DE102018201855A1 - Material, suitable for additive manufacturing - Google Patents

Abstract

The present invention relates to a material comprising or consisting of an alloy. By using this alloy, the material can be advantageously used for additive manufacturing. Furthermore, a component with good mechanical properties can be obtained.

Description

The present invention relates to a material made of an alloy, which has preferred mechanical properties and can be processed in particular by additive manufacturing. The present invention further relates to a component formed from such a material.

State of the art

Alloys for components with good mechanical properties are widely used and often desired. It may be problematic to obtain a suitable alloy which not only has the desired mechanical properties but which is also processable by preferred methods so as to produce components. In particular, it may be challenging to provide a material or alloy that can be processed by additive manufacturing techniques.

The document DE 10 2013 010 771 A1 , for example, describes a generative manufacturing process. In order to successfully perform a generative manufacturing process in continuous operation, this document discloses a protection device for use in a generative manufacturing process. With regard to the material to be processed, this document basically discloses metal powder or plastic powder.

From Stiff, light, strong and ductile: nano-structured High Modulus Steel, H. Springer et al., Nature, Scientific Reports, 7: 2757, DOI: 10.1038 / s41598-017-02861-3, a steel is also known should have good mechanical and physical properties. Such a steel is an alloy which is a Fe-TiB2 composite material, with a proportion of 6.38 wt .-% titanium and 2.4 wt .-% boron, a proportion of 13 vol .-% TiB2 in a ferritic Iron matrix is provided.

Disclosure of the invention

• - Kohlenstoff in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 2,0 Gew.-%;
• - Stickstoff in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 1,0 Gew.-%;
• - Chrom in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 20,0 Gew.-%;
• - Bor in einem Bereich von größer oder gleich 0,01 Gew.-% bis kleiner oder gleich 5 Gew.-%,
• - gegebenenfalls Molybdän in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 10 Gew.-%;
• - gegebenenfalls Nickel in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 20,0 Gew.-%;
• - gegebenenfalls Mangan in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 10,0 Gew.-%; bevorzugt in einem Bereich von größer oder gleich 0,25 Gew.-% bis kleiner oder gleich 10,0 Gew.-%;
• - gegebenenfalls Cobalt in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 20 Gew.-%;
• - gegebenenfalls Aluminium in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 20 Gew.-%;
• - gegebenenfalls Titan in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 10 Gew.-%;
• - gegebenenfalls Vanadium in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 10 Gew.-%;
• - gegebenenfalls Niob in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 10 Gew.-%; wobei

der Rest durch Eisen und durch unvermeidliche Verunreinigungen gebildet ist.The present invention relates to a material which is suitable for producing a component by means of additive manufacturing. In the case of a material described here, it is provided that it comprises an alloy, for example consisting of an alloy. The alloy has the following alloying ingredients in the following proportions:

• - Carbon in a range of greater than 0 wt .-% to less than or equal to 2.0 wt .-%;
• Nitrogen in a range of greater than 0% by weight to less than or equal to 1.0% by weight;
• Chromium in a range of greater than 0 wt% to less than or equal to 20.0 wt%;
• Boron in a range of greater than or equal to 0.01% by weight to less than or equal to 5% by weight,
• optionally molybdenum in a range of greater than 0 wt% to less than or equal to 10 wt%;
• optionally nickel in a range of greater than 0% by weight to less than or equal to 20.0% by weight;
• optionally manganese in a range of greater than 0% by weight to less than or equal to 10.0% by weight; preferably in a range of greater than or equal to 0.25% by weight to less than or equal to 10.0% by weight;
• optionally cobalt in a range of greater than 0% by weight to less than or equal to 20% by weight;
• - optionally aluminum in a range of greater than 0 wt .-% to less than or equal to 20 wt .-%;
• optionally titanium in a range of greater than 0 wt .-% to less than or equal to 10 wt .-%;
• - optionally vanadium in a range of greater than 0 wt .-% to less than or equal to 10 wt .-%;
• optionally, niobium in a range of greater than 0% by weight to less than or equal to 10% by weight; in which

the rest is formed by iron and by unavoidable impurities.

