公开(公告)号：US20150315678A1

公开(公告)日：2015-11-05

申请号：US14690239

申请日：2015-04-17

Applicant: Apple Inc.

Inventor： Joseph C. Poole ,  Theodore A. Waniuk ,  Jeffrey L. Mattlin ,  Michael S. Nashner ,  Christopher D. Prest

IPC: C22C1/00 ,  B05D5/00 ,  C22C45/00

CPC classification number: C22C45/00 ,  B05D5/00 ,  B22F3/1055 ,  B22F3/11 ,  B22F3/1115 ,  B22F9/08 ,  C22C1/00 ,  C22C1/002 ,  C22C33/0214 ,  C22C33/0278 ,  C22C47/14 ,  C22C49/14 ,  C22C2200/02 ,  Y02P10/295

Abstract: Described herein are methods of constructing a part having improved properties using metallic glass alloys, layer by layer. In accordance with certain aspects, a layer of metallic glass-forming powder is deposited to selected positions and then fused to a surface layer (i.e. layer below) by suitable methods such as laser heating or electron beam heating. The deposition and fusing are then repeated as need to construct the part, layer by layer. In certain embodiments, one or more sections or layers of non-metallic glass-forming material can be included as needed to form a composite final part. In certain aspects, the metallic glass-forming powder may be crystalized during depositing and fusing, or may be recrystallized during subsequent processing to provide selectively crystalized sections or layers, e.g., to impart desired functionality. In other aspects, non-metallic glass-forming materials may be deposited and fused at selected positions, e.g., to provide selective shear banding to impart improved ductile properties and plasticity. In yet other aspects, the metallic glass-forming powder or metallic glass material and non-metallic glass-forming material are deposited and fused to form a foam-like, bellow or similar structure, which is able to crumple under high stress to absorb energy under impact.

Abstract translation: 这里描述的是使用金属玻璃合金逐层构造具有改进性能的部件的方法。 根据某些方面，将金属玻璃形成粉末层沉积到选定位置，然后通过诸如激光加热或电子束加热之类的适当方法熔融到表面层（即下面的层）。 然后根据需要重复沉积和熔化以逐层构造部分。 在某些实施例中，可以根据需要包括非金属玻璃形成材料的一个或多个部分或多个层以形成复合最终部件。 在某些方面，金属玻璃形成粉末可以在沉积和熔化期间结晶化，或者可以在随后的加工过程中重结晶以提供选择性结晶化的部分或层，例如赋予所需的功能。 在其他方面，非金属玻璃形成材料可以沉积并在选定位置熔化，例如提供选择性剪切带以赋予改善的延展性和可塑性。 在另一方面，金属玻璃形成粉末或金属玻璃材料和非金属玻璃形成材料被沉积并熔合以形成泡沫状，波纹管或类似结构，其能够在高应力下折叠以吸收能量 受影响。

公开(公告)号：US20150299825A1

公开(公告)日：2015-10-22

申请号：US14690253

申请日：2015-04-17

Applicant: Apple Inc.

Inventor： Joseph C. Poole ,  Theodore A. Waniuk ,  Jeffrey L. Mattlin ,  Michael S. Nashner ,  Christopher D. Prest

IPC: C22C1/00 ,  B05D5/00 ,  B05D3/02 ,  C21D1/18 ,  C22C45/00

CPC classification number: C22C1/002 ,  B22F7/02 ,  C21D1/18 ,  C21D1/38 ,  C21D2251/00 ,  C22C45/00 ,  C23C24/106 ,  H01F1/15308

Abstract: Described herein are methods of constructing a three-dimensional part using metallic glass alloys, layer by layer, as well as metallic glass-forming materials designed for use therewith. In certain embodiments, a layer of metallic glass-forming powder or a sheet of metallic glass material is deposited to selected positions and then fused to a layer below by suitable methods such as laser heating or electron beam heating. The deposition and fusing are then repeated as need to construct the part, layer by layer. One or more sections or layers of non-metallic glass material can be included as needed to form composite parts. In one embodiment, the metallic glass-forming powder is a homogenous atomized powder. In another embodiment, the metallic glass-forming powder is formed by melting a metallic glass alloy to an over-heat threshold temperature substantially above the Tliquidus of the alloy, and quenching the melt at a high cooling rate such that the cooling material is kept substantially amorphous during cooling to form the metallic glass. In various embodiments, the melt is atomized during cooling to form the metallic glass-forming powder.

Abstract translation: 本文描述了使用金属玻璃合金逐层构造三维部件以及为此使用的金属玻璃形成材料的方法。 在某些实施例中，将一层金属玻璃形成粉末或一片金属玻璃材料沉积到选定位置，然后通过合适的方法如激光加热或电子束加热熔合到下面的层。 然后根据需要重复沉积和熔化以逐层构造部分。 根据需要可以包括一个或多个非金属玻璃材料的部分或多层以形成复合部件。 在一个实施方案中，金属玻璃形成粉末是均匀的雾化粉末。 在另一个实施方案中，金属玻璃形成粉末通过将金属玻璃合金熔化到基本上高于合金的Tliquidus的过热阈值温度而形成，并以高冷却速率淬火熔体，使得冷却材料基本保持 在冷却期间无定形以形成金属玻璃。 在各种实施方案中，在冷却期间将熔体雾化以形成金属玻璃形成粉末。