DE212011100068U1 - Device for producing a product by primary molding of liquid, pasty, pasty, powdery, granular, solid material and / or its compositional states - Google Patents

Abstract

Device (10, 110) for producing a product (15, 115) by primary molding (injection molding, pressing) from liquid, pasty, pasty, powdery, granular and / or solid material and / or its composition states by means of a mold (25, 127) , characterized in that through the activation and / or furnishing and / or control of quantum mechanical and / or quantum chemical effects and forces and / or any combinations thereof, a better compacting, shaping and presintering of the pre-product as well as a pre-debinding and significant reduction of the sintering temperatures than the sintering times as well as the primary molding pressures are achieved and that the compaction and pre-sintering is generated and accelerated evenly distributed throughout the mold space, with the activation and / or mobilization and / or control of the quantum mechanical and / or quantum chemical effects and forces through the application of special consequences pulsed controllable energy Influences is generated, whereby the special sequence of pulsed controllable energy influences, for example the primary forming pressure or pressing pressure, preferably consists of several energy influencing pulses of short duration and high intensity or power, that for better compaction, primary forming and pre-sintering ...

Description

The invention relates to an apparatus for the production of products of arbitrarily complex shapes by primary molding (injection molding, pressing) of liquid, pasty, pasty, powdery, granular and / or solid material and / or its compositional states, according to the preamble of claim 1.

STATE OF THE ART

• – Materialaufbereitung
• – Urformen oder Formgebung = Herstellung von so genannten „Grünlingen oder Grünteilen”
• – Entbindern = Herstellung von so genannten „Braunlingen” (aus Metallpulver) oder „Weißlingen” (aus Keramikpulver)
• – Sintern
• – Folgeprozesse, unter anderem Entfernung der Spritzgusskanäle usw.

In all known primary shaping processes from materials in liquid, pasty, pasty, powdery, granular and / or solid state and / or their composition states, the following technology steps are used:

• - Material processing
• - prototyping or shaping = production of so-called "green bodies or green parts"
• - debinding = production of so-called "brownlings" (from metal powder) or "Weißlingen" (from ceramic powder)
• - sintering
• - Follow-up processes, including removal of the injection molding channels, etc.

In material processing, different material states of the constituents as well as different materials are mixed as homogeneously as possible together with various binder agents in order to obtain an injection molding mixture or extrusion mixture. As binders are often used various waxes, polyolefins, polyalcohols, polycaprolactones, polyvinyl alcohols and other polymer solutions and liquid polymers, algae water mixtures, cellulose water mixtures, thermoplastics and others.

Material mixtures, or so-called "feedstocks" are prepared in the above-mentioned manner, in order to then be urformed in special tools, extruded or injected. This results in the shaping and a first compression at ambient temperature. After the primary molding, extrusion and / or injection molding process, the products are removed from the mold in the form of so-called "green parts".

The next technological step involves the debinding (removal) of the binder. Debinding is carried out by thermal, catalytic and / or extraction debinding (solvent removal). For example, in the case of thermal debinding, the preliminary products (green parts) are placed in an oven for several hours in order to ensure debindering that is as damage-free and as slow as possible.

During debindering, about 60-90% of the binding agent is removed from the green body. After debinding the molded part is held together only by the targeted residual binder content (backbone). The weight loss from the greenling to the unbound brownling or white is about 5-15%.

The semi-finished products obtained after debindering, so-called "brown parts" in the case of metal powders or "white parts" in the case of ceramic powders, have different porosities and very low mechanical strengths. These half-finished products must therefore be brought to sintering with great care.

The sintering involves a special physical process; this is done by the thermal treatment in a special oven or by laser sintering or by plasma sintering or by self-sustained chemical sintering or by microwave sintering. The sintering temperatures and sintering times depend on the materials and sometimes reach up to 2700 ° C or higher and can last up to several hours or days.

In some cases, after the last process (sintering) still a calibration of the product, usually when needed a very high dimensional accuracy, which can be achieved by the not exactly calculable volume loss of pure sintering. Here, the quasi-finished product is pressed again under high pressure in a mold.

Thus, a high dimensional accuracy or z. As the compliance with the technical tolerances (shape and position tolerance) possible.

In all known wet mechanical and / or dry powder mechanical processes, numerous difficulties with regard to quality, freedom of design, reproducibility and choice of the composition of the materials and binder agents as well as the blistering when mixing powders with binder and / or solvent occur.

