US 12,076,818 B2
Additively manufactured single-crystal metallic components, and methods for producing the same
John H. Martin, Oxnard, CA (US); Jacob M. Hundley, Thousand Oaks, CA (US); and Brennan D. Yahata, Santa Barbara, CA (US)
Assigned to HRL Laboratories, LLC, Malibu, CA (US)
Filed by HRL Laboratories, LLC, Malibu, CA (US)
Filed on Feb. 6, 2023, as Appl. No. 18/106,333.
Application 18/106,333 is a division of application No. 16/442,614, filed on Jun. 17, 2019, granted, now 11,865,641.
Claims priority of provisional application 62/741,023, filed on Oct. 4, 2018.
Prior Publication US 2023/0364714 A1, Nov. 16, 2023
Int. Cl. C30B 13/06 (2006.01); B22F 3/10 (2006.01); B22F 10/10 (2021.01); B23K 9/04 (2006.01); B23K 26/06 (2014.01); B23K 26/073 (2006.01); B23K 26/342 (2014.01); B33Y 80/00 (2015.01); C30B 13/24 (2006.01); C30B 13/32 (2006.01); C30B 19/08 (2006.01); C30B 29/00 (2006.01); C30B 29/52 (2006.01); C30B 29/68 (2006.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 70/00 (2020.01)
CPC B23K 26/342 (2015.10) [B22F 3/1028 (2013.01); B22F 10/10 (2021.01); B23K 9/044 (2013.01); B23K 26/0604 (2013.01); B23K 26/0734 (2013.01); B33Y 80/00 (2014.12); C30B 13/06 (2013.01); C30B 13/24 (2013.01); C30B 13/32 (2013.01); C30B 19/08 (2013.01); C30B 29/00 (2013.01); C30B 29/52 (2013.01); C30B 29/68 (2013.01); B22F 2999/00 (2013.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 70/00 (2014.12)] 20 Claims
OG exemplary drawing
 
1. A method of making an additively manufactured single-crystal metallic component, said method comprising:
(a) providing a metal-containing feedstock comprising a first metal or metal alloy, wherein said metal-containing feedstock is in the form of a solid powder, a solid wire, or a combination thereof;
(b) providing a build plate comprising a build region consisting of a seed single crystal of a second metal or metal alloy;
(c) adding a first amount of said metal-containing feedstock to said build plate and then exposing said first amount of said metal-containing feedstock to an energy source for melting said first amount of said metal-containing feedstock, thereby generating a first melt layer disposed on said build region; and
(d) solidifying said first melt layer, thereby generating a first solid layer, disposed on said build region, of an additively manufactured metal component, wherein said first solid layer is a single crystal of said first metal or metal alloy.