The unavoidable impurities may include, for example, steel-typical accompanying elements. In particular, the unavoidable impurities may thus result from the production of the steel and / or be present in a proportion of less than or equal to 5 wt .-%, for example of less than or equal to 2 wt .-%. The unavoidable impurities may include, for example, oxygen, sulfur, phosphorus, silicon, and / or copper.

A material described above surprisingly allows the production of a component with good mechanical properties and is very well processable by means of additive manufacturing.

In particular, it can be made possible by the above-described alloy that the material is formed by an Fe-based alloy, or by an alloy with iron as the base material. In this case, it is also possible to design the alloy such that this has a comparatively high boron content compared to the alloys known from the prior art.

Due to the high boron content, mechanical properties of the material or of a component formed therefrom are made possible, which are distinguished, in particular, by improved wear resistance and improved strength. This can thus serve a particularly high mechanical stability, which can allow a high long-term stability.

The latter can be further improved by the fact that it has surprisingly been found that the material or a component produced therefrom has a particularly high resistance to wear and high temperature resistance. This can also enable a particularly high application width for the material or for a component produced therefrom.

In particular, the advantages described above, in particular for steel, such as in particular wear resistance and heat resistance, can be achieved by homogeneously and finely distributed borides. The borides are present as alloying partners due to the proportion of boron. These boride phases can also be called hard phases.

In addition to the abovementioned particularly advantageous mechanical properties of the material or of a component produced therefrom, the material can surprisingly make advantageous processing possible by providing the alloy as a constituent. In other words, the material may be suitably formed into a component. In particular, a processability can be carried out by means of additive processes or by means of additive production. For example, it can be made possible that processability can be carried out by means of additive techniques under moderate conditions and, furthermore, a final contour-related or near-net shape component production can already be made possible.

This has significant advantages against the background of the known art. On the one hand, even complex structures can be easily formed by additive manufacturing, so that a particularly wide applicability is given.

Moreover, in comparison to an additive process, for example, the powder metallurgical steel route for high-carbide steels known from the prior art has the disadvantage of coarsening carbides as the hard phase. Melt metallurgically, steels with carbides as hard phase are only conditionally processable, for example by demixing, increases or Phasenvergröberungen. Furthermore, conventional steels having a high carbon content such as> 0.4 wt% due to hot cracking are difficult to process by additive methods such as SLM (selective laser melting). These disadvantages of the prior art can be prevented precisely by the carbon content of the alloy of the material described here.

Conventional steels with high boron content are likewise difficult to produce by melt metallurgy and difficult to process into semi-finished products. By methods of powder production, for. B. by spraying a powder with fine, uniformly distributed borides can be produced and processed by means of generative processes. In detail, conventional brittle-metallurgical production of such alloys gives rise to coarse brittle borides which can locally accumulate and a subsequent semifinished production, for example. B. hinder strong by rolling. During atomization, fine droplets are first produced from the melt, which only lead to fine, evenly distributed borides during the subsequent rapid solidification and can be further processed without problems.

In contrast to the conventional high carbon steels described above, steels with a comparatively high boron content can be processed near net shape with additive processes and lead to a fine, homogeneous distribution of borides due to the low melt volume and extremely high cooling rates Properties can allow.

Such high boron-containing steels, in particular iron-based alloys, as described above, with borides as hard phase are not known in the prior art. These are very well suited for additive processes as described above.

Depending on the selected composition, the finished processed material may have different material structures in combination with the high boron content with the other alloying elements. This material engineering possibilities are offered that can not be represented with other methods and materials or only with great effort. For example, a non-magnetizable austenitic matrix with a high proportion of hard material (borides) is thereby possible, as a result of which the material becomes high-strength and wear-resistant. Another possibility is the combination of predominantly martensitic matrix and borides, which leads to extremely high wear resistance.

