EP2121222A2 - Corps moulé composite en céramique et/ou de la métallurgie des poudres et procédé d'utilisation dudit corps - Google Patents

Corps moulé composite en céramique et/ou de la métallurgie des poudres et procédé d'utilisation dudit corps

Info

Publication number
EP2121222A2
EP2121222A2 EP08701277A EP08701277A EP2121222A2 EP 2121222 A2 EP2121222 A2 EP 2121222A2 EP 08701277 A EP08701277 A EP 08701277A EP 08701277 A EP08701277 A EP 08701277A EP 2121222 A2 EP2121222 A2 EP 2121222A2
Authority
EP
European Patent Office
Prior art keywords
composite
green
green sheet
mold
molded body
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP08701277A
Other languages
German (de)
English (en)
Inventor
Hartmut Walcher
Marko Maetzig
Andreas Baumann
Reinhard Lenk
Tassilo Moritz
Hans-Jürgen Richter
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Original Assignee
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV filed Critical Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Publication of EP2121222A2 publication Critical patent/EP2121222A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • 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
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/252—Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]

Definitions

  • the invention relates to the field of ceramics and powder metallurgy materials and relates to a composite molding, as for example for cutting tools (combination of hartspröden and ductile properties), heating elements and thermally stressed instruments (combination of electrically conductive and electrically insulating materials) or for products in Dental technology (combination of material and optical properties) is used and a method for their preparation.
  • Powder injection molding is a molding process in which a feedstock consisting of ceramic and / or metallic powders and organic plasticizers is injected into a cavity in the thermoplastic state and, after solidification, assumes the geometric shape of the cavity. After one of the shaping Following binder removal process, the final dimensions and properties of the component to be produced are generated in a final sintering process.
  • a feedstock consisting of ceramic and / or metallic powders and organic plasticizers
  • the final dimensions and properties of the component to be produced are generated in a final sintering process.
  • a wide variety of material and process-related advantages such as the high inherent rigidity of ceramic materials, achievable surface qualities without post-processing, as well as geometric design freedom and complexity, are used.
  • the cost factors material, sintering and processing can thus be significantly reduced.
  • the injection molding process has a high shape complexity and freedom in shaping the shape.
  • the powder injection molding process has also been scientifically well studied in its application on a miniaturized scale.
  • components in sub-millimeter dimensions and detail dimensions in the nm range are produced by using very fine-grained steel and ceramic powder (Benzler, T., Piotter, V .: MicroMIM and MicroCIM: Ingenieur-Materialien 8 (1999), 16-17).
  • the aspect of miniaturized component manufacturing was extended with the aspect of the multifunctionalization of the same using the example of a heating needle, consisting of highly differently conductive ceramics.
  • Multicomponent powder injection molding is establishing itself as a versatile process variant. For example, it was shown that metal joining partners combined with each other can remain movable against each other after sintering (so-called assembly powder injection molding) (Maetzig, M., Walcher, H .: Assembly Molding of MIM Materials.) Proceedings EuroPM2006 Vol. 2 (2006), 43- 48).
  • assembly powder injection molding is another well-studied process variant.
  • the joining partners are injected into the tool mold with consideration of a core-shell aspect in such a way that a component which is completely encased with the joining partner always results.
  • metal gears were produced with wear-resistant stainless steel casing. (Alcock, JR, Logan, PM, Stephenson, DJ .: Surface engineering by co-injection molding, Surface and Coatings Technology 105 (1998), 65-71).
  • Multi-component powder injection molding further advantages.
  • the geometry of the multi-material component is relatively independent of the shape of the interface between the individual materials.
  • the different materials need not overlap one another as layers of uniform thickness, ie, in the production of the outer layer there is no compulsion to follow the contour of the interface.
  • independent and at the same time complicated moldings can be produced.
  • the production of layers and there in particular the production of very thick layers (> 0.5 mm) with a freely selectable layer thickness ratio possible.
  • the particularly cost-intensive high-performance materials on the actually in the component claimed sites are localized without deteriorating the properties of the entire molding.