Bindermittel solutions usually do not have sufficient for the compaction necessary viscosities, which is why all known feedstocks do not have sufficient flow properties.

In addition, there is also a limited maximum wall thickness of the products (for example a maximum of 5-10 mm for metal powder injection molding), since otherwise the binder can no longer be completely removed.

Very disadvantageous is the occurrence of binder residues (eg carbon), which after the "Burning out" of binder in the product remain and affect its composition uncontrolled.

The known primary molding or injection molding is often the cause of defects that are only visible on the sintered product, such as cracks, voids, stresses in the product, mechanical distortion or deformation, alloy changes or C content.

In the known methods for producing the products of several different material compositions requires several injection molding steps or extrusion steps.

To overcome the mentioned disadvantages several different proposals have been made.

The proposal of some patents, such as WO2000020351A and EP0559215A In order to achieve better compaction and debindering is to increase the temperatures during sintering.

WO2007066969 A describes sintering under vacuum to remove residues of binder agents. Such special thermal treatments are very expensive and need a lot of energy and time; For example, the proposed heating of 700 ° C to 1250 ° C at a heating rate of 5 ° C per hour gives a 110 hour treatment time.

US7012036A describes a process which provides for compaction of a precursor in a rubber tube having an isostatic pressure of 1400 bar and then sintering at a temperature of about 1700 ° C.

US 20050082702A describes the preparation of composition products consisting of a metallic or ceramic matrix having a high melting temperature by impregnation with others

Material and binder mixtures and subsequent sintering. Such methods require several technological steps and are very costly and ineffective.

US20040265161 A describes the compaction of powders by applying pressure waves generated by gas explosions. This is a very costly and dangerous process, which requires very complex molding machines with special explosion protection equipment.

Theory of known processes:

Decisive properties for shaping or molding of products from powder-based material mixtures or "feedstocks" is the flow behavior and the packing behavior of the mixtures of powder particles and binder. These properties are determined by bulk forces (mass) and surface forces (attraction and repulsion between the powder particles). The smaller the powder particles, the more the powder properties are marked by the surface forces.

The production of stable suspensions of structural materials and binder mixtures plays an important role in shaping. Stable suspensions are understood to mean well-dispersed powder slurries in which the particles do not accumulate. High stability is achieved when the mutual approach of particles by Brownian motion (thermal kinetic energy) does not lead to the Van der Waals attraction.

Van der Waals attractions always act between particles of the same material; their range is very low. They cause disordered adhesion of the particles and a relatively low packing density.

The shaping of components from powders is hampered by the attractive forces and the shape of the particles (corners, edges, roughness). This is especially evident in fine and dry powders.

The effect of van der Waals attraction can be reduced or compensated for by charging the particles (electrostatic repulsion) and / or by coating the particles with polymers, which hinders mutual contact of the Patrtikeloberflächen (steric hindrance).

The interactions between the particles are essentially determined by the different ranges of attraction, repulsion and hindrance forces.

The sintering in addition to the shaping or prototyping is the core of a powder technology manufacturing of products. In this process step formed from molded powder product with its essential properties.

Sintering is the densification of green bodies under certain physical applications, such as heat treatment by the diffusion transport of atoms. The grains grow together, the porosity decreases, and almost always Grain growth (coarsening of grains) takes place. The driving force is the reduction of surface and interfacial energy. In many polycrystalline materials, atomic transport during sintering takes place exclusively in the solid phase, while in some cases a liquid phase occurs during sintering.

Characteristic of the sintering process is that not all components melt and thus the outer shape is retained. The compaction may only lead to a uniform and reproducible shrinkage. In the course of this process, a homogeneous and crack-free material with the finest possible fine-grained microstructure and certain (in many cases as small as possible) porosity is to be created.

Solid phase sintering occurs at temperatures below the melting point of the lowest melting component.

In liquid phase sintering, at least one component must form a low melting percentage. Another possibility is sintering by viscous flow, in which case there is a high melting percentage.

Reaction sintering is characterized by the emergence of a new phase (from the transitional melt that first formed).

The sintering processes in the solid phase.

The geometrical and microscopic change of the green body during sintering can be divided into three stages:
In the initial stage, the individual powder particles form so-called sintering necks at the points of contact with their neighbors. The necks on the contact points grow, more contacts are formed over time, the pores between the particles are completely interconnected via channels. As the pore shape changes due to neck growth, the pore volume remains approximately constant. The kinetics at this stage is dominated by different radii of curvature. The initial stage is usually regarded as finished when a density of about 60-70% of the theoretical density (theoretical maximum achievable density, all pores disappeared) is reached.

