CN106536095A - 用于制造组件的方法 - Google Patents
用于制造组件的方法 Download PDFInfo
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- CN106536095A CN106536095A CN201580037038.9A CN201580037038A CN106536095A CN 106536095 A CN106536095 A CN 106536095A CN 201580037038 A CN201580037038 A CN 201580037038A CN 106536095 A CN106536095 A CN 106536095A
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Abstract
本发明涉及一种由耐火金属或耐火金属含量>50at%的耐火金属合金制造组件的方法,该方法包含提供由粒子形成的粉末及在激光束或电子束作用下固化该粉末的步骤,该粉末的粒度d50如激光光学测量>10μm且平均表面积如通过BET方法测量>0.08m2/g。
Description
技术领域
本发明涉及一种由耐火金属或耐火金属含量>50at%的耐火金属合金制造组件的方法,该方法包含提供由粒子形成的粉末及在激光束或电子束作用下固化该粉末的步骤。
背景技术
基于数字3D构造数据,通过分层施用粉末及固化粉末来构建组件的方法称为添加制造法。同义使用的术语的实例为生产制造、3D印刷或数字光子制造。添加制造法具有以下优势:
˙对于组件设计的高度自由度;
˙无需工具;及
˙高资源效率。
除实现具有功能性设计的组件之外,也存在开发新颖材料的极大潜能,诸如具有功能上分级式构造的材料、混合复合材料、具有优化微观结构的材料或仿生学材料。
出于此目的,例如通过选择性激光烧结(SLS)、选择性激光熔融(SLM)、激光金属沉积(LMD)、电子束熔融(EBM)或粉末床以及喷墨头3D印刷,以金属粉末为起始物质具有适合性。在选择性激光烧结/熔融的情况下,施用厚度典型地在20μm至100μm范围内的粉末层。如今,激光功率典型地为200W至1000W;未来也将可获得具有更高功率的激光。随后,激光束以高达7m/s的速率,例如在惰性气体例如氩气或氮气的氛围下扫描粉末层。在能量作用下,粉末层经固化。典型地,此也伴随有压实。激光束的焦点直径典型地在20μm至200μm范围内,在某些情况下高达1000μm。构建速率典型地在5cm3/h至15cm3/h范围内。该方法使得组件能够具有典型地在20μm至100μm范围内的表面质量Rz及典型地在50μm至100μm范围内的精确度。为了增加构建速率,有可能构建具有小焦点直径(例如约200μm)的边缘区域以达成良好表面质量及精确度。在核心区域中,粉末层经固化/压实具有例如1000μm的较大焦点直径,以获得高构建速率。
在LMD的情况下,不与SLS/SLM一样分层施用粉末,而实际上将粉末直接引入激光束区域中。此制造的融合珠粒典型地具有0.3mm至3mm的宽度。
在电子束熔融的情况下,施用厚度典型地在约50μm至100μm范围内的粉末层。当前可获得的电子束熔融单元的典型功率为3kW至4kW。由于粉末层曝露至电子束时出现的带电现象,通过电子束熔融,必需在粉末粒子自身之间和/或粉末粒子与预先施用且已经固化的粉末层之间的第一通道中制造导电连接件,否则,在第一粉末层的情况下,制造粉末粒子与底板之间的导电连接件。此可例如借助于散焦电子束来进行,该散焦电子束借助于固相烧结操作而使粉末粒子彼此连接。由于电子束熔融的高达8000m/s的极高扫描速率以及相对厚粉末层的可能性,构建速率也比选择性激光烧结或熔融的情况下的构建速率高得多。在Ti6Al4V的情况下,举例而言,构建速率为55cm3/h至80cm3/h。电子束的焦点直径可典型在0.1mm至1mm范围内变化,且又具有小焦点直径,有可能改良精确度及粗糙度,其分别典型地为130μm至200μm且Rz>100μm。
