US 12,422,424 B1
Additive manufacturing test method for metallic alloy compositions and methods of making the same
Hunter Taylor, Horizon City, TX (US); and Laszlo Kecskes, Havre de Grace, MD (US)
Assigned to Tailored Alloys, LLC, Horizon City, TX (US)
Filed by Tailored Alloys LLC, Horizon City, TX (US)
Filed on Jun. 11, 2021, as Appl. No. 17/345,376.
Int. Cl. G01N 33/2045 (2019.01); B22F 10/28 (2021.01); B22F 10/38 (2021.01); B29C 64/00 (2017.01); B29C 64/10 (2017.01); B33Y 10/00 (2015.01)
CPC G01N 33/2045 (2019.01) [B22F 10/28 (2021.01); B22F 10/38 (2021.01); B29C 64/00 (2017.08); B29C 64/10 (2017.08); B33Y 10/00 (2014.12)] 20 Claims
OG exemplary drawing
 
1. A method of producing powdered feedstock for melt-based additive manufacture by evaluating and modifying the substructural features of a pre-alloyed bulk material having predefined chemical composition, comprising the steps of:
a. melting a defined region on the surface of a coupon of the pre-alloyed bulk material having a predefined chemical composition, using a laser at a first energy level thereby creating a first subsurface volume having a first depth;
b. obtaining a first set of structural modification measurement data associated with the first subsurface volume after allowing the first subsurface volume to solidify;
c. re-heating the defined region on the coupon using the laser at a second energy level thereby creating a second subsurface volume having a second depth, wherein the second depth may be deeper or shallower than the first depth;
d. obtaining a second set of structural modification measurement data associated with the second subsurface volume after allowing the second subsurface volume to cool to a first temperature;
e. determining whether the first and second subsurface volumes comprise one or more desirable structural characteristics, wherein the one or more desirable structural characteristics comprise the following:
i. dissolution of the constituent elements, separation of the constituent elements, redistribution of the constituent elements, separation into phases of constituent elements;
ii. changes in grain morphology, grain size, or grain size distribution;
iii. prior precipitates of constituent elements, changes in precipitate size, and precipitate spatial distribution;
iv. lack of defects such as cracks, fissures, and voids;
v. changes in crystallographic texture;
vi. changes in microhardness; and
f. rendering the pre-alloyed bulk material comprising the one or more desirable structural characteristics into a fine-grained, homogenous substructure having uniform composition.