EP3860789A1 - Procede de fabrication d'une piece en alliage d'aluminium - Google Patents
Procede de fabrication d'une piece en alliage d'aluminiumInfo
- Publication number
- EP3860789A1 EP3860789A1 EP19801953.1A EP19801953A EP3860789A1 EP 3860789 A1 EP3860789 A1 EP 3860789A1 EP 19801953 A EP19801953 A EP 19801953A EP 3860789 A1 EP3860789 A1 EP 3860789A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- heat treatment
- possibly
- filler metal
- optionally
- individually
- 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.)
- Pending
Links
Classifications
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0408—Light metal alloys
- C22C1/0416—Aluminium-based alloys
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/22—Direct deposition of molten metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/64—Treatment of workpieces or articles after build-up by thermal means
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- 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
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/40—Radiation means
- B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
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- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/34—Laser welding for purposes other than joining
- B23K26/342—Build-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/18—Hardening; Quenching with or without subsequent tempering
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/003—Alloys based on aluminium containing at least 2.6% of one or more of the elements: tin, lead, antimony, bismuth, cadmium, and titanium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
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- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/248—Thermal after-treatment
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- 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
- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/05—Light metals
- B22F2301/052—Aluminium
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- 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
- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/20—Refractory metals
- B22F2301/205—Titanium, zirconium or hafnium
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- 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
- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/35—Iron
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- 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
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- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/14—Both compacting and sintering simultaneously
- B22F3/15—Hot isostatic pressing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/10—Aluminium or alloys thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the technical field of the invention is a method of manufacturing an aluminum alloy part, using an additive manufacturing technique.
- additive manufacturing techniques have developed. They consist in shaping a part by adding material, which is the opposite of machining techniques, which aim to remove material.
- machining techniques which aim to remove material.
- additive manufacturing is defined according to the French standard XP E67-001 as a "set of processes for manufacturing, layer by layer, by adding material, a physical object from a digital object".
- ASTM F2792 January 2012 also defines additive manufacturing.
- Different additive manufacturing methods are also defined and described in ISO / ASTM 17296-1.
- the use of additive manufacturing to produce an aluminum part, with low porosity, has been described in document W02015006447.
- the application of successive layers is generally carried out by application of a so-called filler material, then fusion or sintering of the filler material using an energy source of the laser beam, electronic beam, plasma torch type. or electric arc.
- the thickness of each added layer is of the order of a few tens or hundreds of microns.
- the Applicant has determined an alloy composition which, used in an additive manufacturing process, makes it possible to obtain parts with remarkable mechanical performance, without it being necessary to carry out heat treatments of the dissolution and quenching type. .
- the parts used have interesting properties of thermal conductivity or electrical conductivity. This allows to diversify the possibilities of applications of these parts.
- a first object of the invention is a method of manufacturing a part comprising the formation of successive metal layers, superimposed on each other, each layer being formed by the deposition of a filler metal, the filler metal being subjected to a supply of energy so as to enter into fusion and to constitute, by solidifying, said layer, the process being characterized in that the filler metal is an aluminum alloy comprising the following alloying elements (% in weight):
- Fe 2% to 8%, and preferably 2% to 6%, more preferably 3 to 5%;
- Zr 0.5% to 2.5% or 0.5 to 2% or 0.7 to 1.5%;
- Mg optionally Mg: ⁇ 0.2%, preferably ⁇ 0.1% preferably ⁇ 0.05%;
- alloying elements possibly other alloying elements ⁇ 0.1% individually and in total ⁇ 0.5%; impurities: ⁇ 0.05%, even ⁇ 0.01% individually, and in total ⁇ 0.15%;
- the amount of Fe is greater than the amount of Zr.
- alloying elements include, for example, Cr, V, Ti, Mn, Mo, W, Nb, Ta, Sc, Ni, Zn, Hf, Nd, Ce, Co, La, Ag, Li, Y, Yb , Er, Sn, In, Sb, Sr, Ba, Bi, Ca, P, B and / or mischmetal.
- the composition of mischmetal is generally around 45 to 50% of cerium, 25% of lanthanum, 15 to 20% of neodymium and 5% of praseodymium. According to a variant of the present invention, there is no voluntary addition of Zn, in particular due to the fact that it evaporates during the SLM process.
- the alloy is not an AA7xxx type alloy.
