EP4402296A1 - Copper alloy composition and method for manufacturing same, method for manufacturing a part from the copper alloy composition - Google Patents
Copper alloy composition and method for manufacturing same, method for manufacturing a part from the copper alloy compositionInfo
- Publication number
- EP4402296A1 EP4402296A1 EP22786893.2A EP22786893A EP4402296A1 EP 4402296 A1 EP4402296 A1 EP 4402296A1 EP 22786893 A EP22786893 A EP 22786893A EP 4402296 A1 EP4402296 A1 EP 4402296A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- copper alloy
- alloy composition
- powder
- manufacturing
- composition
- 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
- 229910000881 Cu alloy Inorganic materials 0.000 title claims abstract description 100
- 239000000203 mixture Substances 0.000 title claims abstract description 82
- 238000004519 manufacturing process Methods 0.000 title claims description 85
- 238000000034 method Methods 0.000 title claims description 31
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 16
- 239000010949 copper Substances 0.000 claims abstract description 16
- 229910052802 copper Inorganic materials 0.000 claims abstract description 15
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 6
- 239000012535 impurity Substances 0.000 claims abstract description 6
- 239000000843 powder Substances 0.000 claims description 87
- 239000002243 precursor Substances 0.000 claims description 36
- 239000000654 additive Substances 0.000 claims description 35
- 230000000996 additive effect Effects 0.000 claims description 35
- 229910045601 alloy Inorganic materials 0.000 claims description 33
- 239000000956 alloy Substances 0.000 claims description 33
- 239000000463 material Substances 0.000 claims description 30
- 238000002844 melting Methods 0.000 claims description 27
- 230000008018 melting Effects 0.000 claims description 27
- 239000002245 particle Substances 0.000 claims description 15
- 239000007787 solid Substances 0.000 claims description 15
- 239000007789 gas Substances 0.000 claims description 13
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 9
- 229910052726 zirconium Inorganic materials 0.000 claims description 9
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 8
- 239000011651 chromium Substances 0.000 claims description 8
- 238000001816 cooling Methods 0.000 claims description 8
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 7
- 229910052804 chromium Inorganic materials 0.000 claims description 7
- 238000000110 selective laser sintering Methods 0.000 claims description 7
- 238000000151 deposition Methods 0.000 claims description 6
- 238000010894 electron beam technology Methods 0.000 claims description 6
- 239000011261 inert gas Substances 0.000 claims description 6
- 238000005245 sintering Methods 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 5
- 238000002156 mixing Methods 0.000 claims description 5
- 230000007935 neutral effect Effects 0.000 claims description 5
- 229910052786 argon Inorganic materials 0.000 claims description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 4
- 239000001301 oxygen Substances 0.000 claims description 4
- 229910052760 oxygen Inorganic materials 0.000 claims description 4
- 230000001681 protective effect Effects 0.000 claims description 4
- 238000000227 grinding Methods 0.000 claims description 3
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 2
- 230000008021 deposition Effects 0.000 claims description 2
- 230000000295 complement effect Effects 0.000 abstract 1
- 229910052593 corundum Inorganic materials 0.000 abstract 1
- 229910001845 yogo sapphire Inorganic materials 0.000 abstract 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 16
- 238000000889 atomisation Methods 0.000 description 11
- 238000007711 solidification Methods 0.000 description 5
- 230000008023 solidification Effects 0.000 description 5
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- 239000000758 substrate Substances 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 230000007613 environmental effect Effects 0.000 description 3
- 238000001465 metallisation Methods 0.000 description 3
- 239000002244 precipitate Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000004927 fusion Effects 0.000 description 2
- 238000009689 gas atomisation Methods 0.000 description 2
- 239000001307 helium Substances 0.000 description 2
- 229910052734 helium Inorganic materials 0.000 description 2
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- VSZWPYCFIRKVQL-UHFFFAOYSA-N selanylidenegallium;selenium Chemical group [Se].[Se]=[Ga].[Se]=[Ga] VSZWPYCFIRKVQL-UHFFFAOYSA-N 0.000 description 2
- 206010001488 Aggression Diseases 0.000 description 1
- 229910000967 As alloy Inorganic materials 0.000 description 1
- 230000016571 aggressive behavior Effects 0.000 description 1
- 238000004873 anchoring Methods 0.000 description 1
- 238000004581 coalescence Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000010891 electric arc Methods 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 230000006911 nucleation Effects 0.000 description 1
- 238000010899 nucleation Methods 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 238000002310 reflectometry Methods 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
- B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
-
- 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
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
-
- 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
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0093—Welding characterised by the properties of the materials to be welded
-
- 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
-
- 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
-
- 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
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
- B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
-
- 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
- C22C1/0425—Copper-based alloys
-
- 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
- C22C1/05—Mixtures of metal powder with non-metallic powder
- C22C1/059—Making alloys comprising less than 5% by weight of dispersed reinforcing phases
-
- 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
- C22C1/10—Alloys containing non-metals
- C22C1/1084—Alloys containing non-metals by mechanical alloying (blending, milling)
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
- C22C32/001—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides
- C22C32/0015—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides with only single oxides as main non-metallic constituents
- C22C32/0021—Matrix based on noble metals, Cu or alloys thereof
-
- 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
-
- 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
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
-
- 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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/006—Vehicles
-
- 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
- B23K2103/12—Copper or alloys thereof
-
- 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
- Copper alloy composition and method of making same, method of making a part from the copper alloy composition
- the present invention relates to the field of copper alloy compositions, in particular for the manufacture of mechanical parts subjected to significant environmental constraints (high temperature, thermal cycles, various environmental aggressions).