In the intermediate stage grain boundaries grow at all contact points; they replace solid-gaseous interfaces. The pore structure is "softer", it form pore channel structures with a partially cylindrical cross-section. Only at this stage does a strong shrinking process begin, with much of the existing pore volume eliminated. The grain size is slightly larger than the initial, the sintering rate decreases continuously. In the late intermediate stage pores are isolated from each other; this can be associated with strong grain growth. The intermediate stage is complete when all the pores are isolated and closed from each other (it is called 'closed' porosity); this is achieved at about 92% of the theoretical density.

In the final stage, the race between densification and coarsening of the texture decides which density of the sintered body is reached. Only pores at grain boundaries or pores at triple points (pores with three and more adjacent grains) have a good chance of shrinking dramatically. If the grains grow too fast, pores are trapped in the interior of the grain and have hardly any further possibilities to shrink. Whether pore elimination or grain growth dominates depends on the prevailing diffusion mechanism.

Thermodynamics and kinetics of sintering.

The driving force for sintering, neck growth, pore shape change, shrinkage and grain growth is the reduction in surface and interfacial energy, as part of free Gibbs energy G. ΔG = gsδAs + gbδ Ab (1), where gs, gb are the specific surface energy and grain boundary energy and As and Ab, respectively, are the entire surface or grain boundary surface of the sintered body.

Atomic transport takes place with differences in the chemical potential of atoms or vacancies.

The different chemical potential Δμ in the sintered body is associated with locally different curvatures of the grains. Mathematically, this can be formulated as Δμ = ΔK · gsΩ (2), where ΔK is the difference in surface curvature between two sites in the sintered body and Ω is the volume of the atomic species. The curvature scales with 1 / grain size. The ratio of chemical potential to volume Ω is the sintering potential σΣ (unit MPa) ΔΩμ = σΣ (3).

Typical activation energies for the diffusion in oxides are in the range of 200-600 kJ / mol.

Object of the present invention is to provide a device of the type mentioned, the or which avoids the disadvantages of the above-described method / device.

To solve this problem, the features specified in the claim are provided.

The compaction and formation of the metal powder or ceramic powder structures or their compositions is carried out by Van der Waals forces or on a nano basis by Casimir forces.

It is possible to show, based on quantum mechanical calculations, that the composite forces of ceramic as well as metallic particles increase during compaction and sintering through the use of periodic Casimir forces. Therefore, one also needs a periodic energy influence to activate the periodic Casimir forces. As a result, the necessary energy expenditure for the compaction process and the sintering process can be significantly reduced. The activation of the interacting Casimir forces is generated by an energy influence. The interacting Casimir forces could be significantly influenced and controlled, in particular by the application of special consequences of pulsed energy influences.

The necessary energy influence is achieved by the application of the pulsed controllable energy input unit, such as one or more ultrasonic beam elements and / or one or more megasonic radiating elements and / or one or more gigasound beam elements and / or one or more microwave radiating elements and / or one or more laser beam elements and / or one or more magnetic field generating elements and / or one or more electrostatic field generating elements and / or one or more pressure generating elements and / or any combinations thereof.

The pressure-generating elements that serve to generate pulsed pressures can be designed in various ways, for example as a pneumatic, hydraulic, gas-dynamic pulsed pressure generator, ultrasound or megasonic pulsed pressure generator, pulsed laser pressure generator, pulsed magnetostrictive pressure generator, pulsed plasma pressure generator, pulsed thermostrictive pressure generator, pulsed chemical Pressure generator, pressure generator, by means of microscopic explosions, electric discharge pressure generator.

The application of the pulsed energy influences produces an almost ideal homogenous distribution during primary molding for sintering certain constituents in whole primary volumes, generates a significantly higher compaction and thereby reduces the pressures required for the compaction, initiates first presintering by facilitating the chemical bonds, significantly accelerates the debindering process. and sintering processes, thereby ensuring the ideal density of the products and significantly reduces the sintering temperature.

The application of the periodic energy influences by the application of the controllable energy influences also initiates some chemical reactions with binder materials and thereby produces debindering already during prototyping.

In some special cases, the complete debinding and substantial sintering takes place during prototyping. This significantly reduces the sintering temperature.