- the process can include the following characteristics, taken in isolation or in technically feasible combinations:
- the alloy does not contain Cr, V, Mn, Ti, Mo, or according to a mass fraction of less than 500 ppm, 300 ppm, 200 ppm, or even less than 100 ppm;
- the mass fraction of each other alloying element is less than 500 ppm, or even 300 ppm, or even 200 ppm, or even 100 ppm;
- the mass fraction of Zr is strictly less than 0.5%, or even 0.2% or even 0.05%; the mass fraction of Si is strictly less than 0.5%, or even 0.2% or even 0.05%;
- Each layer can in particular describe a pattern defined from a digital model.
- the process may include, following the formation of the layers, an application of at least one heat treatment.
- the heat treatment can be or include tempering or annealing, which can for example be carried out at a temperature preferably between 200 ° C. and 500 ° C.
- the heat treatment can then be carried out:
- the duration of the heat treatment is preferably between 0.1 and 5 hours.
- the heat treatment can also include dissolving and quenching, even if it is preferred to avoid them. It can also include hot isostatic compression. According to an advantageous embodiment, the method does not include quenching following the formation of the layers or the heat treatment. Thus, preferably, the process does not include steps of dissolving followed by quenching.
- the filler metal comes from a filler wire, the exposure of which to a heat source, for example an electric arc, results in a localized melting followed by solidification, so as to form a solid layer.
- the filler metal takes the form of a powder, the exposure of which to a beam of light or of charged particles results in a localized melting followed by solidification, so as to form a solid layer.
- a second object of the invention is a metal part, obtained after application of a method according to the first object of the invention.
- a third object of the invention is a filler material, in particular a filler wire or a powder, intended to be used as a filler material for an additive manufacturing process, characterized in that it is made of an aluminum alloy, comprising the following alloying elements (by weight):
- Fe 2% to 8%, and preferably 2% to 6%, more preferably 3 to 5%;
- Zr 0.5% to 2.5% or 0.5 to 2% or 0.7 to 1.5%;
- Mg optionally Mg: ⁇ 0.2%, preferably ⁇ 0.1% preferably ⁇ 0.05%;
- alloying elements possibly other alloying elements ⁇ 0.1% individually and in total ⁇ 0.5%; impurities: ⁇ 0.05%, even ⁇ 0.01% individually, and in total ⁇ 0.15%;
- the aluminum alloy forming the filler material may have the characteristics described in connection with the first object of the invention.
- the filler material may be in the form of a powder.
- the powder can be such that at least 80% of the particles making up the powder have an average size in the following range: 5 ⁇ m to 100 ⁇ m, preferably from 5 to 25 ⁇ m, or from 20 to 60 ⁇ m.
- the diameter of the wire may in particular be between 0.5 mm and 3 mm, and preferably between 0.5 mm and 2 mm, and more preferably from 1 mm to 2 mm.
- Figure 1 is a diagram illustrating an additive manufacturing method of the SLM type.
- Figure 2 illustrates the tensile and electrical conduction properties determined during experimental tests, from samples produced using an additive manufacturing process according to the invention.
- FIG. 3 Figure 3 is a diagram illustrating an additive manufacturing process of the WAAM type.
- Figure 4 is a diagram of the TOR4 type cylindrical specimen used according to the examples.
- Figure 5 is a diagram of the second test pieces of the example.
- x% - y% means greater than or equal to x% and less than or equal to y%.
- impurity is meant chemical elements present in the alloy unintentionally.
- FIG. 1 shows schematically the operation of an additive manufacturing process of the selective laser melting type (SLM).
- the filler metal 15 is in the form of a powder placed on a support 10.
- An energy source in this case a laser source 11, emits a laser beam 12.
- the laser source is coupled to the material d contribution by an optical system 13, the movement of which is determined according to a digital model M.
- the laser beam 12 propagates along an axis of propagation Z, and follows a movement according to an XY plane, describing a pattern depending on the model digital. The plane is for example perpendicular to the axis of propagation Z.
- the interaction of the laser beam 12 with the powder 15 generates a selective fusion of the latter, followed by solidification, resulting in the formation of a layer 20i. .20 n .
- When a layer has been formed it is covered with powder 15 of the filler metal and another layer is formed, superimposed on the layer previously produced.
- the thickness of the powder forming a layer may for example
- Average particle size of 5 to 100 ⁇ m, preferably 5 to 25 ⁇ m, or 20 to 60 ⁇ m.
- the values given mean that at least 80% of the particles have an average size in the specified range.
- the sphericity of a powder can for example be determined using a morphogranulometer.
- the flowability of a powder can for example be determined according to standard ASTM B213 or standard ISO 4490: 2018. According to ISO 4490: 2018, the flow time is preferably less than 50 s.
