CN114929920A - Printable FeCrAl powder material for additive manufacturing and objects for additive manufacturing and use thereof - Google Patents

Printable FeCrAl powder material for additive manufacturing and objects for additive manufacturing and use thereof Download PDF

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CN114929920A
CN114929920A CN202080073453.0A CN202080073453A CN114929920A CN 114929920 A CN114929920 A CN 114929920A CN 202080073453 A CN202080073453 A CN 202080073453A CN 114929920 A CN114929920 A CN 114929920A
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powder
printable
fecral
additive manufacturing
powder composition
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曹澎乘
米卡埃尔·谢伦
索德·萨利姆
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Kanthal AB
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Kanthal AB
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/05—Metallic powder characterised by the size or surface area of the particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10—Formation of a green body
    • B22F10/12—Formation of a green body by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
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    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
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    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
    • C22C33/0285—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with Cr, Co, or Ni having a minimum content higher than 5%
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    • C22C38/001—Ferrous alloys, e.g. steel alloys containing N
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    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
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    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/005—Ferrous alloys, e.g. steel alloys containing rare earths, i.e. Sc, Y, Lanthanides
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    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
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    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/22—Ferrous alloys, e.g. steel alloys containing chromium with molybdenum or tungsten
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/24—Ferrous alloys, e.g. steel alloys containing chromium with vanadium
    • C—CHEMISTRY; METALLURGY
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    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/26—Ferrous alloys, e.g. steel alloys containing chromium with niobium or tantalum
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/28—Ferrous alloys, e.g. steel alloys containing chromium with titanium or zirconium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/34—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/46—Ferrous alloys, e.g. steel alloys containing chromium with nickel with vanadium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/48—Ferrous alloys, e.g. steel alloys containing chromium with nickel with niobium or tantalum
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/50—Ferrous alloys, e.g. steel alloys containing chromium with nickel with titanium or zirconium
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Abstract

The present disclosure relates to a novel printable powder material for additive manufacturing and an additive manufactured object and uses thereof. The present disclosure also relates to an additive manufacturing method of manufacturing the object.

Description

Printable FeCrAl powder material for additive manufacturing and additively manufactured object and use thereof
Technical Field
The present disclosure relates to a novel printable powder material for additive manufacturing and an additive manufactured object and uses thereof. The present disclosure also relates to an additive manufacturing method of manufacturing the object.
Background
Additive manufacturing has become an increasingly attractive solution for manufacturing metal functional prototypes and components, especially those with complex designs.
The use of aluminum-containing ferritic alloys in electrical heating and high temperature applications is attractive. However, one of the problems with these alloys is that they are difficult to weld due to their brittleness. In addition, these alloys may be difficult to machine. Thus, it can be difficult and complicated to fabricate complex structures in these alloys. The present disclosure aims to solve or at least reduce the above problems.
Disclosure of Invention
Accordingly, one aspect of the present disclosure is to provide a printable ferritic iron-chromium-aluminum (FeCrAl) metal powder composition for additive manufacturing. Accordingly, the present disclosure relates to a printable ferritic FeCrAl powder composition, wherein the FeCrAl powder composition consists of, in weight%:
Cr 9.0-25.0；
Al 2.5-8.0；
Si≤3.0；
Mo≤4.0；
Ni≤1.0；
Mn≤1.0；
C≤0.1；
O≤0.2；
S≤0.01；
P≤0.01；
N≤0.1；
Ti≤1.7；
Y≤3.0；
Nb≤3.3；
Zr≤3.3；
V≤1.8；
Ta+Hf≤6.5；
La≤1.0；
Ce≤1.0；
the balance being Fe and unavoidable impurities; and wherein the powder particle size distribution of the FeCrAl powder composition is between 4 μm and 200 μm, such as between 10 μm and 120 μm.
The powder of the present invention has good flowability, good packing density and good spreadability, and thus its printing effect is excellent. The printable powder composition is also a gas atomized ferritic iron-chromium-aluminum (FeCrAl) powder composition, which means that the powder is obtained by a gas atomization process. The printable ferritic FeCrAl powder composition is advantageous for obtaining 3D shaped objects that are essentially fully dense and have good high temperature oxidation properties and good high temperature creep properties. In addition, the powder may be sieved to a particular desired particle size distribution.
