摘要：
In various embodiment, the present invention relates to method of fabricating a three-dimensional part by a process comprising the steps of: providing a wire comprising arc-melted refractory metallic material; translating a tip of the wire relative to a platform; while the tip of the wire is being translated, melting the tip of the wire with an energy source to form a molten bead, whereby the bead cools to form at least a portion of a layer of a three-dimensional part; and repeating steps (b) and (c) one or more times to produce the three dimensional part.
技术问题语段：
The patent text discusses the challenges associated with additive manufacturing of metallic materials and the need for improved precursor materials. The technical problem is excessive porosity, cracking, material splatter, and insufficient density and machinability of metallic parts made using conventional precursor materials. The text references a micro-plasma transferred arc wire deposition process and a method for minimizing distortion in a workpiece through finite element analysis and compensatory alterations. Overall, the text emphasizes the need for improved materials and techniques for the additive manufacturing of metallic parts.
技术功效语段：
The patent describes a method of making three-dimensional parts using a process called additive manufacturing, which involves melting and deforming wire into a desired shape. The wire is made from a metallic material, such as niobium or tantalum, and is fed through a process where it is compacted, melted, and mechanically deformed. The resulting wire is then used to create the part by melting the tip of the wire and depositing it onto a platform, where it cools and solidifies. The method reduces impurities in the wire and allows for the creation of high-quality parts with minimal defects. The wire can also be used in other manufacturing processes, such as welding. Overall, the patent provides a way to make high-quality metallic parts using advanced manufacturing techniques.
权利要求：
1. A method of fabricating a three-dimensional part comprising a metallic material utilizing wire produced by a process comprising (i) compacting powder to form a feed electrode, the powder comprising the metallic material, (ii) arc-melting the feed electrode in a processing ambient comprising a vacuum or one or more inert gases, thereby forming a billet, and (iii) mechanically deforming the billet into wire having a diameter less than a diameter of the billet, the method comprising: (a) translating a tip of the wire relative to a platform; (b) while the tip of the wire is being translated, melting the tip of the wire with an energy source to form a molten bead, whereby the bead cools to form at least a portion of a layer of a three-dimensional part; and (c) repeating steps (a) and (b) one or more times to produce the three-dimensional part, wherein the three-dimensional part comprises the metallic material, the metallic material comprises at least one of niobium, tantalum, rhenium, tungsten, or molybdenum, and wherein a concentration within the wire of each of sodium, calcium, antimony, magnesium, phosphorous, and potassium is less than 1 ppm by weight and at least 0.001 ppm by weight.
2. The method of claim 1, wherein a concentration of oxygen within the wire is less than 20 ppm by weight.
3. The method of claim 1, wherein a density of the three-dimensional part is greater than 97% of a theoretical density of the metallic material.
4. The method of claim 1, wherein mechanically deforming the billet into wire comprises at least one of drawing, rolling, swaging, extruding, or pilgering.
5. The method of claim 1, wherein the process of producing the wire comprises sintering the compacted powder at a temperature greater than 900°C.
6. The method of claim 1, wherein in step (b) the energy source comprises an electron beam and/or a laser beam.
7. The method of claim 1, wherein the process of producing the wire comprises providing the powder by a process comprising at least one of plasma densification or plasma atomization.
8. The method of claim 1, wherein the process of producing the wire comprises providing the powder by a process comprising: hydrogenating metal to form a metal hydride; mechanically grinding the metal hydride into a plurality of particles; and dehydrogenating the metal hydride particles.
9. A three-dimensional part manufactured by additive manufacturing using a feedstock material comprising a metallic material comprising at least one of niobium, tantalum, rhenium, tungsten, or molybdenum, the part (i) comprising a plurality of layers each comprising solidified metallic material, (ii) being free of gaps between successive layers, and (iii) being free of cracks, wherein a density of the part is no less than 97% of a theoretical density of the metallic material, and wherein a concentration within the part of each of sodium, calcium, antimony, magnesium, phosphorous, and potassium is less than 1 ppm by weight and at least 0.001 ppm by weight; wherein the feedstock material comprises wire fabricated by a process comprising (i) compacting powder to form a feed electrode, the powder comprising the metallic material, (ii) arc-melting the feed electrode in a processing ambient comprising a vacuum or one or more inert gases, thereby forming a billet, and (iii) mechanically deforming the billet into wire having a diameter less than a diameter of the billet, and wherein the additive manufacturing comprises: (a) translating a tip of the wire relative to a platform; (b) while the tip of the wire is being translated, melting the tip of the wire with an energy source to form a molten bead, whereby the bead cools to form at least a portion of a layer of a three-dimensional part; and (c) repeating steps (a) and (b) one or more times to produce the three-dimensional part.
10. The part of claim 9, wherein the density of the part is no less than 99% of the theoretical density of the metallic material.
11. The part of claim 9, wherein a concentration of oxygen within the part is less than 5 ppm by weight.
12. The part of claim 9, wherein the density of the part is not less than 99.5%, of the theoretical density of the metallic material.