  • the ceramic starting powders are treated homogeneously to a Folieng messschlicker together with a dispersing liquid, a condenser and one or more binder components.
  • the bubble-free slip is then applied to the casting station and evenly distributed over a level casting mat by means of a precisely set to a certain height casting mold.
  • the dispersion liquid is expelled uniformly, whereby the height of the film is reduced. If several layers are poured on top of each other, the term multilayer film casting is used.
  • the ceramic powder is first dispersed together with a condenser in the selected liquid. Subsequently, binders, plasticizers and wetting agents are admixed. The finished slurry must be well vented before potting to avoid blistering.
  • the ceramic slip is poured from a container onto a carrier foil. This carrier film is generally passed continuously past the container. But there are also methods with a moving container. On the carrier film, a ceramic layer is formed, which is dried in a drying channel and forms a self-supporting flexible ceramic film. The thickness of the layer is controlled via the exit gap height of the container and the height of the doctor blade.
  • Binders which can be used are water-soluble polymers, water-dispersible polymers, polymers soluble in organic solvents, polymers dispersible in organic solvents.
  • the flexibility of the green sheets can be additionally influenced by the addition of a plasticizer in the binder mentioned.
  • the method is suitable for film thicknesses in the range of 0.05 mm - 1, 5 mm.
  • Lamination can be used to complete individual films to form multilayer composites, so that the overall blow molding technique is characterized by high flexibility.
  • DE 196 52 223 A1 describes a composite molding produced by means of thermoplastic molding, which consists of at least two ceramic and / or powder metallurgical materials and of at least one thermoplastic binder and is characterized in that partial volumes are present within the molded body which have different material compositions and / or have a different content of particles of the material (s) in the thermoplastic or thermosetting binder.
  • US 2003/0062660 describes the production of molded parts consisting of two or more components by means of multi-component injection molding of ceramic and / or metallic powder materials.
  • the object of the invention is to specify ceramic and / or powder metallurgical composite molded bodies which are free both in the design of their surface and in the design of the interface or the boundary region between two materials of the composite molding and only by the general disadvantages of ceramic and / or powder metallurgy Foil production and injection molding are limited and in specifying a simple, flexible and inexpensive process for their production, which can also be used for mass production.
  • the ceramic and / or powder metallurgical composite molded bodies according to the invention consist of a green film or a green film composite of at least one ceramic and / or metallic and / or binder material which (r) the surface of the composite mold body with the same and / or different composition and / or layer thickness or partially covered or contained in the composite form body, and of a ceramic and / or metallic injection molded body which is at least positively connected to the green sheet or the green film composite, wherein the grain size and the grain distribution and / or the packing density of the ceramic and / or metallic powder grains in the green film or the green film composite, as well as their shrinkage behavior during sintering is adapted to the shrinkage behavior of the ceramic and / or metallic injection molded body in the subsequent sintering, and wherein in the case of the use of a thermoplastic Bindeffens in the green film or green film composite, the melting and processing temperature of the injection molding material is smaller than the melting temperature of the thermoplastic binder.
  • the green film or the green film composite of the same or different material composition completely cover a ceramic and / or metallic injection-molded body on its outer surface and / or they are in cavities or undercuts of a one- or multi-part Injection molded body arranged, wherein still advantageously green sheets or green film composites of different composition are applied.
  • the boundary surface or the interface region between the green film or the green film composite and the injection-molded body have the same geometric shape as the outer surface of the green film or of the green-film composite.
  • the green sheet or the green sheet composite and the injection molded body are non-positively connected to each other or via chemical and / or physical bonds.
  • the green sheet or the green sheet composite contains a thermosetting binder.
  • the green sheet or green sheet composite contains a thermoplastic binder, more preferably a polyethylene copolymer.
  • the green sheet or the green sheet composite of the same and / or different layer thickness cover a ceramic and / or metallic injection molded body on the outer surface thereof and / or in cavities or undercuts of a one-part or multi-part injection molded body.