为了实现基于粉末的添加制造法的广泛应用,除改良表面粗糙度及精确度之外,仍必须解决以下技术挑战:
进一步增加构建速率
减小可行的壁厚度(当前限于约100μm)
增加操作恒定性
拓宽材料的托盘(palette)
增加组件尺寸(目前限值630×500×400mm3)
减少内部应力/变形。
该挑战/特性受固化/压实方法高度影响。该方法又将物理粉末特性校准至较高程度。
固化/压实工序可通过固相烧结、液相烧结或熔融/固化进行。在固相烧结的情况下,固化/压实典型地在0.7×至仅低于固相线温度范围内的温度下进行。在此,驱动力为表面能中的减小,同时最重要的运输机制为扩散。扩散又可通过表面(表面扩散)、经由晶界(晶界扩散)或经由粒子体积(体积或晶格扩散)进行。在两个粒子之间的接触点区域中,内切半径较小,而在粒子表面区域中,半径相对较大。倘若空位密度视半径而定且随半径减小而增加,则存在自两个粒子之间的接触面积的区域至具有较大半径的区域的空位扩散,否则同义地,存在自具有较大半径的区域至粒子之间的接触面积的原子扩散。在接触面积区域中,所谓的烧结颈形成于粒子之间。在液相烧结的情况下,也出现(至少暂时)液相以及固相。
在借助于熔融法固化/压实的情况下,伴随固化的收缩为均匀为必需的。另外,若粉末床经均匀加热,则其为有利的,这又需要粉末层中充分高的热导性。此外,对于压实,有效形成的液相润湿仍存在的固体粒子为必需的。这一方面受毛细管力(其又视粉末床的密度而定)影响,并且另一方面受表面化学作用影响。待避免的其他现象为马兰哥尼对流(Marangoni convection)及球状化或蒸发情况。
目前,耐火金属尚未以工业规模经由添加制造法固化/压实。在本发明的情形中,耐火金属涵盖金属铌、钽、铬、钼、钨及铼。添加制造法尚未针对该材料广泛建立的原因之一为适用于该制造法的粉末的有限可用性。通过目前使用的粉末,所得材料特性及操作特性对于该制造方法的广泛应用具有不充分质量。
尤其需要粉末具有极佳填充特性,因此确保每一粉末层中均匀且充分高的密度。粉末层的低密度或不均匀密度导致不均匀收缩和/或形成相对较大孔或孔群。若粒子之间的距离较小且若烧结活性较高,则固化/压实仅可经由固相烧结过程在给定较短能量曝露时间下达成。举例而言,当粉末经由电子束熔融操作经压实时,经由固相烧结的充分固化/压实为必需的,因为在如已提及的这种情况下,在第一通道(预加热)中,粉末层中的粒子必须在一定程度上彼此接合,以便使借助于电子束引入的电荷载流子在第二通道(熔融操作)中借助于预先构建的层和/或借助于底板转向。若粒子在第一通道中未彼此接合至充分高程度,则结果为带电影响,及随后粉末粒子的排斥及所施用粉末层的毁坏。
所施用粉末层的均匀及高密度在选择性激光烧结及熔融的情形下也是有利的。特定言之,在激光烧结的情况下,固相中的高烧结活性具有有益结果。在激光熔融及通过液相的激光烧结的情况下,若所得熔融物具有较低表面张力,则其为有利的。若可在固相中达成充分高固化/压实或若关于待达成的密度的要求较低,则SLS优选历经SLM,因为其允许在组件中达成更好表面质量和/或较高精确度。因此,例如有可能减少或完全消除下游加工操作。
发明内容
因此,本发明的目标为提供一种允许由耐火金属制造具有以下特性中的至少一个的组件的方法:
高表面质量
高精确度
低壁厚度
高密度,或低误差密度,例如孔/孔群
高静态及动态强度
高延展性
细粒结构
低固有应力。
此外,该方法还准许高构建速率。
此目标通过独立权利要求达成。特定具体实例展示于从属权利要求中。
