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The patent badge is an abbreviated version of the USPTO patent document. The patent badge does contain a link to the full patent document.

The patent badge is an abbreviated version of the USPTO patent document. The patent badge covers the following: Patent number, Date patent was issued, Date patent was filed, Title of the patent, Applicant, Inventor, Assignee, Attorney firm, Primary examiner, Assistant examiner, CPCs, and Abstract. The patent badge does contain a link to the full patent document (in Adobe Acrobat format, aka pdf). To download or print any patent click here.

Patent No.:

US 11370068 B1

PDFFull Text
Date of Patent:
Jun. 28, 2022

Filed:

Mar. 19, 2019

Systems and methods for additive manufacturing using aluminum metal-cored wire

Applicant:

Hobart Brothers Llc, Troy, OH (US);

Inventors:

Patrick Berube, Traverse City, MI (US);

Gregory J. Bramer, Traverse City, MI (US);

Shuang Liu, Appleton, WI (US);

Assignee:

HOBART BROTHERS LLC, Troy, OH (US);

Attorney:

McAndrews Held & Malloy, Ltd.

Primary Examiner:

Eric S Stapleton

Int. Cl.
CPC ...
B23K 35/28 (2006.01); B22F 1/00 (2022.01); B22F 9/04 (2006.01); B23K 35/02 (2006.01); B23K 9/04 (2006.01); B23K 9/173 (2006.01); B23K 9/23 (2006.01); C22C 21/14 (2006.01); C22C 1/10 (2006.01); C22C 21/16 (2006.01); C22C 21/02 (2006.01); C22C 21/06 (2006.01); B22F 10/20 (2021.01); B33Y 10/00 (2015.01); C22C 1/04 (2006.01); B23K 103/10 (2006.01); B22F 3/115 (2006.01);
U.S. Cl.
CPC ...
B23K 35/288 (2013.01); B22F 1/0007 (2013.01); B22F 9/04 (2013.01); B22F 10/20 (2021.01); B23K 9/04 (2013.01); B23K 9/044 (2013.01); B23K 9/173 (2013.01); B23K 9/23 (2013.01); B23K 35/0261 (2013.01); C22C 1/10 (2013.01); C22C 21/02 (2013.01); C22C 21/06 (2013.01); C22C 21/14 (2013.01); C22C 21/16 (2013.01); B22F 3/115 (2013.01); B22F 2301/052 (2013.01); B22F 2998/10 (2013.01); B23K 2103/10 (2018.08); B33Y 10/00 (2014.12); C22C 1/0416 (2013.01);
Abstract

A method of forming an additively manufactured aluminum part includes establishing an arc between a metal-cored aluminum wire and the additively manufactured aluminum part, wherein the metal-cored aluminum wire includes a metallic sheath and a granular core disposed within the metallic sheath. The granular core comprises aluminum metal matrix nano-composites (Al-MMNCs) that comprise an aluminum metal matrix and ceramic nanoparticles. The method includes melting a portion of the metal-cored aluminum wire using the heat of the arc to form molten droplets. The method includes transferring the molten droplets to the additively manufactured aluminum part under an inert gas flow, and solidifying the molten droplets under the inert gas flow to form deposits of the additively manufactured aluminum part.

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