COMPONENT PRODUCED BY ADDITIVE MANUFACTURING

Abstract

The present invention relates generally to components prepared by additive manufacturing (AM) methods, along with methods of preparing such components by AM. More especially, there is provided a process for the production of a component of an ignition device using an AM method by forming a layer of metal or alloy on a surface of a metal or alloy substrate; fusing the layer to the substrate; and repeating the addition of such layers upon one another to form a deposited metal or alloy attachment on the substrate.

Claims

1. A process for the production of a component of an ignition device using an additive manufacturing method, comprising: (i) forming a layer of metal or alloy on a surface of a metal or alloy substrate; (ii) fusing the layer to the substrate; and (iii) repeating (i) and (ii) layer upon layer to form a deposited metal or alloy attachment on the substrate.

2. A process according to claim 1, wherein step (i) comprises forming a layer of metal or alloy powder on the surface of the metal or alloy substrate; and step (ii) comprises binding or fusing at least a portion of the powder in the layer both together and to the substrate.

3. A process according to claim 1, wherein the metal or alloy deposited onto the substrate comprises a noble metal or alloy thereof.

4. A process according to claim 1, wherein the substrate comprises nickel or a nickel alloy, optionally comprising a copper core.

5. A process according to claim 4, wherein the substrate comprises Inconel alloy.

6. A process according to claim 1, comprising the production of a plurality of components of ignition devices using an additive manufacturing method, wherein a plurality of substrates is arranged in an array within a single additive manufacturing unit.

7. A process according to claim 6, wherein the spacing between central points on adjacent substrates is in the range 1 to 10 mm, for example 2 to 8 mm.

8. A process according to claim 1, wherein the substrate is located within a recess or bore in a build plate of an additive manufacturing unit.

9. A process according to claim 8, wherein the substrate is located within the recess such that the upper surface of the substrate is substantially level with the upper surface of the build plate, or protrudes above the upper surface of the build plate by a clearance of less than or equal to 5 mm.

10. A process according to claim 8, wherein the substrate is held in position within the recess or bore.

11. A process according to claim 10, wherein the substrate is held in postion by means of abutment between a protrusion from the surface of the substrate and a protrusion from the inner surface of the bore.

12. A process according to claim 1, wherein the additive manufacturing method is selected from powder bed fusion, directed energy deposition, and sheet lamination.

13. A process according to claim 1, further comprising a step (iv) selected from surface finishing and/or isostatic pressing of at least a part of the component.

14. A process according to claim 1, wherein step (iii) comprises repeating steps (i) and (ii) at least 5 times.

15. (canceled)

16. A process according to claim 1, which is a process for the production of a central or ground electrode of a spark plug.

17. A process according to claim 16, which is a process for forming the tip of a central or ground electrode of a spark plug on a substrate which represents the remainder of the central or ground electrode.

18. An ignition device component obtained or obtainable by a process according to claim 1.

19. (canceled)

20. (canceled)

21. (canceled)

22. (canceled)

23. A process for the production of a noble metal-containing component using an additive manufacturing method, comprising: (i) forming a layer of metal or alloy on a surface of a substrate, wherein the metal or alloy comprises a noble metal or alloy thereof, and wherein the substrate is a metal or alloy substrate; (ii) fusing the layer to the substrate; and (iii) repeating (i) and (ii) layer upon layer to form a deposited noble metal or noble metal alloy attachment on the substrate.

24. A process according to claim 23, wherein step (i) comprises forming a layer of metal or alloy powder on the surface of the substrate; and step (ii) comprises binding or fusing at least a portion of the powder in the layer both together and to the substrate.

25. A process according to claim 23 or 21, wherein the metal or alloy deposited onto the substrate comprises a platinum group metal or alloy selected from Ru, Rh, Pd, Ir and Pt or an alloy thereof.

Description

FIGURES

[0131] FIG. 1 is a schematic cross-sectional view of a prior art spark plug electrode.

[0132] FIG. 2 is a schematic cross-sectional view of a spark plug electrode substrate.

[0133] FIG. 3 is a schematic cross-sectional view of a spark plug electrode substrate held within a bore in a build plate.

[0134] FIG. 4 is a schematic cross-sectional view of a spark plug electrode substrate held within a recess in a build plate.

[0135] FIG. 5 is a schematic cross-sectional view of a spark plug electrode substrate held within a recess in a build plate.

[0136] FIG. 6 is a schematic cross-sectional view of a spark plug electrode according to the invention held within a bore in a build plate of an AM machine.

[0137] FIG. 7 is a schematic cross-sectional view of a spark plug electrode according to the invention.

DETAILED DESCRIPTION

[0138] FIG. 2 is a representation of a substrate 2 which may be used to manufacture a spark plug electrode according to the invention.