本发明方法允许由耐火金属或耐火金属含量>50at%的耐火金属合金制造组件。如已提及,术语耐火金属涵盖基于铌、钽、铬、钼、钨及铼的金属。本发明的耐火金属合金的耐火金属含量>50at%,优选>70at%或>80at%。特别优选地,耐火金属含量>90at%、>95at%或99at%。
根据本发明,随后使用由粒子形成且粒度d50如激光光学测量>10μm的粉末。此d50数字借助于激光绕射测定法测量。测量结果报导为分布曲线。d50表示平均粒度。d50意谓50vol%粒子小于所报导的数字。
此外,粉末的平均表面积如通过BET方法测量>0.08m2/g。BET测量根据标准(ISO9277:1995,测量范围:0.01-300m2/g;仪器:Gemini II 2370;加热温度:130℃;加热时间:2小时;吸附物:氮气;经由五点测定的体积评估)进行。BET表面积优选>0.1m2/g或>0.13m2/g。特别优选地,BET表面积>0.15m2/g、>0.2m2/g或>0.25m2/g。
粉末在激光束或电子束作用下经固化和/或压实。出于此目的,粉末优选经分层施用。
该方法的突出点为以下优势:
电子束熔融中改良的操作特性:
在电子束熔融中,在第一通道(预加热操作)中例如通过散焦电子束,经由固相烧结充分形成烧结颈。此阻止高能量密度(第二信道/熔融操作)的情况下的不期望的带电影响。
由此制造的组件的高表面质量:
本发明的粉末产生高填充密度(低粒子间距离)。另外,其具有极高烧结活性。此产生极均匀的压实/固化方法。若关于组件密度的要求不过高,则可省略完全熔融。
高精确度:
由于固化/压实操作可借助于固相或液相烧结(在固相及液相区域中烧结)进行,因此与通过熔融/固化的固化/压实比较,可观察到较窄公差。
低壁厚度:
由于固化/压实操作可通过固相或液相烧结进行,因此有可能达成与通过熔融/固化的固化/压实相比较低壁厚度,因为防止或减少熔融物穿透入粉末层的相邻区域中,其不为固化所预期的。
高密度及低误差密度,诸如孔/孔群:
均匀填充特征及高烧结活性减少大孔及孔群的数目。
低固有应力:
由于固有应力由固化/冷却方法诱发,因此液相部分减少具有有益结果。
细粒结构:
由于在相对较低能量输入下可达成相同密度,因此有可能确立更细粒结构。
高静态及动态强度:
前述特性,诸如高密度、细粒结构及低误差密度例如对于静态与动态强度具有有益结果。
高延展性:
前述特性也对于延展性具有有益结果。
此外,本发明方法也增加构建速率。这特别是在高程度上加快电子束熔融,因为在这种情况下完全避免不期望的带电现象。
粒子宜具有至少部分朝向表面敞开的孔。此经由表面扩散改良相邻粒子之间的烧结颈的形成。另外,若粒子至少部分具有球形形状,则其为有利的。与多孔表面组合,这也确保达成粉末层的均匀且高填充密度。
此外,若涂层材料具有双峰或多峰粒子分布,则其为有利的。双峰分布为具有两个最大值的频率分布。多峰分布具有至少三个最大值。双峰或多峰分布不仅增加粉末层的填充程度并且也促进经由固相烧结现象的固化/压实。已证明双峰或多峰粒度分布在电子束熔融的情况下极有利。
此外,若粉末包含呈由初级粒子形成的聚结物和/或聚集物形式的粒子,则其为有利的。在此情况下,粒子可至少部分呈聚集物形式、至少部分呈聚结物形式或至少部分呈聚集物与聚结物的混合物形式存在。粉末冶金中的聚集物理解为经由较强黏结彼此接合的初级粒子团,而聚结物为经由较弱黏结彼此接合的初级粒子团(参见例如German,R.:「Introduction to powder metallurgy science」,MPIF,Princeton(1984),32)。在本发明的情形中,聚集物指无法由习用超音波解聚集破坏的团簇,而聚结物可至少部分分解成初级粒子。此处,超音波解聚集在20kHz及600W下进行。粉末宜呈聚集物形式。形成聚集物的初级粒子之间的黏结为熔合的(冶金黏结),优选不具有来自其他元素的辅助。特别有利地>50%,特别是>70%且极有利地>90%的所有粒子呈聚集物或聚结物形式。在此情况下,评估进行如下:获取5个样本且使用扫描电子显微镜研究。在截面影像中涵盖20至50个粒子的放大率下,容易确定呈聚集物或聚结物形式存在的粒子的总和。此后,呈聚集物或聚结物形式存在的粒子的数目指经评估粒子的总数,且自5个样本测定平均值。聚结物或聚集物形式允许具有极高表面积的球形形状的组合,又促进填充密度及固相烧结操作。
