Ductile coatings on additive manufactured components

DWPI Title: Forming coated component using additive manufacturing system, involves building body portion of component on build plate, and forming coating layer on outer surface of body portion subsequent to performing post-build process
Abstract: A method of forming a coated component using an additive manufacturing system including building a body portion of the component on a build plate. An outer surface of the body portion can include an indentation resulting from the additive manufacturing system. The method further includes performing at least one post-build process on the body portion. The method yet further includes forming a coating layer on an outer surface of the processed body portion. The coating layer may surround a portion of the body component and may impregnate the indentation. A thickness of the coating layer may be a function of at least one of surface roughness, size of the indentation, or a diameter of particles used to build the additive manufactured bracket.
Use: Method for forming a coated component i.e. topology optimized additive manufactured bracket, using an additive manufacturing system.
Advantage: The coating layer can provide a structural connection across the indentations preventing it from growing, thus increasing the fatigue resistance of additive manufactured components. The coating layer is configured to increase corrosion resistance or electrical conductivity of the component.
Novelty: Forming coated component involves building a body portion of a component on a build plate, where an outer surface of the body portion includes an indentation resulting from an additive manufacturing system. A post-build process is performed on the portion, and a coating layer is formed on the surface, where the layer surrounds a portion of the portion and impregnates the indentation. A thickness of the layer is selected based on one of a surface roughness value, size and diameter of particles used to build the portion. The coating layer comprises sputtering, evaporation, electroless plating, electroplating and chemical displacement reaction.
Filed: 9/8/2020
Application Number: US17014016A
Tech ID: SD 15321.0
This invention was made with Government support under Contract No. DE-NA0003525 awarded by the United States Department of Energy/National Nuclear Security Administration. The Government has certain rights in the invention.
Data from Derwent World Patents Index, provided by Clarivate
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