• - Kohlenstoff in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 0,3 Gew.-%;
• - Stickstoff in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 0,3 Gew.-%;
• - Chrom in einem Bereich von größer oder gleich 13 Gew.-% bis kleiner oder gleich 20 Gew.-%;
• - Bor in einem Bereich von größer oder gleich 0,5 Gew.-% bis kleiner oder gleich 2 Gew.-%;
• - Molybdän in einem Bereich von größer oder gleich 1 Gew.-% bis kleiner oder gleich 3 Gew.-%;
• - gegebenenfalls Nickel in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 20,0 Gew.-%;
• - gegebenenfalls Mangan in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 10,0 Gew.-%; bevorzugt in einem Bereich von größer als 0,25 Gew.-% bis kleiner oder gleich 10,0 Gew.-%;
• - gegebenenfalls Cobalt in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 20 Gew.-%;
• - gegebenenfalls Aluminium in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 20 Gew.-%;
• - gegebenenfalls Titan in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 10 Gew.-%;
• - gegebenenfalls Vanadium in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 10 Gew.-%;
• - gegebenenfalls Niob in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 10 Gew.-%; wobei

der Rest durch Eisen und durch unvermeidliche Verunreinigungen gebildet ist. Particularly preferably, it can be provided that the material comprises an alloy which has the following alloy constituents in the following proportions:

• - Carbon in a range of greater than 0 wt .-% to less than or equal to 0.3 wt .-%;
• Nitrogen in a range of greater than 0% by weight to less than or equal to 0.3% by weight;
• Chromium in a range of greater than or equal to 13% by weight to less than or equal to 20% by weight;
• Boron in a range of greater than or equal to 0.5% by weight to less than or equal to 2% by weight;
• - Molybdenum in a range of greater than or equal to 1 wt .-% to less than or equal to 3 wt .-%;
• optionally nickel in a range of greater than 0% by weight to less than or equal to 20.0% by weight;
• optionally manganese in a range of greater than 0% by weight to less than or equal to 10.0% by weight; preferably in a range of greater than 0.25% by weight to less than or equal to 10.0% by weight;
• optionally cobalt in a range of greater than 0% by weight to less than or equal to 20% by weight;
• - optionally aluminum in a range of greater than 0 wt .-% to less than or equal to 20 wt .-%;
• optionally titanium in a range of greater than 0 wt .-% to less than or equal to 10 wt .-%;
• - optionally vanadium in a range of greater than 0 wt .-% to less than or equal to 10 wt .-%;
• optionally, niobium in a range of greater than 0% by weight to less than or equal to 10% by weight; in which

the rest is formed by iron and by unavoidable impurities.

In particular, the unavoidable impurities may in turn result from the production of the steel and / or be present in a proportion of less than or equal to 5% by weight, for example of less than or equal to 2% by weight. The unavoidable impurities may include, for example, oxygen, sulfur, phosphorus, silicon, and / or copper.

In this embodiment, the advantages described above can be made particularly effective.

• - Kohlenstoff in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 0,3 Gew.-%;
• - Stickstoff in einem Bereich von größer als 0 Gew.-% bis kleiner oder gleich 0,3 Gew.-%;
• - Chrom in einem Bereich von größer oder gleich 13 Gew.-% bis kleiner oder gleich 20 Gew.-%;
• - Bor in einem Bereich von größer oder gleich 0,5 Gew.-% bis kleiner oder gleich 2 Gew.-%;
• - Molybdän in einem Bereich von größer oder gleich 1 Gew.-% bis kleiner oder gleich 3 Gew.-%; wobei

der Rest durch Eisen und durch unvermeidliche Verunreinigungen gebildet ist.For example, the material may comprise an alloy comprising the following alloying ingredients in the following proportions:

• - Carbon in a range of greater than 0 wt .-% to less than or equal to 0.3 wt .-%;
• Nitrogen in a range of greater than 0% by weight to less than or equal to 0.3% by weight;
• Chromium in a range of greater than or equal to 13% by weight to less than or equal to 20% by weight;
• Boron in a range of greater than or equal to 0.5% by weight to less than or equal to 2% by weight;
• - Molybdenum in a range of greater than or equal to 1 wt .-% to less than or equal to 3 wt .-%; in which

the rest is formed by iron and by unavoidable impurities.

In particular, the unavoidable impurities may in turn result from the production of the steel and / or be present in a proportion of less than or equal to 5% by weight, for example of less than or equal to 2% by weight. The unavoidable impurities may include, for example, oxygen, sulfur, phosphorus, silicon, cobalt, nickel, aluminum and / or copper.