The invention also relates to an additive manufactured object comprising alloying elements in the same range as FeCrAl powder as defined above or below and manufactured from said FeCrAl powder. The 3D shape of the additive manufactured object will depend on the end use. The inventors have surprisingly found that an additively manufactured object made from a FeCrAl powder as defined above or below, thereby comprising an alloy consisting of the same elements in the same range as the powder as defined above or below, has excellent mechanical properties at high temperatures, more specifically it has an excellent creep resistance and additionally a high oxidation resistance at high temperatures.
The additive manufactured object is particularly useful as an electrical heating element or as a component in high temperature applications (in applications operating between 400 ℃ and 1350 ℃) or as a component in electrical heating applications. The object may also be used to protect other objects from high temperature wear and corrosion. Thus, the object of the present invention can be used in both electrical heating and high temperature applications.
Another aspect of the disclosure provides an additive manufacturing method. Accordingly, the present disclosure relates to an additive manufacturing method of manufacturing an object as defined above or below from a powder as defined above or below, wherein the additive manufacturing method is selected from a powder bed fusion additive manufacturing method or Direct Energy Deposition (DED).
Drawings
FIG. 1 shows the difference in creep performance at 900 ℃ and 1100 ℃ and 1200 ℃ between the printed samples and conventionally manufactured alloys;
FIG. 2 shows the difference in mass gain at 1100 ℃ between the printed sample and the conventionally manufactured alloy.
Fig. 3 shows a micrograph of an object manufactured from the powder defined above or below by using DED.
Detailed Description
The present disclosure relates to a printable ferritic FeCrAl powder composition, wherein the FeCrAl powder composition consists of, in weight% (wt%):
Cr 9.0-25.0；
Al 2.5-8.0；
Si≤3.0；
Mo≤4.0；
Ni≤1.0；
Mn≤1.0；
C≤0.1；
S≤0.01；
P≤0.01；
N≤0.1；
O≤0.2；
Ti≤1.7；
Y≤3.0；
Nb≤3.3；
Zr≤3.3；
V≤1.8；
Ta+Hf≤6.5；
La<1.0；
Ce<1.0；
the balance being Fe and unavoidable impurities; and is
Wherein the powder particle size distribution of the FeCrAl powder composition is between 4 μm and 200 μm, such as between 10 μm and 120 μm. Furthermore, an aspect of the present disclosure is accordingly to provide a printable ferritic FeCrAl powder composition that can be used in additive manufacturing processes to obtain objects that are excellent in terms of complex structure and mechanical properties. The term "printable" means that the powder may be used in at least one additive manufacturing method.
Most of the alloying elements of the powder will be described below. Some important properties of the elements are listed in the description. However, this list should not be considered a complete list. The element may have other properties not listed herein.
Chromium (Cr)
Chromium promotes the formation of Al on the alloys defined above or below by the so-called tertiary elemental effect, i.e. by forming chromium oxides in the transient oxidation stage 2 O 3 And (3) a layer. Chromium should be present in the alloys defined above or below in an amount of at least 9 wt.%. An increased Cr content will provide an increased solution hardening effect for the ferrite structure. Starting from above about 11 wt% Cr, the ferrite structure will become unstable in the temperature range of 300-500 ℃. The ferrite may then be decomposed into a low Cr ferrite phase and a high Cr ferrite phase. When this happensAs time goes on, the material becomes harder and more brittle. This instability increased with increasing Cr, so the Cr maximum was set to 25 wt%. According to an embodiment of the present disclosure, the Cr content is thus 18 to 24 wt%, such as 19 to 23.5 wt%. According to another embodiment of the present disclosure, the Cr content is thus 9 to 11 wt.%, and according to yet another embodiment, the Cr content is thus 9 to 15 wt.%.
Aluminum (Al)
Aluminium is an important element in the powders defined above or below, since aluminium will form a dense and thin oxide Al when exposed to oxygen at high temperatures 2 O 3 It will protect the underlying alloy surface from further oxidation. The amount of aluminium should be at least 2.5 wt% to ensure the formation of Al 2 O 3 Layer and is present in an amount sufficient to form a layer of Al 2 O 3 Aluminum which repairs the layer when it is damaged. However, aluminium has a negative effect on the formability of objects obtained from the powder composition of the invention, and the amount of aluminium in the powder of the invention as defined above or below should not exceed 8 wt%. According to one embodiment, Al is between 3 and 7 wt%. According to another embodiment, Al is between 3 to 6 wt.%, such as 3.5 to 6 wt.%, such as 4 to 6 wt.%.
