forming a pre-coated particulate, dispensing a quantity of the pre-coated particulate into a container of an electrolytic solution, and applying a charge to the electrolytic solution such that the pre-coated particulate is electrodeposited onto a cathode or an external casing of the cathode. The pre-coated particulate can include particulate of non-uniform size and/or shape. The secondary alloy particulate is protected in the catalytic solution by the superior alloy coated thereon, such as nickel, iron, cobalt, and/or copper. The method also includes a step of vibrating or agitating the electrolytic solution before and/or during applying the charge to the electrolytic solution for even distribution of the pre-coated particulate onto the cathode or an external casing thereof.

1 . A method for producing a rigid, heat-resistant part, the method comprising:
 dispensing a quantity of a pre-coated particulate into a container of an electrolytic solution, wherein the pre-coated particulate is a secondary alloy particulate coated with a superior alloy; and   applying a charge to the electrolytic solution such that the pre-coated particulate is electrodeposited onto a cathode or an external casing of the cathode.   
     
     
         2 . The method of  claim 1 , wherein the superior alloy is at least one of nickel, iron, cobalt, and copper. 
     
     
         3 . The method of  claim 1 , wherein the secondary alloy particulate comprises particles of at least one of chromium (Cr), manganese (Mn), tungsten (W), molybdenum (Mo), rhenium (Re), ruthenium (Ru), titanium (Ti), aluminum (Al), niobium (Nb), tantalum (Ta), zirconium (Zr), vanadium (V), yttrium (Y), cerium (Ce), lanthanum (La), boron (B), phosphorus (P) and carbon (C) with at least one of grain growth inhibitors and recrystallization inhibitors. 
     
     
         4 . The method of  claim 1 , wherein the pre-coated particulate comprises particles of at least one of varying shapes and varying dimensions. 
     
     
         5 . The method of  claim 1 , wherein the cathode or the external casing of the cathode has a complex, non-planar surface. 
     
     
         6 . The method of  claim 1 , further comprising vibrating the container during the steps of dispensing the quantity of the pre-coated particulate and applying the charge to the electrolytic solution. 
     
     
         7 . The method of  claim 6 , wherein vibrating the container comprises applying a high amplitude, low frequency vibration to at least one of the container and the electrolytic solution. 
     
     
         8 . The method of  claim 1 , further comprising drawing partial vacuum from within the container during the step of applying the charge, such that hydrogen is removed from the container. 
     
     
         9 . A method for producing a rigid, heat-resistant part, the method comprising:
 coating a secondary alloy particulate with a superior alloy, forming a pre-coated particulate, wherein the superior alloy is at least one of nickel, iron, cobalt, and copper;   dispensing a quantity of the pre-coated particulate into a container of an electrolytic solution, wherein the electrolytic solution comprises one or more alloying elements;   applying a charge to the electrolytic solution such that the pre-coated particulate is electrodeposited onto a cathode or an external casing of the cathode; and   agitating the electrolytic solution at least one of before and during applying the charge.   
     
     
         10 . The method of  claim 9 , wherein the secondary alloy particulate comprises particles of at least one of chromium (Cr), manganese (Mn), tungsten (W), molybdenum (Mo), rhenium (Re), ruthenium (Ru), titanium (Ti), aluminum (Al), niobium (Nb), tantalum (Ta), zirconium (Zr), vanadium (V), yttrium (Y), cerium (Ce), lanthanum (La), boron (B), phosphorus (P) and carbon (C) with at least one of grain growth inhibitors and recrystallization inhibitors. 
     
     
         11 . The method of  claim 9 , wherein the pre-coated particulate comprises a plurality of particles of varying shapes and varying dimensions from each other. 
     
     
         12 . The method of  claim 9 , wherein the cathode or the external casing of the cathode has a non-planar surface having one or more complex contours. 
     
     
         13 . The method of  claim 9 , wherein agitating the electrolytic solution comprises vibrating the container during the steps of dispensing the quantity of the pre-coated particulate and applying the charge to the electrolytic solution, wherein vibrating the container comprises applying a high amplitude, low frequency vibration to at least one of the container and the electrolytic solution. 
     
     
         14 . The method of  claim 9 , further comprising heat-treating a resulting part formed on the cathode following the electrodeposition of the pre-coated particulate onto the cathode. 
     
     
         15 . The method of  claim 9 , further comprising drawing partial vacuum from within the container during the step of applying the charge, such that hydrogen between the electrolytic solution and the container is removed from the container. 
     
     
         16 . A system for producing a rigid, heat-resistant, complex-contoured part, the system comprising:
 a container with electrolytic solution sealed therein;   an anode;   a cathode;   an electrical source electrically coupled to the anode and the cathode and configured for selectively applying a charge to the electrolytic solution via the anode and the cathode;   a source of pre-coated particulate selectively dispensable into the container, wherein the pre-coated particulate includes a secondary alloy particulate coated with a superior alloy, wherein the superior alloy is at least one of nickel, iron, cobalt, and copper, wherein when the charge is applied to the electrolytic solution the pre-coated particulate is electrodeposited onto a surface of the cathode; and   a vibrating device configured for applying a low frequency, high displacement resonance frequency to at least one of the container and the electrolytic solution sealed therein.   
     
     
         17 . The system of  claim 16 , further comprising a temperature control tank for controlling a temperature of the electrolytic solution. 
     
     
         18 . The system of  claim 16 , wherein the pre-coated particulate comprises a plurality of particles of varying shapes and varying dimensions from each other. 
     
     
         19 . The system of  claim 16 , wherein the cathode comprises a shield and a mandrel, wherein the pre-coated particulate coats the mandrel, wherein the mandrel has a non-planar surface having one or more complex contours. 
     
     
         20 . The system of  claim 16 , wherein the secondary alloy particulate comprises particles of at least one of chromium (Cr), manganese (Mn), tungsten (W), molybdenum (Mo), rhenium (Re), ruthenium (Ru), titanium (Ti), aluminum (AI), niobium (Nb), tantalum (Ta), zirconium (Zr), vanadium (V), yttrium (Y), cerium (Ce), lanthanum (La), boron (B), phosphorus (P) and carbon (C) with at least one of grain growth inhibitors and recrystallization inhibitors. 
     
     
         21 - 60 . (canceled)