Sintering is understood to mean thermal sintering, including self-heating sintering (Self Heating Sintering or Self-Propagating High-Temperature Synthesis), explosion sintering and hydrathermic sintering, microwave sintering, as well as ultrasonic sintering and laser sintering. Moreover, the method according to the invention has further advantages in comparison with the known methods.

On the one hand, a significantly higher compaction of the product during prototyping is achieved. On the other hand, the surface qualities and the strength properties are significantly improved.

A further advantage is that the possibility arises by the new method according to the invention of reducing the height of the applied pressure by at least 10 to 500 bar.

Another advantage is that the sintering temperature can be significantly reduced by up to 900 ° C by the inventive method.

A further advantage is that the process according to the invention overcomes the disadvantages of insufficient viscosities of the material mixtures, the so-called "feedstock" (material constituent states and different materials which are best mixed homogeneously together with different binder agents), and / or the composites This is the first time that it has been possible to achieve ideal densities in the entire volume of the sintered product.

A further advantage is that the targeted control of the pore development is achieved by the method according to the invention. This allows accurate determination of the pore size (from 0.1 nm to 800 μm) or complete elimination of pores.

Another advantage is that by the method according to the invention porous products (for example porous bone implants and others) can be produced in one technological step. This was possible in the known methods only by additional applications with a simultaneous significant increase in costs.

Another advantage is that it is possible by the method according to the invention to produce the products without wall thickness limitation. In known methods, the wall thickness of the producible products is limited by the binder removal process, usually up to 10 mm, otherwise the binder can not be completely removed.

A further advantage is that the method according to the invention makes it possible to produce the products from a plurality of different materials having different properties (for example particle size) and combinations thereof without additional primary shaping steps.

Another advantage is that the process according to the invention makes it possible for the first time to carry out the debindering at least in part already during the forming process. A further advantage lies in the fact that defined geometry structures can also be impressed into the surface by the novel method according to the invention. Such structures are particularly in the micro range and can serve, for example, for improved frictional properties of the product.

Another advantage is that the new process according to the invention offers the possibility of producing the superplastic products in a technological step.

A further advantage is that structural composition material structures which are difficult to produce by the method according to the invention, or structural porous composition material structures, for example in the case of turbine or gas turbine blade production, which have a porous core with metallic or ceramic walls, or porous bone implants are produced in a primary molding process can be.

Another advantage is that, by the method according to the invention, the different parts of a product can have different hardness and strength properties, such as that an inner part has a higher hardness and strength compared to the outer part by the application of a specially aligned pressure pulse train and a having matching binder mixture.

A further advantage is that the method according to the invention ensures a gradual introduction of energy, a leveling of the temperature increase and an increase in the particle composite forces up to the presintering temperature and pre-sintering force so that the compacting and pre-sintering are uniformly generated and distributed throughout the mold space.

Another advantage is better handling of semi-finished products due to higher strength.

A further advantage lies in the fact that the binder removal is generated and accelerated in an even distribution throughout the molding space by the process according to the invention.

Another advantage is that the process of the invention and the use of supercritical fluids, the complete debindering and complete binder agent trace elimination is achieved.

Another advantage is that the compacting, pre-sintering and binder removal in the entire mold cavity is uniformly generated, distributed and accelerated by the application of one or more ultrasonic pulses with preferably different power and / or pulse duration, by a gradual energy input ensure a leveling of the temperature increase and the increase of the particle composite forces up to the presinter temperature and Vorsinterverbundkraft.

Further advantageous embodiments will become apparent from the features of one or more of claims 2 to 17.

In the following, further aspects of the invention will be described. A fundamental aspect relates to a method for producing a product by primary molding (injection molding, pressing) of liquid, pasty, pasty, powdery, granular and / or solid material and / or its compositional states by means of a form, wherein the activation and / or Moblisierung and / or control of quantum mechanical and / or quantum chemical effects and forces and / or any combination thereof better compaction, initial shaping and presintering of the precursor as well as a predentering and significant reduction of the sintering temperatures and the sintering times and the original compression pressures is achieved and that the compaction and pre-sintering is generated and accelerated evenly throughout the entire shape space.

As a second aspect, the above is configured by generating the activation and / or mobilization and / or control of the quantum mechanical and / or quantum chemical effects and forces through the application of special sequences of pulsed controllable energy influences.