- Additive manufacturing is a process that involves layer-by-layer construction or manufacturing by adding material, as opposed to removing material in conventional machining.
- Additive manufacturing processes include, but are not limited to, selective laser melting (SLM), selective laser sintering (SLS), and direct metal deposition ( DMD for “Direct Metal Deposition”).
- Additive manufacturing allows the production of parts with complex shapes with a gain in mass and the possibility of adding new functionalities.
- the properties of copper alloys mean that the energy delivered by the laser beam is largely reflected rather than absorbed.
- the mechanical strength of copper alloy parts manufactured by additive manufacturing is deteriorated by the presence of defects (porosity, lack of fusion) which can eventually lead to premature breakage of the parts.
- One of the aims of the invention is to propose a copper alloy composition which allows the manufacture of parts having satisfactory mechanical properties, including by additive manufacturing.
- the invention proposes a composition of copper alloy of composition by mass Cu C omp (Al 2 O3) aZrbCrc in which, in mass percentage: 1.5% ⁇ a ⁇ 5%, 0.01% ⁇ b ⁇ 5%, 0% ⁇ c ⁇ 5%, the balance being copper and unavoidable impurities.
- the alloy composition is for example in the form of a powder or in the form of a solid, in particular in the form of a wire or a plate.
- the invention also proposes a process for manufacturing a copper alloy composition as defined above, the process comprising the steps of:
- the process for manufacturing a copper alloy composition comprises one or more of the following optional characteristics, taken individually or according to all technically possible combinations:
- the precursor materials are provided in the form of alloy precursor powders, and the combining step comprises mechanical mixing of the alloy precursor powders to obtain the copper alloy composition in the form of a powder;
- the alloy precursor powders each have a particle size between 1 ⁇ m and 100 ⁇ m;
- the precursor materials are supplied in the form of solids, the step of combining the precursor materials comprising grinding of said solids;
- the step of combining the precursor materials comprises a step of melting a mixture of the precursor materials, and a step of atomizing under neutral gas the molten mixture in the form of powder particles to obtain the copper alloy composition in powder form.
- the invention also proposes a process for manufacturing a copper alloy part by additive manufacturing using a copper alloy composition as defined above.
- the process for manufacturing a copper alloy part comprises one or more of the following optional characteristics, taken individually or according to all technically possible combinations:
- the copper alloy composition is in the form of powder and the additive manufacturing is carried out by melting or sintering particles of the copper alloy composition in the form of powder, by means of a high density beam d energy, in particular a high energy density laser beam;
- additive manufacturing comprises the implementation, on the copper alloy composition, of at least one additive manufacturing technique chosen from among the laser projection technique, the selective laser melting technique, the selective sintering technique by laser, electron beam fusion;
- the process for manufacturing a copper alloy part comprises the supply of the copper alloy composition in powder form and the implementation of the following succession of steps (b) to (d):
- the method for manufacturing a copper alloy part further comprises, before step (b), a step (a) of depositing a layer of the copper alloy composition in powder form on a support, and in that step (b) of heating the part of the alloy composition in powder form is carried out by directing the high energy density beam onto a region of the composition layer d the deposited powder copper alloy forming said powder copper alloy composition part;
- steps (b) to (d) are implemented in a heated closed enclosure and/or under a protective atmosphere of an inert gas, in particular argon, the mass percentage of oxygen in said atmosphere being less than 10,000 ppm ;
- the step of supplying the alloy powder comprises the implementation of the process for manufacturing a copper alloy composition as defined above;
- Additive manufacturing comprises the implementation of a deposit of material in solid form from the copper alloy composition in solid form, in particular arc-wire additive manufacturing.
- the invention also proposes a copper alloy part obtained by a manufacturing process as defined above, said copper alloy having the mass composition Cuco m p(Al 2 O 3 )aZrbCrc in which, in mass percentage: 1 .5% ⁇ a ⁇ 5%, 0.01% ⁇ b ⁇ 5%, 0% ⁇ c ⁇ 5%, the balance being copper and unavoidable impurities.
- FIG. 1 is a schematic view of an atomization device for the implementation of a process for manufacturing a copper alloy powder according to one embodiment
- FIG. 2 is a schematic view of an additive manufacturing device for the additive manufacturing of a mechanical part.