- Low porosity preferably from 0 to 5%, more preferably from 0 to 2%, even more preferably from 0 to 1% by volume.
- the porosity can in particular be determined by image analysis from optical micrographs or by helium pycnometry (see standard ASTM B923).
- the Applicant has observed that the application of heat treatments of the quenching type could induce distortion of the part, due to the sudden variation in temperature.
- the distortion of the part is generally all the more significant as its dimensions are important.
- the advantage of an additive manufacturing process is precisely to obtain a part whose shape, after manufacture is final, or almost final. The occurrence of significant deformation resulting from heat treatment is therefore to be avoided.
- a finishing machining can be carried out on the part after its manufacture: the part manufactured by additive manufacturing extends according to its final form, except for the final machining.
- the applicant sought an alloy composition, forming the filler material, making it possible to obtain acceptable mechanical properties, without requiring the application of heat treatments, subsequent to the formation of the layers, risking d 'induce distortion. This is particularly to avoid heat treatments involving a sudden change in temperature.
- the invention makes it possible to obtain, by additive manufacturing, a part whose mechanical properties are satisfactory, in particular in terms of elastic limit.
- the filler material may be in the form of a wire or a powder.
- the Applicant considered that it was useful to reach a compromise between the number and the quantity of the elements added to the alloy, so as to obtain acceptable mechanical and thermal (or electrical) properties.
- the alloy consists essentially of two elements (Al and Fe);
- the alloy consists essentially of three elements (Al, Fe and Zr).
- the presence of Zr generally improves the mechanical properties after heat treatment.
- the alloy can also include other alloying elements, such as Cr, V, Ti, Mn, Mo, W, Nb, Ta, Sc, Ni, Zn, Hf, Nd, Ce, Co, La, Ag, Li, Y, Yb, Er, Sn, In, Sb, Sr, Ba, Bi, Ca, P, B and / or mischmetal individually having a content ⁇ 0.1% by weight.
- alloying elements such as Cr, V, Ti, Mn, Mo, W, Nb, Ta, Sc, Ni, Zn, Hf, Nd, Ce, Co, La, Ag, Li, Y, Yb, Er, Sn, In, Sb, Sr, Ba, Bi, Ca, P, B and / or mischmetal individually having a content ⁇ 0.1% by weight.
- some of these alloying elements, in particular Cr, V, Ti and Mo degrade the conductivity so it is better to avoid them.
- Cu is considered less harmful in terms of thermal conductivity.
- the alloy is not an AA7xxx type alloy.
- the alloy used according to the present invention does not comprise Mg or else according to an amount of impurity, ie ⁇ 0.05%.
- the other alloying elements are for example Y, Yb, Er, Sn, In, Sb
- these elements are preferably present individually according to a mass fraction strictly less than 500 ppm, and preferably strictly less than 300 ppm, or even 200 ppm or even 100 ppm.
- the alloys according to the present invention are not alloys of the AA6xxx type, due to the absence of simultaneous addition of Si and Mg in amounts greater than 0.2%.
- a test was carried out using a binary alloy, the composition of which included Fe 4%; impurities and other alloying elements: ⁇ 0.05% individually.
- Test pieces were produced by SLM, using an EOS290 SLM type machine (supplier EOS).
- the laser power was 370 W.
- the scanning speed was 1400 mm / s.
- the difference between two adjacent scan lines, usually referred to as the "vector gap" was 0.11 mm.
- the layer thickness was 60 ⁇ m, with heating of the build plate to 200 ° C.
- the powder used had a particle size essentially between 3 ⁇ m and 100 ⁇ m, with a median of 40 ⁇ m, a 10% fractile of 16 ⁇ m and a 90% fractile of 79 ⁇ m.
- First test pieces were produced in the form of vertical cylinders with respect to the construction plate (direction Z) with a diameter of 11 mm and a height of 46 mm. Second test pieces were produced, taking the form of parallelepipeds of dimensions
- Certain first parts underwent a post-production heat treatment at 350 ° C, 400 ° C or 450 ° C, the duration of the treatment being from 1 h to 104 h. All of the first pieces
- 0 represents the diameter of the central part of the test piece
- M the width of the two ends of the test piece
- LT the total length of the test piece
- R the radius of curvature between the part center and the ends of the test piece
- the length of the central part of the test piece and F the length of the two ends of the test piece.
- NF EN ISO 6892-1 (2009-10).
- Some second test pieces have undergone post-production heat treatment, as described in connection with the first pieces.