It may also be preferred that the material is present in powder form. If the material is present in a powder form or as a powder, the material may particularly preferably be suitable for an additive process. With respect to the powder, as which the material is present, it may be particularly preferred that this has a particle size d50, which is present in a range of greater than or equal to 10 .mu.m to less than or equal to 50 .mu.m. The powder size can be determinable in a conventional manner by laser diffractometry. The powder particles may also be spherical and / or produced by gas atomization.

Thus, the material may be particularly suitable in powder form and thereby preferably in the above-described particle size for an additive process, such as selective laser melting or electron beam melting (EBM), and be used directly. Further processing steps can thus be omitted.

It may also be preferred that the boron is present in the alloy as boride. As a result, in particular a further wear resistance can be made possible, which can further improve the mechanical stability of this steel.

With regard to further advantages and technical features of the material is based on the description of the component, the method and the use, and vice versa.

The subject of the present invention is also a use of a material as described above for producing a component by means of additive manufacturing.

By using a material described above, an additive manufacturing can be easily possible and easily manageable even under moderate conditions. This allows the formation of a variety of different configurations and thus a particularly wide range of applications.

It is also possible to produce a component which has particularly good mechanical properties, in particular improved wear resistance and high heat resistance.

For further advantages and technical features of the use reference is made to the description of the material, the component and the method and vice versa.

The subject matter of the present invention is furthermore a component, which is characterized in that it is formed at least partially from a material, as described in detail above. For example, the component may consist of the material described above.

Such a component may be characterized in that it has particularly good mechanical properties, such as in particular improved wear resistance and high heat resistance. This can allow a high long-term stability with a high application width. Non-limiting examples include, for example, components for direct fuel injection, such as for gasoline direct injection.

With regard to further advantages and technical features of the component, reference is made to the description of the material, the use and the method and vice versa.

1. a) Bereitstellen eines Werkstoffs, wie dieser vorstehend beschrieben ist; und
2. b) Formen des Bauteils, wobei

Verfahrensschritt b) mittels additiver Fertigung erfolgt.The invention further provides a method for producing a component, comprising the method steps

1. a) providing a material as described above; and
2. b) molding of the component, wherein

Process step b) takes place by means of additive production.

In particular, by the method described above can form components that have particularly good mechanical properties, such as in particular an increased wear resistance and high heat resistance. This can make the applicability of such an additive method using the material described above particularly large.

In addition, the use of additive manufacturing can provide further significant advantages, as described above.

With respect to process step a), and thus the provision of a material as described above, it may be configured in a conventional manner as known for alloys.

For example, reference is made to the above description regarding the powder atomization.

For example, the material, which may be made of the alloy, may be provided in the form of a powder. The powder may have a particle size D50 in a range of greater than or equal to 10 .mu.m to less than or equal to 50 .mu.m. This can be of particular advantage for process step b), since this can be carried out advantageously in particular with such a powder.

In accordance with this method step b), the component is formed, wherein method step b) takes place by means of additive production. As specific additive manufacturing, for example, selective laser melting (SLM) or electron beam melting (EBM) may be used, but the additive method is not limited thereto.

After generative fabrication, additional heat treatment may be performed, such as curing with, for example, deep-freezing and tempering.

It can thus be a hardening of the shaped material and thereby in particular of the produced component. For example, the curing may include a temperature treatment and a freezing and / or tempering. Thus, it can be provided in particular that the hardening or that process step d) comprises the following steps: heating of the component, quenching of the component and tempering of the component.

For example, a first step of curing, namely a heating of the component by a temperature treatment, such as by the Material is subjected to a temperature treatment in a range of greater than or equal to 700 ° C to less than or equal to 1300 ° C, for example, greater than or equal to 900 ° C to less than or equal to 1150 ° C for a suitable period of, for example, at least 15 minutes. Suitable atmospheres here include, for example, vacuum, argon or nitrogen. In this step, austenitizing the material or its microstructure takes place.

Quenching may in particular take place when the temperature, for example in the case of a previous austenitization or a previously performed heating, is in a range from greater than or equal to 900 ° C. to less than or equal to 1300 ° C. By way of example, the previously used medium comprising or consisting of nitrogen, argon and helium can be used for quenching. The quenching pressure may be, for example, in a range between greater than or equal to lbar to less than or equal to 40bar. With regard to the temperature to be selected during quenching, it may be in a range from greater than or equal to -273 ° C. to less than or equal to + 70 ° C.