Silicon (Si)
In FeCrAl alloys, silicon is typically present at levels up to about 0.5 wt%. Thus, according to one embodiment, Si is present at levels up to 0.5 wt%. However, Si may play an important role in improving oxidation resistance and corrosion resistance. Thus, Si may be present at greater than 0.5 wt% to less than or equal to 3 wt%, such as 1 wt% to 2.5 wt%, such as 1.5 wt% to 2.5 wt%. The upper limit of Si is due to brittle Cr during long-term exposure 3 The sensitivity of Si and sigma phase formation is limited by the increase. Therefore, the addition of Si must take into account the contents of Al and Cr.
Manganese (Mn)
Manganese may be present as an impurity in the powders defined above or below. Manganese may also negatively impact oxidation life above 1100 ℃. Therefore, the maximum content of Mn is as high as 1.0 wt%. According to one embodiment, the content of Mn is 0.5 wt.% or less.
Molybdenum (Mo)
Molybdenum may be an impurity or may be added as an alloying element. In embodiments where Mo is considered an impurity, the maximum level is less than or equal to 0.5 wt%. In embodiments where Mo is considered an alloying element and is added to provide a solid solution hardening effect, the minimum level is greater than 0.5 wt%, such as greater than 1.0 wt%, such as between 1.0 wt% and 4.0 wt%.
Carbon (C)
Carbon may be included to increase strength. At too high a level, carbon may result in difficult material formation and have a negative impact on corrosion resistance. Thus, C is therefore limited to ≦ 0.1 wt%, such as ≦ 0.05 wt%. According to one embodiment, the C content is 0.001 to 0.1 wt%.
Nitrogen (N)
Nitrogen may be included to increase strength. Nitrogen may also be present as an inevitable impurity generated during the manufacturing process. At too high a level, nitrogen may make it difficult to form the material and may have a negative impact on corrosion resistance. Thus, N is therefore limited to ≦ 0.1 wt%. According to one embodiment, the N content is 0.001 to 0.1 wt%.
Oxygen (O)
Oxygen may be present as an impurity generated during the manufacturing process. Thus, O is therefore limited to ≦ 0.2 wt%, such as ≦ 0.1 wt%.
Reactive Element (RE)
The reactive element has a high reactivity with carbon, nitrogen and oxygen, as defined in the present disclosure. Yttrium (Y), titanium (Ti), zirconium (Zr), niobium (Nb), vanadium (V), hafnium (Hf), tantalum (Ta), lanthanum (La) and Ce (cerium) may be added to improve oxidation properties.
According to the disclosure, these elements have the following contents in the inventive powder and thus in the object produced from said powder
Ti is less than or equal to 1.7 weight percent;
y is less than or equal to 3.0 weight percent;
nb is less than or equal to 3.3 weight percent;
zr is less than or equal to 3.3 weight percent;
v is less than or equal to 1.8 weight percent;
ta + Hf is less than or equal to 6.5 wt%;
la is less than or equal to 1.0 percent by weight;
ce is less than or equal to 1.0 wt percent.
According to one embodiment, the FeCrAl powder as defined above or below may have the following weight (wt%) of these elements:
Ti≤0.5；
Y≤1.0；
Nb≤0.5；
Zr≤0.5；
V≤0.5；
Ta+Hf≤1.0；
La≤0.5；
Ce≤0.5。
according to one embodiment, the printable FeCrAl powder composition consists of, in weight%:
Cr 18-24；
Al 4-6；
Mn≤0.5；
si is less than or equal to 0.5 or more than 0.5 and less than or equal to 3;
Mo≤0.5；
Ti≤0.5；
Y≤1.0；
Nb≤0.5；
Zr≤0.5；
V≤0.5；
Ta+Hf≤1.0；
La≤0.5；
Ce≤0.5。
the balance being Fe and unavoidable impurities; and wherein C is ≦ 0.1 wt% or C is ≦ 0.05 wt%.
According to another embodiment, the printable FeCrAl powder composition consists of, in weight%:
Cr 18-24；
Al 4-6；
Mn≤0.5；
si is less than or equal to 0.5 or more than 0.5 and less than or equal to 3;
Mo 1-4；
Ti≤0.5；
Y≤1.0；
Nb≤0.5；
Zr≤0.5；
V≤0.5；
Ta+Hf≤1.0；
La≤0.5；
Ce≤0.5。
the balance being Fe and unavoidable impurities; and wherein C is ≦ 0.1 wt% or C is ≦ 0.05 wt%.