- the copper alloy composition according to the invention has a composition by mass Cu C omp (Al 2 O3) aZrbCrc in which, in mass percentage: 1.5% ⁇ a ⁇ 5%, 0.01% ⁇ b ⁇ 5% , 0% ⁇ c ⁇ 5%, the balance (comp) being copper and unavoidable impurities.
- Aluminum oxide or alumina (Al 2 Os) generates precipitates which act as low-energy nucleation sites which promote the multiplication of copper seeds during the solidification of the copper alloy.
- the solidification rates are high and the presence of aluminum oxide with a content by weight greater than 1 .5% makes it possible to obtain a sufficiently large number of germinating precipitates so that the rapid movement of the solidification front does not precede the formation of new grains.
- Al 2 Os aluminum oxide or alumina
- the addition of aluminum oxide also improves the stability of the copper alloy at high temperatures, especially above 600°C.
- Zirconium forms thermally stable dispersoids which have the effect of anchoring the grain boundaries (so-called Zener Pinning effect) and therefore of refining the size of the grains while increasing the mechanical properties of the copper alloy.
- Zirconium does not exhibit good resistance to high temperature, but the inventors have identified that its addition to the copper alloy does however make it possible to improve the anti-recrystallizing power of the aluminum oxide.
- zirconium reduces the minimum amount of aluminum oxide needed to limit grain size. If very little zirconium is added, then the amount of aluminum oxide should be increased.
- Zirconium acts as a heterogeneous element which leads to the formation of a finer aluminum oxide distribution and limits the aluminum oxide coalescence mechanisms.
- zirconium therefore makes it possible to reduce the quantity of aluminum oxide necessary to refine the grain size.
- chromium makes it possible to form hardening precipitates which maximize the mechanical properties of the copper alloy at room temperature, i.e. around 20°C.
- chromium makes it possible to limit the quantity of aluminum oxide necessary to refine the grain size.
- the copper alloy composition is in the form of a powder or a solid, in particular in the form of a wire or a plate.
- this copper alloy powder has a particle size of less than 150 ⁇ m, for example less than 100 ⁇ m, and generally greater than one micron.
- the copper alloy composition is for example made from several precursor materials containing copper, aluminum oxide, zirconium and optionally chromium.
- the process for preparing the copper alloy composition includes, for example:
- the various precursor materials are chosen as a function of the final composition of the desired copper alloy composition, of course taking into account the dilution effect resulting from the mixing of the precursor materials.
- the precursor materials are for example supplied in the form of several powders, hereinafter referred to as alloy precursor powders.
- the precursor materials are provided as solids which are then ground into powders.
- the process for preparing the alloy powder thus comprises:
- alloy precursor powders comprising copper, aluminum oxide, zirconium and optionally chromium
- the contents of the various elements of the precursor powder are chosen according to the final composition of the desired alloy powder.
- the alloy precursor powders are combined by mechanical mixing, so as to obtain a homogeneous alloy powder with a particle size between 1 ⁇ m and 100 ⁇ m.
- the mechanical mixing is for example carried out by grinding and kneading.
- the alloy precursor powders are combined in a crucible then atomized, preferably under an inert gas atmosphere.
- the precursor materials are for example provided in the form of powder or pre-alloyed bars.
- the step of combining the precursor materials includes, for example:
- the molten mixture is sprayed into fine droplets thanks to a jet of gas under high pressure.
- the droplets then solidify as particles of copper alloy powder.
- the gas jet is for example a neutral gas jet, for example nitrogen, helium, argon or a mixture of several of these gases.
- This gaseous atomization device 1 comprises a melting chamber or autoclave 3, into which are introduced the alloy elements which are melted therein to produce a molten mixture, under a blanket of air or neutral gas, or else under vacuum. .
- the gas atomization device 1 further comprises an atomization chamber 5, an atomization nozzle 7 and a gas source 9.
- the atomization nozzle 7 is suitable for spraying the molten mixture from the melting chamber 3 in the form of fine droplets in the atomization enclosure 5 thanks to a high-pressure gas jet supplied by the gaseous source 9.
- the atomization chamber 5 comprises, in its lower part, a collection chamber 11 in which the particles of copper alloy powder resulting from the solidification of the droplets are collected.
- the gaseous source 9 is preferably fitted with a pump (not shown) capable of collecting the gas injected into the enclosure in order to reinject it via the atomization nozzle 7.
- the atomization enclosure 5 further comprises an annex collection chamber 13 intended for the collection of the powder particles entrained by the pump during the collection of the gas.
- the copper alloy powder according to the invention is used for the manufacture of parts by additive manufacturing, by melting or sintering particles of the copper alloy powder by means of a high energy beam.
- the high energy beam is for example a high energy density laser beam, for example developing a specific power of the order of 10 5 W/cm 2 .
- the additive manufacturing process uses, for example, a selective laser melting or sintering technique on a powder bed, or a laser projection technique.
- the implementation of the manufacturing process according to these techniques includes in all cases a step of supplying the copper alloy powder, and the implementation of the following successive steps (b) to (d):
- step (d) The cooling, during step (d), of the region of the alloy powder occurs for example as a consequence of the withdrawal during step (c) of the high energy density beam.