As a third aspect, the second aspect is characterized in that the particular consequences of the pulsed controllable energy effects include electromagnetic energy.

A fourth aspect is that aspects two or three are characterized in that the particular consequences of pulsed controllable energy inputs include electromagnetic energy, ultrasonic energy or megasonic energy or giga-sound energy.

As a fifth aspect of the method, aspects two or three are configured such that the particular consequences of the pulsed controllable energy effects are the electromagnetic energy, microwave energy or electrostatic energy or laser energy of photon emitters and / or phonon radiating lasers and / or their combination or pulsed magnetic field energy and / or the Energy of rotating magnetic fields include.

Aspects two or three are characterized according to a sixth aspect in that the specific consequences of the pulsed controllable energy influences are the electromagnetic energy, any compositions of ultrasonic energy and / or megasonic energy and / or giga-sound energy and / or microwave energy and / or electrostatic energy and / or laser energy of photon radiators and / or phonon radiating lasers and / or their combination and / or pulsed magnetic field energy and / or rotating magnetic fields.

Aspects two or three according to a seventh aspect of the invention are characterized in that the specific consequences of the pulsed controllable energy influences include any combination of electromagnetic and mechanical energy.

An eighth aspect is that, in addition, the mechanical energy is applied inter alia in the form of pressure energy and / or sound energy.

A ninth aspect is that the invention is embodied in that pressure pulses from pneumatic, hydraulic, gas-dynamic, pulsed pressure generators, thermostrictive pressure generators, plasma pressure generators, laser pressure generators, chemical pressure generators, and / or by discharges and / or laser-initiated discharges, and / / or generated by pulsed by microscopic explosions pressure generators.

As the tenth aspect, the fourth aspect is configured by the sound energy including any combination of ultrasonic energy and / or megasonic energy and / or giga-sound energy.

According to an eleventh aspect, the second or third aspect is characterized in that special sequences of the electromagnetic energy and mechanical energy and / or combinations thereof in the form of one or more energy influence pulses of short duration and high intensity are used as special consequences of the pulsed controllable energy influences.

For a further embodiment of the invention according to a twelfth aspect, the method is characterized in that a leveling of the temperature increase and the increase of the particle composite forces is up to the Vorsintertemperatur and Vorsinterverbundkraft ensured by a gradual energy input and that the compaction and pre-sintering generated evenly distributed throughout the mold space and is accelerated.

Moreover, according to one aspect 13 be provided that the special consequences of the pulsed controllable energy effects in any combination are used for better compaction, formation and pre-sintering of the precursor as well as the Vorentbinderung and the significant reduction of sintering temperatures as well as for Urformdrücken and so by a gradual energy input leveling the Increase in temperature and the increase of the particle composite forces up to the pre-sintering temperature and Vorsinterverbundkraft ensure, and that the compacting and pre-sintering is generated and accelerated evenly distributed throughout the mold space.

A fourteenth aspect is that 1 to 10,000 energy impact pulses, more preferably 1 to 5,000, most preferably 1 to 500 energy impact pulses, with a pulse duration between 1 femtosec and 30 minutes, better 1 μs to 10 minutes, most preferably between 1 ns and 5 minutes and a pulse interval between 1 μs to 30 minutes, more preferably from 1 ns to 10 minutes, is best applied between 100 ns and 5 minutes.

As another aspect 15 It is conceivable that, depending on the material composition of a product and its required surface condition, the number of energy impact pulses and / or or whose intensity or power and / or duration and / or time is selected.

A sixteenth aspect is that the height of the pressures used in the prototyping be reduced by 10 to 500 bar.

It is also conceivable (aspect 17 ) that the heights of the sintering temperatures used during sintering are reduced by at least 10 ° C to 800 ° C.

For further embodiment (aspect 18 ) it is conceivable that the disadvantages of insufficient viscosities of the material mixtures, the so-called "feedstocks" (material constituent states and different materials which are best mixed homogeneously together with different binders), and / or the composites are overcome and thus the possibility for the first time arises to achieve ideal densities throughout the volume of the sintered product.

An aspect 19 This is because the process and application of the supercritical fluids achieves complete debindering and complete binder lane elimination.

According to a twentieth aspect, it is provided for further embodiment that the pore development is controlled.

The above-mentioned, tenth aspect is thereby further developed (aspect 21 ) that a pore size of 0.1 nm to 800 microns is set.

Another aspect (aspect 22 ) is characterized in that the wall thickness of the producible products is unlimited.

