US 12,005,505 B2
Surface treatment of additively manufactured components
Quinlan Yee Shuck, Indianapolis, IN (US); and Sungbo Shim, Irvine, CA (US)
Assigned to Rolls-Royce Corporation, Indianapolis, IN (US); and Rolls-Royce High Temperature Composites, Inc., Cypress, CA (US)
Filed by Rolls-Royce Corporation, Indianapolis, IN (US); and Rolls-Royce High Temperature Composites, Inc., Cypress, CA (US)
Filed on Jun. 15, 2020, as Appl. No. 16/901,855.
Claims priority of provisional application 62/862,281, filed on Jun. 17, 2019.
Prior Publication US 2020/0391292 A1, Dec. 17, 2020
Int. Cl. B22F 3/15 (2006.01); B22F 1/05 (2022.01); B22F 10/18 (2021.01); B22F 10/60 (2021.01); B22F 10/64 (2021.01); B28B 1/00 (2006.01); B33Y 10/00 (2015.01)
CPC B22F 3/15 (2013.01) [B22F 1/05 (2022.01); B22F 10/18 (2021.01); B22F 10/60 (2021.01); B22F 10/64 (2021.01); B28B 1/001 (2013.01); B33Y 10/00 (2014.12)] 21 Claims
OG exemplary drawing
 
1. A method comprising:
additively manufacturing an additively manufactured component, the additively manufactured component comprising a sacrificial binder and a metal or alloy;
sintering, at a first time, the additively manufactured component, wherein the sacrificial binder is removed from the additively manufactured component;
applying, at a second time that is after the first time, a slurry or suspension to the additively manufactured component using dip coating, wherein the slurry or suspension includes one or more of a dispersant, a surfactant, or a pH adjustor;
depositing, at a third time that is after the second time, from the slurry or suspension, on a surface of the additively manufactured component, powder comprising at least one of a metal, an alloy, or a ceramic, wherein the powder has an average grain size that is smaller than an average grain size of the material used to form the additively manufactured component;
sintering the powder to form a surface layer on the additively manufactured component; and
hot isostatic pressing the additively manufactured component and the surface layer.