- step (d) the region of heated copper alloy powder solidifies to thereby form a layer of the part.
- Steps (b) to (d) can again be implemented iteratively to form successive layers of the part.
- Selective laser melting is an additive manufacturing technique for producing parts from copper alloy powder by selectively, i.e. locally, melting a region of a layer of copper powder. alloy deposited on a support.
- the technique of selective laser sintering differs from the technique of selective laser melting essentially in that the region of the layer of copper alloy powder is not brought to a temperature above the melting point, but sintered.
- the implementation of the manufacturing process by sintering or selective laser melting further comprises, before step (b) or before each step (b), a step (a) of depositing a layer of the powder of alloy on a support.
- the support is for example a manufacturing platform, or a layer of the part, of powder previously deposited or projected.
- the layer of copper alloy powder is thus for example deposited on the manufacturing platform, or on a layer of the part previously manufactured by implementing steps (a) to ( d).
- step (b) the laser beam is directed onto a region of the deposited copper alloy powder layer.
- the region of powder mentioned with reference to steps (b) and (d) then corresponds to the region of the layer of powder onto which the laser beam is directed.
- step (b) the region of the layer of copper alloy powder is brought to a temperature higher than the melting temperature of this alloy powder, to form a molten region.
- step (b) the region of the copper alloy powder layer is not brought to a temperature higher than the melting temperature, but sintered.
- the shape of the region on which the laser beam is directed which is not necessarily convex, corresponds to a layer of the manufactured part.
- the layer of powder deposited during step (a) thus comprises a melted or sintered region, and one or more regions of unmelted and unsintered powder.
- step (d) the molten or sintered region solidifies to thereby form a layer of the part.
- Steps (a) to (d) can again be implemented iteratively to form successive or adjacent layers of the part.
- each new layer of copper alloy powder can be deposited on the layer of powder deposited during the previous iteration, or away from this previous layer.
- the excess copper alloy powder corresponding to the unmelted portions of the layer of copper alloy powder, can then be recovered, either at the end of the manufacturing process, or at the end of each succession of steps (a) to (d), or even at the end of some of the successions of steps (a) to (d).
- an additive manufacturing device 15 comprising an enclosure 17 inside which are located a support 19 to receive successive layers of alloy powder for the manufacture of a part and a laser 21 for generating a laser beam 23 that can be steered so as to direct the laser beam 23 onto a region to be solidified of the last layer of powder 25 deposited to form a part 27 resulting from the superposition of the solidified regions of the superimposed layers.
- the laser projection technique or DMD for "Direct Metal Deposition” in English, consists of emitting a high energy density laser beam on a substrate while projecting alloy powder by means of a coaxial projection nozzle to the laser beam.
- the alloy powder is heated by the laser beam during its transport to the substrate and is deposited, in the form of molten alloy powder, on this substrate.
- the geometry of the part is obtained by moving on the one hand the substrate in a plane, and on the other hand the laser beam orthogonal to this plane.
- the part is then manufactured layer by layer from the design data of this part.
- step (b) the part of alloy powder is both heated and projected onto the support.
- Electron Beam Melting differs from Selective Laser Melting in that it uses a high-energy electron beam as a heat source to melt and merge the powder.
- step (b) the part of alloy powder is heated by an electron beam.
- additive manufacturing implements a manufacturing technique known as material deposition in solid form.
- the additive manufacturing is carried out using the copper alloy composition in "solid" form, as opposed to the composition of copper in the form of a powder which can flow.
- Additive manufacturing in this case is carried out, for example, from a wire made in the copper alloy composition, using an electric arc to melt the wire and deposit it in the desired place before it does not solidify again.
- the layering of threads makes it possible to create a three-dimensional structure or shape.
- the additive manufacturing is carried out by wire arc additive manufacturing (or WAAM for “Wire Arc Additive Manufacturing”).
- the manufacturing process according to the invention is preferably implemented in a closed enclosure, i.e. isolated from the external environment.
- the manufacturing process is preferably implemented in a closed enclosure under a protective atmosphere of an inert gas, the mass percentage of oxygen in the atmosphere being less than 10,000 ppm.
- This protective atmosphere makes it possible to avoid contamination of the part, in particular by oxygen which can lead to oxidation, during manufacture.
- the inert gas is for example argon, nitrogen, helium or another neutral gas, or a mixture of several of these gases.
- the enclosure and/or the manufacturing support can be heated in order to limit the residual stresses in the part and the deformations of the part during cooling.
- the part produced by such a manufacturing process has a composition corresponding to that of the alloy powder used.
- the copper alloy composition allows the manufacture, by an additive manufacturing process, of a part with satisfactory mechanical characteristics.
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Abstract
The copper alloy composition is a Cucomp(Al2O3)aZrbCrc mass composition in which, in mass percent: 1.5% ≤ a ≤ 5%, 0.01% ≤ b ≤ 5%, 0% ≤ c ≤ 5%, the complement consisting of copper and unavoidable impurities.