  • the green sheet or the green sheet composite has wholly or partially structuring on one or both surfaces, wherein the patterning advantageously also contains further other materials and also advantageously contains the structuring of polymers or natural substances.
  • glass or glassy materials are present as fillers in the green film or in the green film composite and / or in the injection molded body.
  • the outer surface has a green sheet of a metallic material, including a green sheet of a metallic and ceramic material is arranged, then followed by a ceramic injection-molded body.
  • a binder of the same composition is present both in the green film and in the entire green film composite and in the injection-molded body.
  • a binder is present both in the green film and in the entire green film composite, which corresponds in terms of composition, which is at least partially contained in the injection molded body and expelled there as the last binder from the injection molded body.
  • a green film or a green film composite of at least one ceramic and / or metallic and / or binder material is placed in or on a mold, the mold being wholly or partly covered with green film or green film composite of the same and / or different composition and / or or the same and / or different layer thickness is covered, and subsequently at least one ceramic and / or powder metallurgical injection molding compound on and / or on and / or in the mold by injection molding and / or on and / or introduced, and subsequently the one - Or multi-part mold removed and / or the one or more part composite body parts are removed from the mold, these steps can be repeated one or more times.
  • a preformed green film or green film composite even more advantageously punched, embossed, curved, drawn green film or green film composites are used. Also advantageously, a preformed green film or green film composite is used with a carrier film.
  • the mold for producing the preformed green sheet or the green sheet composite is subsequently used as an injection mold, wherein advantageously a divisible mold is used.
  • a green sheet or green film composite is used, which consists of partial surfaces of different material.
  • the injection molding composition is discontinuously and / or on and / or introduced.
  • an injection molding compound is applied or applied to and / or to and / or into a green film or a green film composite.
  • thermoplastic and / or thermosetting and / or biopolymeric binder is used as the binder for the green films or green film composites. It is likewise advantageous if the green sheet or the green sheet composite is deformed during the application, application or introduction of the injection-molded body.
  • a binder is introduced in the green sheet or in the green film composite, which is introduced at least partially in the injection molded body and which is driven out of the composite body last.
  • the composite form body is debindered and sintered.
  • the advantage of the solution according to the invention consists in the simplified tool technology, in which the ability to thin structure and / or functional layers to realize over large areas and paths and thus prefabricate large-scale, inexpensive and effective, for example, to be separated miniature components. Also advantageous in the inventive solution is a simplified process technology. Ceramic and / or powder metallurgical green films or green film composites can be produced in different layer thicknesses and can be processed by subsequent processes, for example embossed, stamped, microstructured, screen-printed or laminated, wherein, for example, intermediate layers can be applied.
  • green sheets or green sheet composites are used, for example, in an injection molding tool, then these sheets can assume the geometric and / or surface shape of the injection molding tool, whereby extremely filigree structures and contours can be produced.
  • the process control can be designed so that the composite body according to the invention produced according to the invention can be sintered in one step.
  • the matching of the sintering behavior of the components of the composite molding takes place by the adjustment of the relative particle packing densities of the composite partners as a function of the achievable absolute sintering densification in the cosintering. That is, material composites within the meaning of the composite molding according to the invention, which can not be completely densely sintered within a temperature window because either the sintering temperature for a partner too low or the particle size distributions of the powder of the composite partners are too large, can by selecting asymmetric relative particle packing densities a common Sinterschwindungsbetrag be set.
  • the so-called placeholder method in which powder particles are partly substituted by organic fillers, in order to achieve increased sinter shrinkage or increased residual porosity after sintering.