It is also conceivable in principle (aspect 23 ) that products made of several different materials with different properties, such as particle size and their combination are produced together without additional prototyping steps.

An embodiment of the aspects mentioned results from the fact that the debindering during the forming is carried out at least partially.

Another aspect of the invention is that porous structures are made of composite materials, such as porous core products and metallic or ceramic walls.

Another embodiment results from the fact that products are made with parts of different hardness and strength properties.

It is also conceivable in the abovementioned aspects that the binder removal is uniformly distributed and accelerated throughout the entire mold cavity.

For further embodiment, it is provided that defined in the surface of the products geometry structures are impressed.

It is also an aspect of the invention that such structures serve, in particular in the micro range, for example for improved frictional properties of the product.

In addition, products with superplastic properties can be produced in one technological step.

Furthermore, the invention relates to products produced by the described method and / or with the device, such as. Implant, which has an increased osseous and also osteotic property or an increased waxing property, or dental blanks of any geometry with or without special machine mount which significantly improved processing properties and stabilities or technical components, such as. Turbine blades and their parts, screws, brake discs, gears, engine parts, propellers (rotors), moldings, structural mold carrier (T-beam and the like), body moldings, combustion chambers, pressure vessels, cutters, plates and tools.

Further details of the invention can be found in the following description in which the invention with reference to the embodiment shown in the drawing is described and explained in more detail. Show it:

1 and 2 in schematic side view respectively an apparatus for producing a product by primary molding (injection molding, pressing) of a material which is present in a liquid, pasty, pasty, powdery, granular and / or solid state and / or a mixed state, according to two embodiments present invention.

In the 1 illustrated device 10 for producing a product by injection molding of a material of certain initial state has a press screw 11 in a housing 21 that with a funnel 22 is provided by the interior 23 of the housing 21 in which the press screw 11 is rotatably mounted, one mixture 12 from the material used (material) and a binder is introduced. The binder may be of a customary in injection molding and tailored to the material to be processed substance. The material (material) used in the injection molding can be in liquid, pasty, pasty, powdery, granular and / or solid state and / or its compositional states and mixed with the binder means are introduced. It is understood that instead of a rotationally driven pressing device may be provided which is driven linearly.

By the rotating driven press screw 11 becomes the material-binder mixture 12 in the axial direction of the housing 21 to one or more spray nozzles 13 brought during which process the mixture 12 is compressed under pressure applied by the press screw 11. That with the spray nozzle or nozzles 13 equipped end of the housing 21 is with the stationary part 14 an injection mold 25 connected, between which fixed part 14 and one in the direction of the double arrow A for opening and closing the injection mold 25 moving part 16 an injection molding room 26 or mold space is arranged, in which the sprayed product 15 will be produced.

In the area of the spray nozzle 13 or the injection molding room 26 opens radially a not shown in detail pressure line, the other end with a generator 17 connected by pulsed pressures. These pressure pulses are in the spray nozzle 13 or the injection mold due to the press screw 11 existing pressure on the mixture 12 superimposed. On the spray nozzle (s) 13 a sealer also acts 18 For example, as a check valve for materials of very high viscosity and pressure in the injection chamber 26 can be trained.

The in the 2 illustrated device 110 for producing a product, for example a dental blank 115 by pressing from a material specific initial state has a vertically or axially movable upper tool part 116 with a die 127 and a stationary tool base 114 with a die recess 128 , which is hydraulically driven, for example. In the die recess 128 , which represents the form space, becomes a mixture 112 from the material used (material) and a binder means introduced. The binding agent may be of a customary in pressing and tailored to the material to be processed substance. The material (material) used in the injection molding can be in liquid, pasty, pasty, powdery, granular and / or solid state and / or its compositional states and mixed with the binder means are introduced.

In the die recess 128 becomes the material-binder mixture 112 in the axial direction by the application of the die 127 compressed by the applied pressure.

In the area of the die recess 128 preferably open two radially extending pressure lines 129 . 130 whose other end has one producer each 117 . 118 connected by pulsed pressures. These pressure pulses are in the filled Matrizenausnehmung 128 due to the matrix 127 existing pressure on the mixture 112 superimposed.