Description
Composition d’alliage de cuivre et son procédé de fabrication, procédé de fabrication d’une pièce à partir de la composition d’alliage de cuivre Copper alloy composition and method of making same, method of making a part from the copper alloy composition
La présente invention concerne le domaine des compositions d’alliage de cuivre, en particulier pour la fabrication de pièces mécaniques soumises à des contraintes environnementales importantes (haute température, cycles thermiques, agressions environnementales diverses). The present invention relates to the field of copper alloy compositions, in particular for the manufacture of mechanical parts subjected to significant environmental constraints (high temperature, thermal cycles, various environmental aggressions).
De telles contraintes environnementales sont rencontrées par exemple dans le domaine aéronautique, mais aussi dans le domaine spatial, dans le domaine automobile ou dans tout autre domaine. Such environmental constraints are encountered for example in the aeronautical field, but also in the space field, in the automobile field or in any other field.
La fabrication additive est un procédé qui implique une construction couche par couche ou une fabrication par apports de matière, par opposition à l'enlèvement de matière en usinage classique. Les procédés de fabrication additive comprennent, d'une manière non limitative, la fusion sélective par laser (SLM pour « Selective Laser Melting »), le frittage sélectif par laser (SLS pour « Selective Laser Sintering ») et le dépôt direct de métal (DMD pour « Direct Metal Deposition »). Additive manufacturing is a process that involves layer-by-layer construction or manufacturing by adding material, as opposed to removing material in conventional machining. Additive manufacturing processes include, but are not limited to, selective laser melting (SLM), selective laser sintering (SLS), and direct metal deposition ( DMD for “Direct Metal Deposition”).
La fabrication additive permet la réalisation de pièces de formes complexes avec un gain de masse et une possibilité d’ajout de nouvelles fonctionnalités. Additive manufacturing allows the production of parts with complex shapes with a gain in mass and the possibility of adding new functionalities.
Actuellement, la mise en œuvre d’alliages de cuivre dans des procédés de fabrication additive par faisceau laser est ralentie par la grande réflectivité du cuivre qui nécessite l’utilisation de faisceaux laser de grande puissance pour la mise en œuvre de la fabrication additive par faisceau laser. Currently, the implementation of copper alloys in additive manufacturing processes by laser beam is slowed down by the high reflectivity of copper which requires the use of high power laser beams for the implementation of additive manufacturing by beam. laser.
Les propriétés des alliages de cuivre font que l’énergie apportée par le faisceau laser est en grande partie réfléchie plutôt qu’absorbée. La tenue mécanique des pièces en alliage de cuivre fabriquées par fabrication additive est détériorée par la présence de défauts (porosités, manque de fusion) pouvant à terme mener à la rupture prématurée des pièces. The properties of copper alloys mean that the energy delivered by the laser beam is largely reflected rather than absorbed. The mechanical strength of copper alloy parts manufactured by additive manufacturing is deteriorated by the presence of defects (porosity, lack of fusion) which can eventually lead to premature breakage of the parts.
Il est possible d’obtenir des alliages de cuivre durcis structuralement afin d’obtenir des pièces mécaniques présentant des propriétés mécaniques satisfaisantes, par exemple en renforçant le cuivre par une fine dispersion d’oxyde d’aluminium ou alumine (AI2O3) connue pour sa stabilité à haute température. Les particules d’oxyde d’aluminium bloquent les dislocations, empêchent la croissance des grains tout en préservant une grande résistance de l’alliage de cuivre aux températures élevées. It is possible to obtain structurally hardened copper alloys in order to obtain mechanical parts with satisfactory mechanical properties, for example by reinforcing the copper with a fine dispersion of aluminum oxide or alumina (Al2O3) known for its stability. at high temperature. The aluminum oxide particles block dislocations, prevent grain growth while preserving high resistance of the copper alloy at high temperatures.
Toutefois, ces alliages de cuivre ne sont pas adaptés aux conditions de solidification des procédés de fabrication additive. Les propriétés mécaniques des pièces obtenues sont
inférieures à celles obtenue avec le même alliage de cuivre mais par des procédés de fabrication conventionnels. However, these copper alloys are not suited to the solidification conditions of additive manufacturing processes. The mechanical properties of the parts obtained are lower than those obtained with the same copper alloy but by conventional manufacturing processes.
Un des buts de l’invention est de proposer une composition d’alliage de cuivre qui permettent la fabrication de pièces présentant des propriétés mécaniques satisfaisantes, y compris par fabrication additive. One of the aims of the invention is to propose a copper alloy composition which allows the manufacture of parts having satisfactory mechanical properties, including by additive manufacturing.
A cet effet, l’invention propose une composition d’alliage de cuivre de composition massique CuComp(AI2O3)aZrbCrc dans laquelle, en pourcentage massique : 1 ,5% < a < 5%, 0,01% < b < 5%, 0% < c < 5%, le complément étant constitué de cuivre et d’impuretés inévitables. To this end, the invention proposes a composition of copper alloy of composition by mass Cu C omp (Al 2 O3) aZrbCrc in which, in mass percentage: 1.5% <a <5%, 0.01% <b < 5%, 0% < c < 5%, the balance being copper and unavoidable impurities.