  • the possibilities of multicomponent molding of composite material components are drastically expanded, and mass production capability can be achieved by keeping the powder injection molding process reduced to one component.
  • the integration of thin functional layers into a corresponding multi-component component by molding green films filled with ceramic and / or metallic powder materials, with ceramic and / or metallic feedstocks provides an advance into new manufacturing dimensions which can not be achieved technically and financially with conventional multicomponent powder injection molding , dar.
  • Active material composites are characterized by chemical correspondence (chemical bonding) of the combined materials or individual components of the composite material (doping, elements, phases).
  • covalent and / or ionic bonds cause the bond strength in the joining zone.
  • Passive material composites are by geometric modifications (for example, undercuts, gears, mechanical Verklammerept) and / or by variation of the powder packing density and powder particle size and of the macroscopic surface structure (rough, structured) of the interfaces and / or the interface region of the joint zone determined.
  • mechanical forces cause the bond strength in the joining zone.
  • the composite molding according to the invention can be described by two mutually independent strategies that complement each other.
  • Active composites can be achieved directly by combining at least two materials compatible with respect to their material affiliation without intermediate layers in the joining zone or indirectly by mixing (graded systems) materials of different classes and using them as adhesion promoters between the respective foreign materials (intermediate layers).
  • Foreign components can also be used as adhesion promoters and realize an active material composite
  • Passive composite bodies have combinations of materials which interact little or not with regard to a chemical bond and are essentially capable of bonding due to their geometric configuration in the joining zone. This can be done, for example, by concurrent use of the materials to be combined.
  • Pen-shaped, to the structural partners towards becoming wider Studentssphtzungen can form a bracket-like composite. According to the invention, this can be achieved, for example, by filling perforated film areas during injection molding. By laminating or superimposing at least two foils, the perforated regions can be designed to be deep and flat, so that one or more material anchors which become wider in the direction of the spraying arise.
  • the present invention is essentially arbitrary in terms of view, but process control should be considered.
  • binder systems are used which are contained both in the green film or in the green film composite as well as in the injection molding material. As a result, the expulsion of the binder is much easier and better. If different binders are used, it is a particular advantage of the invention if the green film or the green film composite is produced with so-called backbone binders which are at least one constituent of the binder of the injection molding material. These binder systems take longer time to to be expelled. As a result, the more easily expelled binder components present in the injection-molded part can escape first and the green film or the green-film composite still remains elastic.
  • backbone binder portions of the injection molding matehal are expelled, the shares in the green sheet or green film composite escape with and the debindering is complete.
  • backbone binders are, for example, polyolefins, such as polyethylene or polyethylene copolymer.
  • Ceramic feedstock (filling degree: 60Vol .-%):
  • a composite of organic solvents (90 Ma -% hexane, 9% polyethylene copolymer, 1% alkyl succinimide) and 83 Ma. -% steel powder 430L filled slurry produced.
  • the homogenization of the suspension takes place with the aid of grinding balls on the roll mill.
  • An ultrasonic treatment (2x 30s) helps to destroy the powder agglomerates in the slurry.
  • the well-homogenized slurry is poured on a film caster (doctor blade method) and dried.
  • the dried steel foil (thickness 500 .mu.m, width 20 cm, length 1 m) is removed from the casting pad and geometrically assembled so that it can be inserted into the profile of the mold cavity of the injection mold and molded with a ceramic feedstock.
  • the ceramic powder ZrO 2 type Y5-5 (92 wt .-%) with a thermoplastic binder (45% paraffin, 45% LD polyethylene, 10% stearic acid) under temperature (130 ° C) and Scherenergieein Koch on a Shearing roller compactor (mixed for 1 h).
  • the homogenized powder-binder mixture is granulated and fed in this form the Sphtzg imagine mixes.
  • a temperature-change-resistant steel-ceramic composite which has at least a strength of 1 MPa, is obtained.
  • a continuous closed composite zone can be seen under the electron microscope.
  • the interface between film and injection molding forms the surface geometry of the cavity in which the film was inserted.

