US 11,833,604 B2
Method of preparing an electrode for use in forming a honeycomb extrusion die
Timothy Eugene Antesberger, Vestal, NY (US); Dana Craig Bookbinder, Corning, NY (US); Dana Eugene Coots, Tioga, PA (US); Seyed Amir Farzadfar, Corning, NY (US); Dominick John Forenz, Hammondsport, NY (US); Ryan Joseph Grohsmeyer, Addison, NY (US); Mark Lee Humphrey, Burdett, NY (US); Zakariya Radwan Khayat, State College, PA (US); Kenneth Richard Miller, Addison, NY (US); Richard Curwood Peterson, Elmira Heights, NY (US); and John Charles Rector, Beaver Dams, NY (US)
Assigned to Corning Incorporated, Corning, NY (US)
Appl. No. 17/613,822
Filed by CORNING INCORPORATED, Corning, NY (US)
PCT Filed May 21, 2020, PCT No. PCT/US2020/033934
§ 371(c)(1), (2) Date Nov. 23, 2021,
PCT Pub. No. WO2020/237012, PCT Pub. Date Nov. 26, 2020.
Claims priority of provisional application 62/851,973, filed on May 23, 2019.
Prior Publication US 2022/0234108 A1, Jul. 28, 2022
Int. Cl. B23H 7/24 (2006.01); B33Y 10/00 (2015.01); B22F 10/28 (2021.01); B22F 10/36 (2021.01); B22F 10/38 (2021.01); B33Y 80/00 (2015.01); B29C 48/30 (2019.01); B29C 48/32 (2019.01); B33Y 40/20 (2020.01); B28B 3/26 (2006.01); B22F 10/66 (2021.01); B22F 10/62 (2021.01); B22F 10/25 (2021.01)
CPC B23H 7/24 (2013.01) [B22F 10/28 (2021.01); B22F 10/66 (2021.01); B28B 3/269 (2013.01); B29C 48/3001 (2019.02); B29C 48/32 (2019.02); B33Y 10/00 (2014.12); B33Y 40/20 (2020.01); B33Y 80/00 (2014.12); B22F 10/25 (2021.01); B22F 10/36 (2021.01); B22F 10/38 (2021.01); B22F 10/62 (2021.01); B22F 2301/10 (2013.01); B22F 2301/20 (2013.01); B22F 2304/10 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A method for additively manufacturing a copper-tungsten electrode, the method comprising:
forming an electrode as a series of layers, wherein each layer is formed by:
depositing a layer of powder on a manufacturing platform or a previous layer in the series, wherein the layer of powder comprises a tungsten powder and a copper powder; and
fusing the layer of powder using a laser to apply a laser energy of about 1 to about 10 J/mm2 to the layer of powder;
wherein the electrode is comprised of an interconnected network of tungsten infiltrated by copper formed by the series of layers fused together; and
smoothing the electrode using a secondary electrode in a plunge electrical discharge machining process.