La composition d’alliage se présente par exemple sous la forme d’une poudre ou sous la forme d’un solide, en particulier sous la forme d’un fil ou d’une plaque. The alloy composition is for example in the form of a powder or in the form of a solid, in particular in the form of a wire or a plate.
L’invention propose aussi un procédé de fabrication d’une composition d’alliage de cuivre telle que définie ci-dessus, le procédé comprenant les étapes de : The invention also proposes a process for manufacturing a copper alloy composition as defined above, the process comprising the steps of:
- fourniture d’un ou plusieurs matériaux précurseurs comprenant du cuivre, de l’alumine, du zirconium et optionnellement du chrome ; - supply of one or more precursor materials including copper, alumina, zirconium and optionally chromium;
- combinaison des matériaux précurseurs pour former la composition d’alliage.- combination of precursor materials to form the alloy composition.
Selon des modes de mise en œuvre particuliers, le procédé de fabrication d’une composition d’alliage de cuivre comprend une ou plusieurs des caractéristiques optionnelles suivantes, prises individuellement ou selon toutes les combinaisons techniquement possibles : According to particular embodiments, the process for manufacturing a copper alloy composition comprises one or more of the following optional characteristics, taken individually or according to all technically possible combinations:
- les matériaux précurseurs sont fournis sous forme de poudres de précurseur d’alliage, et l’étape de combinaison comprend un mélange mécanique des poudres de précurseur d’alliage pour obtenir la composition d’alliage de cuivre sous la forme d’une poudre ; - the precursor materials are provided in the form of alloy precursor powders, and the combining step comprises mechanical mixing of the alloy precursor powders to obtain the copper alloy composition in the form of a powder;
- les poudres de précurseurs d’alliage présentent chacune une granulométrie comprise entre 1 pm et 100 pm ; - the alloy precursor powders each have a particle size between 1 μm and 100 μm;
- les matériaux précurseurs sont fournis sous la forme de solides, l’étape de combinaison des matériaux précurseurs comprenant un broyage des dits solides ; - the precursor materials are supplied in the form of solids, the step of combining the precursor materials comprising grinding of said solids;
- l’étape de combinaison des matériaux précurseurs comprend une étape de fusion d’un mélange des matériaux précurseurs, et une étape d’atomisation sous gaz neutre du mélange fondu sous forme de particules de poudre pour obtenir la composition d’alliage de cuivre sous forme de poudre. - the step of combining the precursor materials comprises a step of melting a mixture of the precursor materials, and a step of atomizing under neutral gas the molten mixture in the form of powder particles to obtain the copper alloy composition in powder form.
L’invention propose aussi un procédé de fabrication d’une pièce en alliage de cuivre par fabrication additive au moyen d’une composition d’alliage de cuivre telle que définie ci- dessus.
Selon des modes de mise en œuvre particuliers, le procédé de fabrication d’une pièce en alliage de cuivre comprend une ou plusieurs des caractéristiques optionnelles suivantes, prises individuellement ou selon toutes les combinaisons techniquement possibles : The invention also proposes a process for manufacturing a copper alloy part by additive manufacturing using a copper alloy composition as defined above. According to particular embodiments, the process for manufacturing a copper alloy part comprises one or more of the following optional characteristics, taken individually or according to all technically possible combinations:
- la composition d’alliage de cuivre se présente sous la forme de poudre et la fabrication additive est réalisée par fusion ou frittage de particules de la composition d’alliage de cuivre sous forme de poudre, au moyen d'un faisceau à haute densité d’énergie, notamment un faisceau laser à haute densité d’énergie ; - the copper alloy composition is in the form of powder and the additive manufacturing is carried out by melting or sintering particles of the copper alloy composition in the form of powder, by means of a high density beam d energy, in particular a high energy density laser beam;
- la fabrication additive comprend la mise en œuvre, sur la composition d’alliage de cuivre, d’au moins une technique de fabrication additive choisie parmi la technique de projection laser, la technique de fusion sélective par laser, la technique de frittage sélectif par laser, la fusion par faisceau d’électrons ; - additive manufacturing comprises the implementation, on the copper alloy composition, of at least one additive manufacturing technique chosen from among the laser projection technique, the selective laser melting technique, the selective sintering technique by laser, electron beam fusion;
- le procédé de fabrication d’une pièce en alliage de cuivre comprend la fourniture de la composition d’alliage de cuivre sous forme de poudre et la mise en œuvre de la succession des étapes (b) à (d) suivantes : - the process for manufacturing a copper alloy part comprises the supply of the copper alloy composition in powder form and the implementation of the following succession of steps (b) to (d):