[0139] The substrate 2 is shown in axial cross-section in FIG. 2, and is cylindrical in shape with the exception of an annular protrusion 24 near the base of the substrate. This annular protrusion is present on such substrates as a means to secure the substrate within the ceramic sleeve in which it is held when incorporated into a spark plug. The substrate 2 comprises a composite structure which includes a NiCr (Inconel) outer portion 22 which surrounds a Cu metal core portion 23. Such substrates are commercially available and may be formed by the co-extrusion of the Inconel and Cu materials.

[0140] FIG. 3 is a representation of a substrate 3 identical to that shown in FIG. 2, held in place within a bore 32 defined by a build plate 31, which is part of an Additive Manufacturing machine (not shown). For simplicity, a single bore 32 is shown, although a single build plate may include a plurality of bores as described herein. The diameters of the bore 32 and the protrusion 24 are substantially identical such that the substrate 2 is held in a stable position within the build plate 31. Furthermore, the inner surface of the bore 32 includes an annular ridge 38a, 38b which creates a lip within the bore against which the lower surface of the protrusion 24 abuts. The annular ridge 38a, 38b follows a contour perpendicular with the axis of the bore 32. Further movement of the substrate 2 into the bore 32 is therefore prevented by the abutment of the protrusion 24 against the annular ridge 38a, 38b and the substrate 2 is effectively held in position. The axial position of the annular ridge 38a, 38b within the bore 32 is designed such that the upper surface 35 of the substrate 2 is substantially coplanar with the upper surface 36 of the build plate 31.

[0141] Although in this embodiment the annular ridge 38a, 38b within the bore 32 is continuous, alternatively the ridge may be discontinuous, such that it is instead a plurality of protrusions from the inner surface of the bore 32. For example, the annular ridge 38a, 38b may be replaced by two simple protrusions which sit in diametrically opposite positions on either side of the inner surface of the bore 32. However, the annular ridge 38a, 38b is preferred as it provides a more stable platform upon which the protrusion 24 rests, ensuring coplanarity of surfaces 35 and 36.

[0142] An alternative embodiment 4 is shown in FIG. 4. The bore 32 of FIG. 3 is replaced with a recess 41 within a modified build plate 41. All aspects of this embodiment are identical to that shown in FIG. 3, except that the recess 41 does not extend through the entire thickness of the build plate 41. Like the embodiment shown in FIG. 3, the position of the substrate 2 is controlled by the presence of an annular ridge 48a, 48b. The axial position of the annular ridge 48a, 48b within the bore 42 is designed such that the upper surface 45 of the substrate 2 is substantially coplanar with the upper surface 46 of the build plate 41.

[0143] An alternative embodiment 5 is shown in FIG. 5. The bore 32 of FIG. 3 is replaced with a recess 52 within a modified build plate 51, and the bottom of the substrate 2 rests on the floor 52a of the recess 52. The depth of the recess 52 is designed such that the upper surface 55 of the substrate 2 is substantially coplanar with the upper surface 56 of the build plate 51.

[0144] The upper surface 35 of the substrate, which has a circular shape, is coplanar with the upper surface 36, 46, 56 of the build plate. The arrangements shown in FIGS. 3-5 facilitates the deposit of material onto the substrate by AM, and the subsequent formation of an attachment fixed to the upper surface 35 of the substrate 2.

[0145] FIG. 6 shows a spark plug electrode 6 according to the invention. A platinum-group metal attachment 61 has been deposited in stages by a powder bed fusion AM process onto the upper surface of the substrate 2. The attachment 61 is fused to the substrate 2. The component 6 is still positioned within the build plate 31, ready for removal.

[0146] For simplicity, the AM process itself is not depicted in the Figures. However, referring to FIG. 3, an exemplary PBF process will now be described. A layer of Rh alloy powder is first deposited across the entire surface 36 of the build plate and surface 35 of the substrate in order to form a layer of thickness 30 m. Some powder inevitably fills the gap between the outside of the substrate and the inner walls of the bore 32. This powder is reclaimed after the process and used again in further print runs. After the first layer has been deposited in this way, an energy beam (for example a laser beam or electron beam) is directed at a portion of the powder layer which lies over the surface 35 of the substrate 2. The irradiated portion is circular and has a slightly smaller diameter than the upper surface of the substrate, such that a small border of the upper surface of the substrate does not become fused to the attachment. The energy beam melts and fuses the metal or alloy powder in the irradiated region together and to the surface of the substrate below. A further layer of powder is then deposited over the entire surface of the first layer. A portion of the second layer which lies over the fused portion of the first layer is irradiated in the same way as the first, to fuse the powder together and to the layer beneath.

[0147] This process is repeated a predetermined number of times until an attachment 61 of 4 mm height above the substrate has been formed. Once the PBF process is complete the un-fused powder is removed by blowing and is reclaimed for future use.

[0148] FIG. 7 shows a spark plug electrode 7 which has been manufactured by AM deposition of an attachment 61 onto a substrate 2. The electrode can be incorporated into a spark plug to provide the central electrode, the attachment 61 forming the tip from which a spark is generated during use.