Abstract

L'invention se rapporte au domaine de la céramique et concerne des corps moulés composites, tels que ceux utilisés par exemple pour des outils d'usinage par enlèvement de copeaux. L'objectif de cette invention est de fournir des corps moulés composites à structure de surface et d'interface libre, pouvant être fabriqués en série. A cet effet, des corps moulés composites en céramique et/ou de la métallurgie des poudres sont composés d'une feuille crue et d'un corps moulé par injection. De plus, selon un procédé de l'invention, une feuille crue est incorporée dans ou appliquée sur un moule; au moins une matière de moulage par injection en céramique et/ou de la métallurgie des poudres est appliquée et/ou placée et/ou incorporée sur et/ou dans le moule par injection puis le moule en une ou plusieurs parties est retiré et/ou les pièces moulées composites en une ou plusieurs parties sont démoulées, les étapes de ce procédé pouvant être répétées une ou plusieurs fois.
EP08701277A 2007-01-15 2008-01-07 Corps moulé composite en céramique et/ou de la métallurgie des poudres et procédé d'utilisation dudit corps Withdrawn EP2121222A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102007003192A DE102007003192B4 (de) 2007-01-15 2007-01-15 Keramischer und/oder pulvermetallurgischer Verbundformkörper und Verfahren zu seiner Herstellung
PCT/EP2008/050101 WO2008087064A2 (fr) 2007-01-15 2008-01-07 Corps moulé composite en céramique et/ou de la métallurgie des poudres et procédé d'utilisation dudit corps

Publications (1)

Publication Number Publication Date
EP2121222A2 true EP2121222A2 (fr) 2009-11-25

Family

ID=39509967

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08701277A Withdrawn EP2121222A2 (fr) 2007-01-15 2008-01-07 Corps moulé composite en céramique et/ou de la métallurgie des poudres et procédé d'utilisation dudit corps

Country Status (5)

Country Link
US (1) US20100047557A1 (fr)
EP (1) EP2121222A2 (fr)
JP (1) JP2010515829A (fr)
DE (1) DE102007003192B4 (fr)
WO (1) WO2008087064A2 (fr)

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DE102006060338A1 (de) * 2006-12-13 2008-06-19 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Haftfester Metall-Keramik-Verbund und Verfahren zu seiner Herstellung
US10226818B2 (en) * 2009-03-20 2019-03-12 Pratt & Whitney Canada Corp. Process for joining powder injection molded parts
DE102011088132A1 (de) * 2011-08-09 2013-02-14 Robert Bosch Gmbh Magnetanker
DE102011087110A1 (de) * 2011-11-25 2013-05-29 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Keramische und/oder pulvermetallurgische Formteile und Verfahren zu ihrer Herstellung
DE102012112775A1 (de) * 2012-12-20 2014-07-10 Bayer Technology Services Gmbh Computerimplementiertes Verfahren zum Herstellen eines Produktionsanlagenmodells
DE102013215735B4 (de) 2013-08-09 2021-04-29 Volkswagen Aktiengesellschaft Verfahren zur Herstellung von mehrschichtigen Grünkörpern für keramische Bauteile
DE102014209519B4 (de) * 2014-05-20 2018-10-18 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Verfahren zur herstellung keramischer und/oder metallischer bauteile
US9970318B2 (en) 2014-06-25 2018-05-15 Pratt & Whitney Canada Corp. Shroud segment and method of manufacturing
DE102015212335A1 (de) 2015-07-01 2017-01-05 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Metall-keramik-werkstoffverbund und verfahren zu dessen herstellung
WO2019226627A1 (fr) * 2018-05-22 2019-11-28 Corning Incorporated Substrat en céramique enduite de glaçure pour lentilles liquides et procédés associés
EP3826791A1 (fr) * 2018-07-24 2021-06-02 Straumann Holding AG Procédé de préparation d'un article par moulage par injection de poudre
RU2705744C1 (ru) * 2018-12-12 2019-11-11 федеральное государственное автономное образовательное учреждение высшего образования "Национальный исследовательский ядерный университет "МИФИ" (НИЯУ МИФИ) Способ электроимпульсного нанесения упрочняющего покрытия из порошка на поверхность стальной детали и устройство для его осуществления
CN113172728B (zh) * 2021-04-21 2022-07-19 连云港东睦新材料有限公司 一种采用粉末注射成形由原形件复制零件的方法

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Also Published As

Publication number Publication date
WO2008087064A2 (fr) 2008-07-24
WO2008087064A3 (fr) 2008-11-27
US20100047557A1 (en) 2010-02-25
DE102007003192A1 (de) 2008-07-17
DE102007003192B4 (de) 2012-04-26
JP2010515829A (ja) 2010-05-13

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