(b) chauffage, au moyen du faisceau à haute densité d’énergie, d’une partie de la composition d’alliage de cuivre sous forme de poudre, (b) heating, by means of the high energy density beam, a part of the copper alloy composition in powder form,
(c) retrait du faisceau à haute densité d’énergie de la partie de composition d’alliage de cuivre, (c) removing the high energy density beam from the copper alloy composition part,
(d) refroidissement de la partie de la composition d’alliage de cuivre ; (d) cooling the part of the copper alloy composition;
- le procédé de fabrication d’une pièce en alliage de cuivre comprend en outre, avant l’étape (b), une étape (a) de dépôt d’une couche de la composition d’alliage de cuivre sous forme de poudre sur un support, et en ce que l’étape (b) de chauffage de la partie de la composition d’alliage sous forme de poudre est mise en œuvre en dirigeant le faisceau à haute densité d’énergie sur une région de la couche de composition d’alliage de cuivre sous forme de poudre déposée formant ladite partie de composition d’alliage de cuivre sous forme de poudre ; - the method for manufacturing a copper alloy part further comprises, before step (b), a step (a) of depositing a layer of the copper alloy composition in powder form on a support, and in that step (b) of heating the part of the alloy composition in powder form is carried out by directing the high energy density beam onto a region of the composition layer d the deposited powder copper alloy forming said powder copper alloy composition part;
- le refroidissement de la partie de la composition d’alliage de cuivre survient en conséquence de l’étape (c) de retrait du faisceau à haute densité d’énergie ; - the cooling of the part of the copper alloy composition occurs as a consequence of step (c) of withdrawing the high energy density beam;
- les étapes (b) à (d) sont mises en œuvre dans une enceinte fermée chauffée et/ou sous atmosphère protectrice d’un gaz inerte, notamment d’argon, le pourcentage massique d’oxygène dans ladite atmosphère étant inférieur à 10.000 ppm ; - steps (b) to (d) are implemented in a heated closed enclosure and/or under a protective atmosphere of an inert gas, in particular argon, the mass percentage of oxygen in said atmosphere being less than 10,000 ppm ;
- l’étape de fourniture de la poudre d’alliage comprend la mise en œuvre du procédé de fabrication d’une composition d’alliage de cuivre tel que défini ci-dessus ;
- la fabrication additive comprend la mise en œuvre d’un dépôt de matière sous forme solide à partir de la composition d’alliage de cuivre sous forme solide, en particulier une fabrication additive arc-fil. - the step of supplying the alloy powder comprises the implementation of the process for manufacturing a copper alloy composition as defined above; - Additive manufacturing comprises the implementation of a deposit of material in solid form from the copper alloy composition in solid form, in particular arc-wire additive manufacturing.
L’invention propose encore une pièce en alliage de cuivre obtenue par un procédé de fabrication tel que défini ci-dessus, ledit alliage de cuivre ayant la composition massique Cucomp(AI2O3)aZrbCrc dans laquelle, en pourcentage massique : 1 ,5% < a < 5%, 0,01% < b < 5%, 0% < c < 5%, le complément étant constitué de cuivre et d’impuretés inévitables. The invention also proposes a copper alloy part obtained by a manufacturing process as defined above, said copper alloy having the mass composition Cuco m p(Al 2 O 3 )aZrbCrc in which, in mass percentage: 1 .5% < a < 5%, 0.01% < b < 5%, 0% < c < 5%, the balance being copper and unavoidable impurities.
L’invention et ses avantages seront mieux compris au regard d’exemples de réalisation de l’invention qui vont maintenant être décrits en faisant référence aux dessins annexés, sur lesquels : The invention and its advantages will be better understood with regard to exemplary embodiments of the invention which will now be described with reference to the appended drawings, in which:
- la Figure 1 est une vue schématique d’un dispositif d’atomisation pour la mise en œuvre d’un procédé de fabrication d’une poudre d’alliage de cuivre selon un mode de réalisation ; et - Figure 1 is a schematic view of an atomization device for the implementation of a process for manufacturing a copper alloy powder according to one embodiment; And
- la Figure 2 est une vue schématique d’un dispositif de fabrication additive pour la fabrication additive d’une pièce mécanique. - Figure 2 is a schematic view of an additive manufacturing device for the additive manufacturing of a mechanical part.
La composition d’alliage de cuivre selon l’invention présente une composition massique CuComp(AI2O3)aZrbCrc dans laquelle, en pourcentage massique : 1 ,5% < a < 5%, 0,01% < b < 5%, 0% < c < 5%, le complément (comp) étant constitué de cuivre et d’impuretés inévitables. The copper alloy composition according to the invention has a composition by mass Cu C omp (Al 2 O3) aZrbCrc in which, in mass percentage: 1.5% <a <5%, 0.01% <b <5% , 0% < c < 5%, the balance (comp) being copper and unavoidable impurities.
L’oxyde d’aluminium ou alumine (AI2Os) génère des précipités qui agissent comme des sites de nucléation à basse énergie qui favorisent la démultiplication de germes de cuivre lors de la solidification de l’alliage de cuivre. Aluminum oxide or alumina (Al 2 Os) generates precipitates which act as low-energy nucleation sites which promote the multiplication of copper seeds during the solidification of the copper alloy.