- the second test pieces were subjected to electrical conductivity tests, based on the fact that the electrical conductivity changes in a similar way to the thermal conductivity.
- a linear dependence relation of thermal conductivity and electrical conductivity, according to Wiedemann Franz's law, was validated in the publication Hatch "Aluminum properties and physical metallurgy" ASM Metals Park, OH, 1988.
- the second test pieces have undergone a surface polishing on each side of 45 mm x 46 mm for conductivity measurements using an abrasive paper with roughness 180.
- the electrical conductivity measurements were carried out on the polished faces using a Foerster Sigmatest 2.069 at 60 kHz measurement.
- Table 2 below represents, for each first test piece, the heat treatment temperature (° C.), the heat treatment time, the elastic limit at 0.2% Rp0.2 (MPa), the resistance at tension (Rm), elongation at break A (%), as well as electrical conductivity (MS.m 1 ).
- the tensile properties yield strength, tensile strength and elongation at break
- the electrical properties thermal conductivity
- the elastic limit Rp0.2 reaches 282 MPa, and the elongation at break is equal to 4.5%.
- the application of a heat treatment makes it possible to reduce the elastic limit, but it makes it possible to increase the electrical conductivity as well as the elongation at break. It can be seen that the elongation at break is always greater than 3%.
- the mechanical properties of the manufactured part are considered to be satisfactory.
- it is preferable to apply a heat treatment and for example:
- a heat treatment When a heat treatment is applied in order to improve the thermal or electrical conduction properties, it is preferable that its temperature is less than 500 ° C or preferably less than 450 ° C, and for example between 100 ° C and 450 ° C. It can in particular be an income or an annealing. Its duration can exceed 10 hours, even 100 hours.
- Figure 2 illustrates the tensile properties (ordinate axis, representing the elastic limit Rp0.2) as a function of thermal conductivity properties (abscissa axis, representing thermal conductivity). It is recalled that the thermal conduction properties are assumed to be representative of the electrical conduction properties. In Figure 2, the percentages indicate the elongation at break. The term "No TTH" means no heat treatment.
- Such a binary alloy has a relatively low liquidus temperature (of the order of 660 ° C.), which allows good ability to be atomized using standard industrial atomizers for aluminum alloys.
- the liquidus was determined from the powder.
- the relative density of the samples is greater than 99%, which translates a porosity ⁇ 1% measured by image analysis on a polished section of samples.
- the method can include a hot isostatic compression (CIC).
- CIC treatment can in particular make it possible to improve the elongation properties and the fatigue properties.
- Hot isostatic compression can be performed before, after or in place of the heat treatment.
- the hot isostatic compression is carried out at a temperature of 250 ° C to 500 ° C and preferably from 300 ° C to 450 ° C, at a pressure of 500 to 3000 bars and for a period of 0.5 to 50 hours.
- the possible heat treatment and / or hot isostatic compression makes it possible in particular to increase the electrical or thermal conductivity of the product obtained.
- suitable for alloys with structural hardening it is possible to carry out dissolution followed by quenching and tempering of the formed part and / or hot isostatic compression.
- the hot isostatic compression can in this case advantageously replace the dissolution.
- the method according to the invention is advantageous, since it preferably does not require a solution treatment followed by quenching. Dissolution can have a detrimental effect on the mechanical resistance in certain cases by participating in a magnification of the dispersoids or of the fine intermetallic phases.
- the method according to the present invention also optionally comprises a machining treatment, and / or a chemical, electrochemical or mechanical surface treatment, and / or a tribofinishing. These treatments can be carried out in particular to reduce the roughness and / or improve the resistance to corrosion and / or improve the resistance to the initiation of fatigue cracks.
- FIG. 3 shows such an alternative.
- An energy source 31 in this case a torch, forms an electric arc 32.
- the torch 31 is held by a welding robot 33.
- the part 20 to be manufactured is placed on a support 10.
- the manufactured part is a wall extending along a transverse axis Z perpendicular to a plane XY defined by the support 10.
- a filler wire 35 melts to form a weld bead.
- the welding robot is controlled by a digital model M. It is moved so as to form different layers 20i ... 20 n , stacked on each other, forming the wall 20, each layer corresponding to a weld bead.
- Each layer 20i ... 20 n extends in the XY plane, according to a pattern defined by the digital model M.
- the diameter of the filler wire is preferably less than 3 mm. It can be understood from 0.5 mm to 3 mm and is preferably understood from 0.5 mm to 2 mm, or even from 1 mm to 2 mm. It is for example 1.2 mm.