Iron (Fe) and unavoidable impurities make up the balance in the powder or object as defined above or below.
Non-limiting examples of unavoidable impurities are metals that will form low melting point phases, as these low melting point phases have been shown to have an effect on crack resistance.
Thus, it has been found that by eliminating specific alloying elements in the FeCrAl powder, products with, but not limited to, excellent high temperature corrosion resistance and creep strength can be obtained. Examples of such elements are cobalt, copper, zinc and magnesium.
According to some embodiments, the powder particle size distribution may be selected from 4 to 200 μm, 10 to 120 μm, 10 to 90 μm.
An additively manufactured object manufactured by using a ferritic FeCrAl powder as defined above or below will perform well at operating temperatures up to 1350 ℃. Furthermore, the object of the invention will have a significant high temperature corrosion resistance as well as a high oxidation resistance, sulfidation resistance and carburization resistance. Furthermore, the additively manufactured object has a significant high temperature creep strength and a high shape stability and a high electrical resistivity compared to conventionally manufactured objects.
The additive manufacturing methods described above or below use computer-aided design of 3D shaped objects to be printed, decomposed into 2D sheets using software that also links the generated data to hardware.
According to one embodiment of the present disclosure, a powder bed fusion additive manufacturing method is used. According to another embodiment, the powder bed fusion manufacturing method is selected from Selective Laser Melting (SLM) or Electron Beam Melting (EBM). In both methods, a powder bed is used. The powder layer will be exposed to an energy source and thus melt or at least partially melt. A new layer of powder will be provided and this will continue until the desired object is obtained. In SLM the energy source is one or more laser beams, such as an energy source continuous laser beam or a pulsed laser beam, whereas in EBM the energy source is an electron beam.
SLM is performed in an inert atmosphere, such as an argon or nitrogen atmosphere. Furthermore, the method may be used with a stent (support) when needed, e.g. for strengthening small angles, after which the stent will be removed. Furthermore, SLM printing is performed directly on the loose powder layer.
In EBM, the individual powder layers may be preheated before they are locally melted by the electron beam. The process is carried out under vacuum and at elevated temperature. Furthermore, in EBM, each new powder layer is first pre-sintered with an electron beam before starting the actual printing of the powder layer.
According to one embodiment, the powder layer thickness is between 10 and 250 μm. For example, in SLM the layer thickness may be 10 to 80 μm, whereas in EBM the layer thickness may be 10 to 250 μm.
According to yet another embodiment, the energy power at printing is between 80-400W when using laser beam and 300-. Optionally, more than one laser beam may be used, each beam having the power mentioned herein.
According to one embodiment, the energy source has an energy density of 1 to 6J/mm 2 Within the range of (1). The energy density being delivered by an energy source during printingTo the energy per unit area in the powder layer.
According to one embodiment, the additive manufacturing method used is Direct Energy Deposition (DED). In this type of process, an energy source is used to create a local molten pool. Metal powder is fed into this bath as a filler material. The position of the melt pool is constantly moving so that the solidified material creates a 3-dimensional body. The energy source may be a laser beam or a plasma arc. According to one embodiment, in a DED, the power of the laser source may be between 50 and 2000W.
According to one embodiment, the DED process is carried out under an inert protective gas atmosphere protecting the bath. According to one embodiment, the material feed angle may vary depending on what the predetermined shaped object is.
According to one embodiment, an object manufactured by DED may be stress relieved. The stress relief temperature range will be in the range of 650 ℃ to 1200 ℃ and will depend on the volume of the object being manufactured. Stress relief times will vary from very short (such as 15 minutes) to longer (such as several hours). According to one embodiment, pre-oxidation may be performed simultaneously with post-printing stress relief. The purpose of the pre-oxidation is to form a surface layer of alumina. According to one embodiment, the thickness of the aluminum oxide layer is at least 0.5 μm.
The additive manufactured object obtained by any of the methods/processes mentioned above or below may be post-processed.
Embodiments of the present disclosure will be disclosed in more detail in connection with the following examples. The described embodiments are to be considered as illustrative and not restrictive embodiments.
Examples
Example 1
Printing by SLM
Three powders (powder 1 to powder 3) according to table 1 were produced using gas atomization, with the chemical composition expressed in weight%, and then sieved to the appropriate fractions, such that the particle sizes of powder 1 and powder 3 and powder 4 were within 10 to 45 μm and the particle size of powder 2 was within 1 to 45 μm.