此外,已证明若粉末包含0.005at%至5at%的至少一种来自由Ni、Co、Fe及Pd组成的群的元素,则其为有利的。由于该合金化元素,甚至在极短能量曝露时间的情况下触发晶界扩散现象以及表面扩散,且已证明此对于在电子束熔融的情况下接触的粒子与在选择性激光烧结的情况下的压实方法均有益。由于该元素减小液体熔融相的表面张力,因此通过SLM与EBM可获得极光滑表面。
在另一优选具体实例中,粉末至少部分呈复合粉末形式存在。特定言之,复合粉末理解为由两种或两种以上相的成分组成的粉末,其中该相的成分优选极小且均质分布。在此,复合粉末的一种优选可能性为至少部分呈涂层形式存在的粉末。在此,可形成极薄(例如50nm至5μm)层。已证明层包含具有熔点比近核心区域中的粒子的熔点低的金属、合金或化合物为尤其有利的。熔点差(以K为单位)优选为0.04至0.7×靠近中心区域的熔点(以K为单位)。优选范围为0.04至0.5及0.04至0.3×熔点(以K为单位)。通过此手段,不仅固相烧结现象有可能促进固化/压实方法,并且也压实经由液相烧结进行。此处,液相优选由粒子涂层形成。液相又可有利地初步溶解一些区域中粒子的剩余部分。另外,有利地,涂层材料具有足够低的蒸汽压。特定有利地,使涂层为多孔的。通过该手段,固相烧结现象有可能经由固相线温度降低与经由表面积增加而加速。另外,若由涂层形成的相比在使用未经涂布的粒子的情况下具有较低表面张力,则其为有利的。
多孔表层可通过流体化床方法以简单方式沉积。在流体化床(也称作流体床)中,通过载体介质(优选气体)搅拌尚未经涂布的粉末。在特定流速下,粉末床变为流体化床。在流体化床涂层的情况下,随后,例如可经由喷嘴将包含优选呈极细形式的涂层材料以及包含液体及黏合剂的浆液喷射入反应腔室中且该浆液可沉积于粒子上。随后,液体及黏合剂可通过习用方法移除,诸如热处理。
然而,在简单方式中,对于本发明必需的粉末也可通过粒化金属粉末的前驱物(例如氧化物)后续还原制造。尤其适合的粒化方法的实例包括喷雾粒化。粒化之后的还原步骤优选在温度>500℃,特别优选>800℃下进行。
如已提及,对于本发明必需的粉末优选用于通过电子束的反应来压实/固化。出于此目的,粉末经分层施用,并且在第一步骤(预加热操作)中经由通过例如散焦电子束的固相烧结现象来固化/压实到一定程度,使得至少部分形成烧结颈且可防止下游熔融操作中的不期望的带电现象。然而,特别当固化/压实通过固相烧结或液相烧结进行时,对于本发明必需的粉末也显著地适用于在激光束作用下压实。
具体实施方式
借助于以下实施例描述本发明。
实施例1
将细粒MoO3粉末引入搅拌贮槽中且与一些水组合以便形成浆液。在喷雾粒化单元中将此浆液处理成颗粒。在两阶段方法中将该颗粒还原成Mo金属粉末(还原温度分别为600℃及1050℃)。在90μm下筛选以此方式制造Mo金属粉末。粉末粒子形式为球状且具有朝向表面敞开的孔。根据说明书中提供的定义,粒子呈聚结物/聚集物形式。如根据说明书测定的d50为21μm,BET表面积为0.15m2/g。以此方式制造的粉末用于选择性电子束熔融。操作提供于说明书中。在不导致熔融的条件下,通过散焦电子束进行预加热。在通过聚焦电子束之后续扫描步骤而导致粒子的完全熔融的过程中,不存在不期望的带电过程。
实施例2