The pressure generators 17 respectively. 117 and 118 , which serve to generate periodic pressures may be formed in various ways, for example as a pneumatic, hydraulic, gas-dynamic, pulsed pressure generator, as a pulsed ultrasonic pressure generator, pulsed magnetostrictive pressure generator, pulsed thermostrictive pressure generator, pulsed plasma pressure generator, pulsed laser pressure generator, pulsed chemical pressure generator and / or by electrical discharges and / or laser initiated discharges and / or pulsed microscopic explosions.

This can be the pressure generator 17 respectively. 117 . 118 be designed so that the number of pressure pulses and / or their power or energy and / or the pulse duration and / or the time can be controlled. The shape of the pressure pulses may ideally be approximately rectangular or approximately sawtooth.

For example, in both embodiments, the number of pressure pulses ≥ 1, for example in the range of 1 to 1000 pressure pulses, preferably in the range of 1 to 500, but more preferably in the range of 1 to 100 pressure pulses. The pulse duration may be between 1 ns and 30 minutes, preferably between 2 μs to 10 minutes, but most preferably between 100 ms and 5 minutes. The pulse interval ranges between 1 ns and 30 minutes, preferably between 1 μs and 10 minutes, preferably between 100 ms and 5 minutes.

The generated pulsed pressure is transferred to the material mixture feedstock, which is in the injection mold 25 located. Preferably, the pulsed pressures are applied together with the injection molding or pressing pressure.

In an embodiment, not shown, the pulsed pressures generated by the application of special membranes, according to 1 for example, in the injection mold 25 or in the injection molding nozzles 13 located on the injection molding room 26 transfer. But it is also possible that pulsed pressures, which are generated by plasma pressure generator and / or laser-initiated discharges and / or microscopic explosions, directly to the material mixture 12 to bring without the interposition of membranes.

• – Nickel-basierende Legierungen mit Tantal, Chrom, Hafnium;
• – Nickel-Tantal Aluminiden;
• – Chrom-Titan-Niobium-Aluminium;
• – Chrom-Titan-Tantal-Aluminium;
• – Nickel-Hafnium-Wolfram-Titan-Molybdän-Chrom-Zirkonium-Yttium Oxide;
• – Oben genannte Kompositionen gemischt mit Keramiken.

The inventive method was further tested using the example of a hot gas turbine blade with different material mixtures, such as:

• Nickel-based alloys with tantalum, chromium, hafnium;
• - nickel-tantalum aluminides;
• - chromium-titanium-niobium-aluminum;
• - Chrome Titanium Tantalum Aluminum;
• Nickel-hafnium-tungsten-titanium-molybdenum-chromium-zirconium-yttrium oxides;
• - The above compositions mixed with ceramics.

The tests have shown that turbine blades including the sintering process can be produced in just 50 minutes. A comparison of the sintering temperature to the conventional method for the same material compositions shows a reduction of the temperature by about 700 ° C.

Quality inspection of the turbine blades has given excellent strength, thermal stability and hot gas service lives.

With equally good results, the turbine blades were also made with a ceramic top layer.

The process according to the invention was also tested on the example of ceramic composition parts, such as, for example, aluminum oxides with BN fiber.

The method according to the invention also offers the possibility of producing toothed wheels with different material properties, such as lightweight on the inside and hard on the outside.

The production of porous products was exemplified. shown by parts that resemble metallic foams. As a result, structures such as closed and / or open metallic foams were produced.

The pulsed pressurization of the mixture 12 . 112 in the respective mold cavity in addition to the injection molding or pressing pressure or this superimposed can be effected by other pulsed controllable energy influences. For example, specific consequences of the pulsed controllable energy effects include electromagnetic energy and / or sound energy, such as ultrasonic energy or megasonic energy or giga-sound energy. Furthermore, the specific consequences of the pulsed controllable energy influences include the electromagnetic energy, any compositions of ultrasound energy and / or megasonic energy and / or gigasound energy and / or microwave energy and / or electrostatic energy and / or laser energy of photon emitters and / or phonon radiating lasers and / or their Combination and / or pulsed magnetic field energy and / or energy of rotating magnetic fields. Also, the particular consequences of the pulsed controllable energy effects may include any combination of electromagnetic and mechanical energy.

According to the invention, the activation and / or mobilization and / or control of quantum mechanical and / or quantum chemical effects and forces and / or their arbitrary combinations results in better compaction, primary shaping and pre-sintering of the precursor product as well as predentraction and significant reduction of sintering temperatures and sintering times Even Urformdrücken achieved, the compaction and pre-sintering is generated evenly distributed and accelerated throughout the cavity.