TABLE 1
Powder 1 Powder 2 Powder 3 Powder 4
Fe Balance of Balance of Balance of Balance of
Cr 23.5 21.0 9.9 21
Al 5.1 5.0 3.7 6.0
Mn 0.38 0.15 0.3 0.13
Si 0.33 0.35 0.26 0.32
C 0.02 0.04 0.03 0.02
Mo 2.8 -
Ti 0.42
Zr 0.06
Nb 0.41
Several samples of different powders were printed as follows:
the powder is provided to the SLM machine by adding to the powder delivery system. During the printing process, the powder is supplied by a powder delivery system in the machine, while the doctor blade spreads a layer of powder over the building board (building plate). The laser then passes through the powder layer according to the provided 3D drawing sheet, thereby exposing the powder layer to the laser beam and thus melting. After the powder layer is melted, a new layer is provided until the desired sample is formed according to the 3D drawing.
The thickness of the powder layer is between 20 and 30 μm. Printing was performed in an inert atmosphere using argon gas. The scanning speed is between 500 and 800 mm/s. The power of the energy source is between 80 and 200W.
The sample was allowed to cool to room temperature under an inert atmosphere. The printed sample was de-dusted and the building panel containing the sample was then removed from the machine. The building panel with the sample is heat treated at 650 ℃ to 1200 ℃ for 0.5 to 3 hours. The building panel and sample are then cooled to room temperature and then processed (cut) to remove the sample from the building panel.
Example 2
Printing by DED
Two powders having compositions according to table 2 were manufactured using gas atomization and then sieved to the appropriate fractions, obtaining powders within the 45 μm to 90 μm particle size.
TABLE 2
Powder 5 Powder 6
Fe Balance of Balance of
Cr 21.0 23.5
Al 5.0 5.1
Mn 0.15 0.38
Si 0.35 0.33
C 0.04 0.02
Mo 2.8 -
Several samples from these powders were printed in cube form as follows:
a laser source is used to create a local melt pool. The powder was fed into the bath and rapidly solidified. The powder was added to the cell by using a focused powder flow. The laser is moved along a pre-designed path to form a cured substrate layer (X-Y plane). The laser then moves upward (Z axis) and begins to create a puddle on the surface of the previous substrate, creating a new layer following a particular path. Thereby, a 3-dimensional body is manufactured.
The powder layer height is between 0.3 and 2 mm. Printing was performed with or without the use of an argon atmosphere. The deposition rate is between 1000 mm/min and 2500 mm/min. The powder feed was between 4 g/min and 25 g/min. The power of the laser source is between 50 and 2000W.
In fig. 3, a micrograph of the DED printed structure of powder 5 is disclosed. The structure was very dense and did not show any signs of cracks, defects or pores. A laika stereomicroscope was used.
Example 3 testing
Fig. 1 provides a comparison of creep strength of samples containing conventionally manufactured FeCrAl (CP1) alloys and samples manufactured by additive manufacturing using SLM (SLM1) and samples manufactured by additive manufacturing using (SLM 2).
Conventional samples were manufactured by casting and rolling and according to s.s.en ISO6892-2:2018 "Cylindrical test pieces with threaded clamping ends (Cylindrical test ends)" with diameter d 0 4mm and original gauge length L 0 20 mm.
The conventional sample had a composition according to the following specifications:
CP1 minimum value Maximum value
Fe Balance of
Cr 20.5 23.5
Al 5.3 5.3
Mn - 0.4
Si - 0.7
C - 0.08
The additively manufactured samples after printing were according to standard s.s.en ISO6892-2:2018 to clamp (turn) the end, diameter d 0 4mm and original gauge length L 0 And processing the workpiece with the thickness of 20 mm. The additive manufactured samples (SLM1 and SLM2) had a composition according to the following specifications:
SLM1 minimum value Maximum value
Fe Balance of
Cr 19.0 23.5
Al 4.5 5.5
Mn - 0.4
Si - 0.7
C - 0.08
SLM2 Minimum value Maximum value of
Fe Balance of
Cr 20.5 23.5
Al 5.0 5.0
Mn - 0.4
Si - 0.7
C - 0.08
The sample was loaded statically. The creep rate was calculated as the percentage change in sample length over time at constant load and temperature. The printed samples were tested at 1100 ℃ and 1200 ℃. The conventionally manufactured sample (CP1) was tested at 900 ℃ and 1100 ℃.