- SLS Selective Laser Sintering
- SHS Selective Heat Sintering
- EBM Electro Beam Melting
- DED Direct Energy Deposition
- DMD Direct Metal Deposition
- DLD direct laser deposition
- LFMT - laser freeform manufacturing technology
- CSC Cold Spray Consolidation
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Abstract
Description
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FR1871133A FR3086873B1 (fr) | 2018-10-05 | 2018-10-05 | Procede de fabrication d'une piece en alliage d'aluminium |
FR1908678A FR3086954B1 (fr) | 2018-10-05 | 2019-07-30 | Procédé de fabrication d'une pièce en alliage d'aluminium |
PCT/FR2019/052348 WO2020070453A1 (fr) | 2018-10-05 | 2019-10-03 | Procede de fabrication d'une piece en alliage d'aluminium |
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EP19801953.1A Pending EP3860789A1 (fr) | 2018-10-05 | 2019-10-03 | Procede de fabrication d'une piece en alliage d'aluminium |
EP19801952.3A Active EP3860788B1 (fr) | 2018-10-05 | 2019-10-03 | Procede de fabrication d'une piece en alliage d'aluminium et une poudre d'alliage d'aluminium |
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US (2) | US11692240B2 (fr) |
EP (2) | EP3860789A1 (fr) |
CN (2) | CN112805107B (fr) |
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FR3077524B1 (fr) * | 2018-02-08 | 2021-01-15 | C Tec Constellium Tech Center | Procede de fabrication d'une piece en alliage d'aluminium et de chrome |
FR3092777A1 (fr) * | 2019-02-15 | 2020-08-21 | C-Tec Constellium Technology Center | Procédé de fabrication d'une pièce en alliage d'aluminium |
EP4140623A4 (fr) * | 2020-04-21 | 2024-05-15 | Nippon Light Metal Co., Ltd. | Corps moulé en alliage d'aluminium et son procédé de production |
WO2021215306A1 (fr) * | 2020-04-21 | 2021-10-28 | 日本軽金属株式会社 | Corps moulé en aluminium et son procédé de production |
FR3110095B1 (fr) * | 2020-05-13 | 2022-11-11 | C Tec Constellium Tech Center | Procédé de fabrication d'une pièce en alliage d'aluminium |
CN112813310B (zh) * | 2020-06-28 | 2022-09-02 | 中南大学 | 一种可用于激光增材制造的高强度Al-Fe-Sc合金 |
CN113430422B (zh) * | 2021-06-25 | 2022-04-22 | 中南大学 | 一种高强高韧耐热铝铁合金及其3d打印方法 |
CN116334452A (zh) * | 2023-02-24 | 2023-06-27 | 江苏中超航宇精铸科技有限公司 | 增材制造用高强韧耐热合金及其制备方法 |
CN117535565B (zh) * | 2024-01-09 | 2024-04-26 | 苏州慧金新材料科技有限公司 | 一种基于弥散增强高导电压铸铝合金及其制备方法和应用 |
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-
2018
- 2018-10-05 FR FR1871133A patent/FR3086873B1/fr active Active
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2019
- 2019-07-30 FR FR1908678A patent/FR3086954B1/fr active Active
- 2019-10-03 WO PCT/FR2019/052347 patent/WO2020070452A1/fr active Application Filing
- 2019-10-03 US US17/282,285 patent/US11692240B2/en active Active
- 2019-10-03 US US17/282,262 patent/US20210230716A1/en active Pending
- 2019-10-03 EP EP19801953.1A patent/EP3860789A1/fr active Pending
- 2019-10-03 EP EP19801952.3A patent/EP3860788B1/fr active Active
- 2019-10-03 CN CN201980065700.XA patent/CN112805107B/zh active Active
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FR3086873A1 (fr) | 2020-04-10 |
US11692240B2 (en) | 2023-07-04 |
WO2020070452A1 (fr) | 2020-04-09 |
FR3086954A1 (fr) | 2020-04-10 |
CN112805107A (zh) | 2021-05-14 |
CN112805105A (zh) | 2021-05-14 |
FR3086873B1 (fr) | 2022-05-27 |
US20210331244A1 (en) | 2021-10-28 |
EP3860788B1 (fr) | 2024-07-17 |
FR3086954B1 (fr) | 2021-12-10 |
CN112805105B (zh) | 2023-12-01 |
CN112805107B (zh) | 2023-10-27 |
EP3860788A1 (fr) | 2021-08-11 |
US20210230716A1 (en) | 2021-07-29 |
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