In quenching, martensite can form, so that the material of the component as described above has, at least in large part, a structure consisting of a martensitic matrix with embedded borides.

It may further be preferred that the process after quenching and before tempering is treated at a temperature of less than or equal to -50 ° C, which temperature should be colder than the temperature used during quenching. This step can be described as freezing. Freezing leads to a reduction in the retained austenite content and thus also to an increase in hardness and dimensional stability.

After quenching or freezing, the method may further include tempering the material, and in particular the component. For this purpose, in particular, the component can be heated. Example temperature ranges for tempering in a temperature range of greater than or equal to 150 ° C to less than or equal to 600 ° C.

After starting, the component can be completed.

With regard to further advantages and technical features of the method, reference is made to the description of the material, the component and the use and vice versa.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102013010771 A1 [0003]

Claims (10)

Material suitable for producing a component by means of additive manufacturing, characterized in that the material comprises an alloy, the alloy having the following alloy components in the following proportions: carbon in a range from greater than 0 wt.% To less than or equal to 2.0% by weight; Nitrogen in a range of greater than 0% by weight to less than or equal to 1.0% by weight; Chromium in a range of greater than 0 wt% to less than or equal to 20.0 wt%; - Boron in a range of greater than or equal to 0.01 wt .-% to less than or equal to 5 wt .-%, - optionally molybdenum in a range of greater than 0 wt .-% to less than or equal to 10 wt .-%; optionally nickel in a range of greater than 0% by weight to less than or equal to 20.0% by weight; optionally manganese in a range of greater than 0% by weight to less than or equal to 10.0% by weight; optionally cobalt in a range of greater than 0% by weight to less than or equal to 20% by weight; - optionally aluminum in a range of greater than 0 wt .-% to less than or equal to 20 wt .-%; optionally titanium in a range of greater than 0 wt .-% to less than or equal to 10 wt .-%; - optionally vanadium in a range of greater than 0 wt .-% to less than or equal to 10 wt .-%; optionally, niobium in a range of greater than 0% by weight to less than or equal to 10% by weight; the remainder being formed by iron and by unavoidable impurities. Material after Claim 1 , characterized in that the material comprises an alloy, the alloy having the following alloy constituents in the following proportions: carbon in a range of greater than 0 wt .-% to less than or equal to 0.3 wt .-%; Nitrogen in a range of greater than 0% by weight to less than or equal to 0.3% by weight; Chromium in a range of greater than or equal to 13% by weight to less than or equal to 20% by weight; Boron in a range of greater than or equal to 0.5% by weight to less than or equal to 2% by weight; - Molybdenum in a range of greater than or equal to 1 wt .-% to less than or equal to 3 wt .-%; optionally nickel in a range of greater than 0% by weight to less than or equal to 20.0% by weight; optionally manganese in a range of greater than 0% by weight to less than or equal to 10.0% by weight; optionally cobalt in a range of greater than 0% by weight to less than or equal to 20% by weight; - optionally aluminum in a range of greater than 0 wt .-% to less than or equal to 20 wt .-%; optionally titanium in a range of greater than 0 wt .-% to less than or equal to 10 wt .-%; - optionally vanadium in a range of greater than 0 wt .-% to less than or equal to 10 wt .-%; optionally, niobium in a range of greater than 0% by weight to less than or equal to 10% by weight; the remainder being formed by iron and by unavoidable impurities. Material according to one of Claims 1 or 2 , characterized in that the material is present as a powder. Material after Claim 3 , characterized in that the powder has a particle size d50, which is in a range of greater than or equal to 10 microns to less than or equal to 50 microns. Material according to one of Claims 1 to 4 , characterized in that the boron is present in the form of boride. Use of a material according to one of Claims 1 to 5 for producing a component by means of additive manufacturing. Component, characterized in that the component is at least partially made of a material according to one of Claims 1 to 5 is trained. A method for producing a component, comprising the method steps a) providing a material according to one of Claims 1 to 5 ; and b) molding the component, wherein process step b) takes place by means of additive manufacturing. Method according to Claim 8 , characterized in that method step b) comprises a selective laser melting or an electron beam melting. Method according to Claim 8 or 9 , characterized in that the material after process step b) is subjected to a temperature treatment.