The printed material was found to be anisotropic. The creep results shown in fig. 1 are for a stronger direction of the material, where the sample was loaded parallel to the printing direction. Furthermore, as can be seen in fig. 1, the additive manufactured samples have a much lower creep rate than the conventionally manufactured samples. Even when the conventionally manufactured samples were tested at lower temperatures, the creep strength of the printed samples was still higher because the creep rate was lower. Furthermore, the printed samples will not break over a longer period of time, which means that the lifetime of such products will be longer.
Figure 2 shows mass gain curves at 1100 ℃ versus time for additively manufactured samples made from powder 4 of table 1 and conventionally manufactured samples having a similar composition to powder 4. The mass gain weight was checked at 100 hour intervals. The mass gain curve indicates that the additively manufactured sample has better oxidation properties than the conventionally manufactured sample, thus meaning that it will perform well in high temperature applications and will have a longer service life.

Claims (14)

1. A printable ferritic FeCrAl powder composition,
wherein the FeCrAl powder composition consists of, in weight%:
Cr 9.0-25.0；
Al 2.5-8.0；
Si≤3.0；
Mo≤4.0；
Ni≤1.0；
Mn≤1.0；
C≤0.1；
S≤0.01；
P≤0.01；
N≤0.1；
O≤0.2；
Ti≤1.7；
Y≤3.0；
Nb≤3.3；
Zr≤3.3；
V≤1.8；
Ta+Hf≤6.5；
La≤1.0；
Ce≤1.0；
the balance being Fe and unavoidable impurities; and is provided with
Wherein the powder particle size distribution of the FeCrAl powder composition is between 4 μm and 200 μm, such as between 10 μm and 120 μm.
2. Printable FeCrAl powder composition according to claim 1, wherein the C content is ≤ 0.05 wt%.
3. Printable FeCrAl powder composition according to claim 1 or 2, wherein the Mn content is ≦ 0.5 wt%.
4. Printable FeCrAl powder composition content according to any of claims 1 to 3, wherein Si content is less than 0.5 wt% or is more than 0.5 wt% up to less than or equal to 3.0 wt%.
5. Printable FeCrAl powder composition according to any of claims 1 to 4, wherein the Al content is between 3 and 6 wt.%.
6. Printable FeCrAl powder composition according to any one of claims 1 to 5, wherein the Cr content is 9 to 11 weight-% or 18 to 24 weight-%.
7. Printable FeCrAl powder composition according to claim 1 or 2, consisting in weight-%:
Cr 18-24；
Al 4-6；
Mn≤0.5；
si < 0.5 or from more than 0.5 to less than or equal to 3;
Mo≤0.5；
Ti≤0.5；
Y≤1.0；
Nb≤0.5；
Zr≤0.5；
V≤0.5；
Ta+Hf≤1.0；
La≤0.5；
Ce≤0.5；
the balance being Fe and unavoidable impurities.
8. Printable FeCrAl powder composition according to claim 1 or 2, consisting of in weight-%:
Cr 18-24；
Al 4-6；
Mn≤0.5；
si < 0.5 or from more than 0.5 to less than or equal to 3;
Mo 1-4；
Ti≤0.5；
Y≤1.0；
Nb≤0.5；
Zr≤0.5；
V≤0.5；
Ta+Hf≤1.0；
La≤0.5；
Ce≤0.5；
the balance being Fe and unavoidable impurities.
9. An additive manufactured object comprising the printable powder composition of any one of claims 1 to 8.
10. The additive manufactured object according to claim 9, wherein the object is a high temperature resistant heating element or a high temperature resistant component.
11. The additive manufactured object of claim 9, wherein the object is an electrical heating element or a resistive component.
12. Additive manufacturing method of manufacturing an object according to any of claims 9 to 11, wherein the additive manufacturing method is selected from a powder bed fusion additive manufacturing method or Direct Energy Deposition (DED), and wherein a ferritic FeCrAl powder according to any of claims 1 to 9 is used.
13. The additive manufacturing method of claim 12, wherein a powder bed fusion additive manufacturing method is used, and wherein the powder bed fusion additive manufacturing method is SLM or EBM.
14. Use of an additively manufactured object according to any of claims 9-13 as a component in electrical heating or high temperature applications or as a heating element.
CN202080073453.0A 2019-10-22 2020-10-22 Printable FeCrAl powder material for additive manufacturing and objects for additive manufacturing and use thereof Pending CN114929920A (en)

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