US 11,840,750 B2
Tungsten heavy metal alloy powders and methods of forming them
Michael T. Stawovy, Cleveland Heights, OH (US); Scott D. Ohm, Coldwater, MI (US); and Fahrron C Fill, Bronson, MI (US)
Assigned to H.C. Starck Solutions Euclid, LLC, Euclid, OH (US)
Filed by Michael T. Stawovy, Cleveland Heights, OH (US); Scott D. Ohm, Coldwater, MI (US); and Fahrron C Fill, Bronson, MI (US)
Filed on Jun. 14, 2022, as Appl. No. 17/839,800.
Application 17/839,800 is a continuation of application No. 17/022,281, filed on Sep. 16, 2020, granted, now 11,389,872.
Application 17/022,281 is a continuation of application No. 15/835,519, filed on Dec. 8, 2017, granted, now 10,807,168, issued on Oct. 20, 2020.
Claims priority of provisional application 62/432,080, filed on Dec. 9, 2016.
Prior Publication US 2022/0331864 A1, Oct. 20, 2022
Int. Cl. C22C 27/04 (2006.01); B22F 9/04 (2006.01); B22F 9/02 (2006.01); B33Y 70/00 (2020.01); B22F 10/00 (2021.01); B22F 1/103 (2022.01); B22F 10/14 (2021.01); B22F 9/08 (2006.01); B22F 3/10 (2006.01); B33Y 10/00 (2015.01); C22C 1/04 (2023.01); B22F 1/10 (2022.01); B22F 1/148 (2022.01); B22F 10/25 (2021.01); B22F 10/32 (2021.01); B22F 10/66 (2021.01)
CPC C22C 27/04 (2013.01) [B22F 1/103 (2022.01); B22F 9/026 (2013.01); B22F 9/04 (2013.01); B22F 9/082 (2013.01); B22F 10/00 (2021.01); B22F 10/14 (2021.01); B33Y 70/00 (2014.12); B22F 1/10 (2022.01); B22F 1/148 (2022.01); B22F 3/10 (2013.01); B22F 3/1021 (2013.01); B22F 10/25 (2021.01); B22F 10/32 (2021.01); B22F 10/66 (2021.01); B22F 2009/041 (2013.01); B22F 2201/013 (2013.01); B22F 2202/13 (2013.01); B22F 2207/13 (2013.01); B22F 2207/17 (2013.01); B22F 2301/10 (2013.01); B22F 2301/15 (2013.01); B22F 2301/20 (2013.01); B22F 2301/35 (2013.01); B22F 2999/00 (2013.01); B33Y 10/00 (2014.12); C22C 1/045 (2013.01)] 28 Claims
OG exemplary drawing
 
1. A powder for additive manufacturing of a part comprising a refractory metal alloy, wherein the refractory metal alloy (i) comprises (a) one or more refractory metals selected from the group consisting of niobium, tantalum, rhenium, tungsten, and molybdenum, and (b) one or more additional metals each having a melting point lower than a melting point of each said refractory metal, and (ii) has a theoretical density corresponding to a weighted average of the densities of the one or more refractory metals and the one or more additional metals, the powder comprising a plurality of substantially spherical and dry composite particles, wherein:
each composite particle comprises a plurality of grains (i) comprising at least one said refractory metal element and (ii) surrounded by a matrix comprising the one or more additional metals,
a bulk density of the powder is approximately 35% or more of the theoretical density,
a tap density of the powder ranges from approximately 40% to approximately 75% of the theoretical density,
the powder is flowable, a Hall flow rate of the powder ranging from approximately 1 s/50 g to approximately 15 s/50 g and
the powder is disposed within a powder bed of an additive manufacturing apparatus.