Carpenter Technology Corporation

Francis William Herbert

Philip Anthony Carroll

Chins Chinnasamy

James William Sears

Christopher Phillip Allen

John Robert Rushton

Nicholas Paul Weeks

Nir Vaks

Ben Ian Ferrar

Jaydip Das

Christopher Wooder

A powder including a plurality of particulates, each particulate including a soft magnetic metallic core coated with a continuous dielectric coating having a thickness selected from a range of 100 nanometers to 100 micrometers. The particulates have a mean particle size selected from a range of 100 nanometers to 250 micrometers. Methods for forming the powder are disclosed. A soft magnetic composite component includes a soft magnetic material in a dielectric matrix, wherein (i) the soft magnetic material comprises a plurality of particulates comprising metallic cores, (ii) each metallic core is coated by a continuous dielectric coating covering >90% of a surface area of the metallic core, (iii) the metallic cores are electrically isolated from each other, and (iv) the dielectric coatings of adjacent metallic cores are consolidated together. Methods for formation of the soft magnetic component by additive manufacturing and hot isostatic pressing are disclosed.

Soft magnetic composite materials and methods and powders for producing the same

Closed-loop metal powder management methods for additive manufacturing. Virgin metal powder is provided in a closed powder container comprising at least one sensor, tracker, or optical device. The metal powder is transferred to an additive manufacturing system, a portion of a metal powder layer is consolidated, and excess metal powder is transferred from the additive manufacturing system to the powder container, a second powder container, or an internal powder container. Virgin metal powder or a second metal powder are added to the excess metal powder, a quality of the mixed powder is validated, the process is repeated at least once, and powder physical transfer data associated with at least one of the steps is collected and stored in a data repository. Powder material parameters may be measured and assessed, and may be also be stored in the data repository.

Metal powder management system for additive manufacturing

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Pennsylvania, PA, United States of America

Francis William Herbert