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

• WO 2000020351 A [0018]
• EP 0559215 A [0018]
• WO 2007066969 A [0019]
• US7012036A [0020]
• US 20050082702 A [0021]
• US20040265161A [0023]

Claims (17)

Contraption ( 10 . 110 ) for the manufacture of a product ( 15 . 115 ) by primary molding (injection molding, pressing) of liquid, pasty, pasty, powdery, granular and / or solid material and / or its compositional states by means of a mold ( 25 . 127 ), characterized in that by the activation and / or mobilization and / or control of quantum mechanical and / or quantum chemical effects and forces and / or their arbitrary combinations better compaction, shaping and presintering of the precursor as well as a Vorentbinderung and significant reduction of sintering temperatures as well as the sintering times and the original molding pressures is achieved and that the compaction and pre-sintering is generated and accelerated evenly distributed throughout the mold space, wherein the activation and / or mobilization and / or control of the quantum mechanical and / or quantum chemical effects and forces by the application of special Consequences of pulsed controllable energy influences is generated, wherein the special sequence of pulsed controllable energy influences, for example, the primary pressure or compression pressure of preferably several energy-influencing pulses short time duration and high intensity or power bes Teht that for a better compaction, Urformung and pre-sintering of the precursor as well as for Vorentbinderung and the significant reduction of sintering temperatures several Energieeinflussimpulse preferably different intensity or power and / or Energieeinflussimpulszeitdauer are applied and so by a gradual energy input leveling the temperature increase and the Increase the particle composite forces up to the pre-sintering temperature and pre-sintering force ensure, and that the compaction and pre-sintering generated in the entire mold cavity evenly and are accelerated. Device according to claim 1, characterized in that the device ( 10 . 110 ) comprises a primary molding device and / or any, for example coaxial or hydrostatic press and / or extrusion device and / or injection molding device, which comprises a device ( 17 ) for generating a pulsed energy influence, of which the pulsed energy influence, for example in the form of pressure pulses on the material mixture, which is urgeformt, transferable. Apparatus according to claim 2, characterized in that as the energy influence generating means a pressure generating device ( 17 ) is provided for generating the pulsed pressure sequences in the form of a hydraulic, pneumatic, magnetostrictive, chemical, explosive or microwave, plasma, sound pressure system (ultrasound, megasonic, gigasound) or combinations thereof. Apparatus according to claim 3, characterized in that as an energy influence generating means electromagnetic energy generating device ( 17 ) and at least one ultrasonic beam system or at least one megasonic beam system or at least one ultrasonic beam system or at least one gigasound beam system or at least one microwave beam system or at least one laser beam system or at least one magnetic field generating system or at least one generating an electrostatic field system is provided. Apparatus according to claim 2, characterized in that the energy influence generating device ( 17 ) one or more one or more arbitrary combinations of one or more ultrasound elements and / or one or more megasonic beam elements and / or one or more gigasound beam elements and / or one or more microwave beam elements and / or one or more laser strands Elements and / or one or more magnetic field generating elements and / or one or more electrostatic field generating elements and / or one or more pressure generating elements includes. Device according to at least one of claims 1 to 5, characterized in that the pressure pulses through one or more membranes on the injection molding space ( 26 ) are transferable. Device according to at least one of claims 1 to 6, characterized in that the pore development is controllable. Apparatus according to claim 7, characterized in that a pore size of 0.1 nm to 800 microns is adjustable. Apparatus according to claim 7, characterized in that possible pores are eliminated. Device according to at least one of claims 1 to 9, characterized in that the wall thickness of the producible products is unlimited. Device according to at least one of claims 1 to 10, characterized in that products made of several different materials with different properties, such as particle size and their combination together without additional primary forming steps are produced. Device according to at least one of claims 1 to 11, characterized in that the debindering during the forming is at least partially feasible. Device according to at least one of claims 1 to 12, characterized in that defined in the surface of the products geometry structures are einprägbar. Apparatus according to claim 13, characterized in that such structures are particularly in the micro range for example, improved friction properties of the product. Device according to at least one of claims 1 to 16, characterized in that porous structures of composite materials can be produced, such as, for example, products with a porous core and metallic or ceramic walls. Device according to at least one of claims 1 to 15, characterized in that products with parts of different hardness and strength properties can be produced. Device according to at least one of claims 1 to 16, characterized in that the binder removal means in the entire mold cavity is uniformly distributed and accelerated.

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