混合在25μm及5μm下筛选的具有球形形状的钨粉末与0.1质量%细粒Ni粉末。混合物的d50及BET分别为>10μm及>0.08m2/g。通过由此制造的粉末混合物,以极短操作时间进行烧结实验(在3分钟中加热至1200℃)以便在低D×t值(D为扩散系数,t为时间)下评定固相烧结性,且因此使得评估在通过散焦电子束预加热期间和/或借助于激光束固化/压实(激光烧结)期间是否存在粒子的间的充分接触成为可能。相比而言,在3分钟中将具有球形形状且筛网级分为5μm至25μm(BET表面积<0.08m2/g)的纯W粉末加热至1200℃。尽管在纯钨的情况下仍不可观察到烧结颈形成,但本发明的W-Ni混合物已经展示粒子之间的烧结颈。
实施例3
将WO3粉末引入搅拌贮槽中且与一定量水组合以便形成浆液。在喷雾粒化单元中将此浆液处理成颗粒。在一段操作中将该颗粒还原成W金属粉末(还原温度1000℃)。在90μm下筛选由此制造的W金属粉末。粉末形式为球状且具有朝向表面敞开的孔。根据说明书中所提供的定义,粒子呈聚结物/聚集物形式。如根据说明书测定的d50为17μm,BET表面积为0.18m2/g。将大致1μm厚的Ni层施用于粉末粒子。在基于实施例2的工序中,借助于快速加热测定在较低的D×t值的条件下的固相烧结性。由于涂层,有可能甚至在1000℃下形成烧结颈。
Claims (19)
1.一种由耐火金属或耐火金属含量>50at%的耐火金属合金制造组件的方法,所述方法包含提供由粒子形成的粉末以及在激光束或电子束作用下固化所述粉末的步骤,其特征在于,
所述粉末的激光光学测量的粒度d50>10μm并且通过BET方法测量的平均表面积>0.08m2/g。
2.根据权利要求1所述的方法,其特征在于,所述粒子的表面至少部分具有孔。
3.根据前述权利要求中任一项所述的方法,其特征在于,所述粒子至少部分具有球形形状。
4.根据前述权利要求中任一项所述的方法,其特征在于,所述粉末具有双峰或多峰粒度分布。
5.根据前述权利要求中任一项所述的方法,其特征在于,所述粉末包含呈由初级粒子形成的聚结物形式和/或聚集物形式的粉末粒子。
6.根据前述权利要求中任一项所述的方法,其特征在于,所述粉末包含0.005at%至5at%的至少一种来自由Ni、Co、Fe及Pd组成的组的元素。
7.根据前述权利要求中任一项所述的方法,其特征在于,所述粉末至少部分地以复合粉末的形式存在。
8.根据前述权利要求中任一项所述的方法,其特征在于,所述粉末至少部分以涂布粉末的形式存在。
9.根据前述权利要求中任一项所述的方法,其特征在于,所述粒子在靠近表面区域中至少部分具有比在靠近中心区域中低的熔点。
10.根据权利要求9所述的方法,其特征在于,熔点差(以K为单位)为0.04至0.7×该靠近中心区域的熔点(以K为单位)。
11.根据前述权利要求中任一项所述的方法,其特征在于,粉末制造包含粒化步骤。
12.根据权利要求11所述的方法,其特征在于,所述粒化步骤之后为在温度>500℃下的还原步骤。
13.根据前述权利要求中任一项所述的方法,其特征在于,粉末制造包含涂布步骤。
14.根据前述权利要求中任一项所述的方法,其特征在于,所述粉末包含>80at%的至少一种选自由Mo和W组成的组的元素。
15.根据前述权利要求中任一项所述的方法,其特征在于,BET表面积>0.1m2/g,优选>0.13m2/g。
16.根据前述权利要求中任一项所述的方法,其特征在于,所述粉末经分层施用。
17.根据前述权利要求中任一项所述的方法,其特征在于,所述粉末的固化在电子束的作用下进行,其中经分层施用的粉末的所述粒子在第一步骤中经由固相烧结至少部分形成烧结颈并且在后续步骤中至少部分熔融。
18.根据权利要求17所述的方法,其特征在于,所述第一步骤通过散焦电子束进行。
19.根据权利要求1至16中任一项所述的方法,其特征在于,所述粉末的固化至少部分通过固相烧结或液相烧结在激光束的作用下进行。
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