Dans un procédé de fabrication additive, en particulier par fusion laser sélective (connue sous le sigle SLM pour « Selective Laser Melting »), les vitesses de solidification sont élevées et la présence d’oxyde d’aluminium avec une teneur en poids supérieure à 1 ,5% permet d’obtenir un nombre de précipités germinant suffisamment important afin que le déplacement rapide du front de solidification ne précède pas la formation de nouveaux grains. In an additive manufacturing process, in particular by selective laser melting (known by the acronym SLM for "Selective Laser Melting"), the solidification rates are high and the presence of aluminum oxide with a content by weight greater than 1 .5% makes it possible to obtain a sufficiently large number of germinating precipitates so that the rapid movement of the solidification front does not precede the formation of new grains.
L’ajout d’oxyde d’aluminium ou alumine (AI2Os) permet ainsi de limiter la taille des grains dans la structure cristallographique de l’alliage de cuivre, ce qui permet d’obtenir des propriétés mécaniques souhaitées pour l’alliage de cuivre, et en particulier d’obtenir une dureté suffisante de l’alliage de cuivre. The addition of aluminum oxide or alumina (Al 2 Os) thus makes it possible to limit the size of the grains in the crystallographic structure of the copper alloy, which makes it possible to obtain the desired mechanical properties for the alloy of copper, and in particular to obtain sufficient hardness of the copper alloy.
L’ajout d’oxyde d’aluminium améliore également la stabilité de l’alliage de cuivre à haute température, en particulier au-dessus de 600°C.
Le zirconium (Zr) forme des dispersoïdes stables thermiquement qui ont pour effet d’ancrer les joints de grains (effet dit Zener Pinning) et donc d’affiner la taille des grains tout en augmentant les propriétés mécaniques de l’alliage de cuivre. Le zirconium ne présente pas une bonne tenue à haute température, mais les inventeurs ont identifié que son ajout dans l’alliage de cuivre permet cependant d’améliorer le pouvoir anti-recristallisant de l’oxyde d’aluminium. The addition of aluminum oxide also improves the stability of the copper alloy at high temperatures, especially above 600°C. Zirconium (Zr) forms thermally stable dispersoids which have the effect of anchoring the grain boundaries (so-called Zener Pinning effect) and therefore of refining the size of the grains while increasing the mechanical properties of the copper alloy. Zirconium does not exhibit good resistance to high temperature, but the inventors have identified that its addition to the copper alloy does however make it possible to improve the anti-recrystallizing power of the aluminum oxide.
L’ajout de zirconium (Zr) permet de réduire la quantité minimale d’oxyde d’aluminium nécessaire pour limiter la taille des grains. Si très peu de zirconium est ajouté, alors la quantité d’oxyde d’aluminium doit être augmentée. Adding zirconium (Zr) reduces the minimum amount of aluminum oxide needed to limit grain size. If very little zirconium is added, then the amount of aluminum oxide should be increased.
Le zirconium agit comme un élément hétérogène qui conduit à la formation d’une distribution d’oxyde d’aluminium plus fine et limite les mécanismes de coalescence de l’oxyde d’aluminium. Zirconium acts as a heterogeneous element which leads to the formation of a finer aluminum oxide distribution and limits the aluminum oxide coalescence mechanisms.
La présence du zirconium permet donc de réduire la quantité d’oxyde d’aluminium nécessaire pour affiner la taille de grains. The presence of zirconium therefore makes it possible to reduce the quantity of aluminum oxide necessary to refine the grain size.
L’ajout éventuel de chrome (Cr) permet de former des précipités durcissant qui maximisent les propriétés mécaniques de l’alliage de cuivre à température ambiante, i.e. autour de 20°C. The possible addition of chromium (Cr) makes it possible to form hardening precipitates which maximize the mechanical properties of the copper alloy at room temperature, i.e. around 20°C.
L’ajout éventuel de chrome permet aussi de limiter la quantité d’oxyde d’aluminium nécessaire pour affiner la taille de grains. The possible addition of chromium also makes it possible to limit the quantity of aluminum oxide necessary to refine the grain size.
Au-dessus d’une teneur en poids de 5% d’oxyde d’aluminium, d’une teneur en poids de 5% de zirconium et/ou d’une teneur en poids de 5% de chrome, la conductivité thermique de l’alliage de cuivre est trop fortement réduite, ce qui n’est pas souhaitable. Above a 5% weight content of aluminum oxide, a 5% weight content of zirconium and/or a 5% weight content of chromium, the thermal conductivity of the copper alloy is too greatly reduced, which is undesirable.
De préférence, la composition d’alliage de cuivre se présente sous la forme d’une poudre ou d’un solide, en particulier sous la forme d’un fil ou d’une plaque. Preferably, the copper alloy composition is in the form of a powder or a solid, in particular in the form of a wire or a plate.
De préférence, lorsque la composition d’alliage de cuivre se présente sous la forme d’une poudre, cette poudre d’alliage de cuivre a une granulométrie inférieure à 150 pm, par exemple inférieure à 100 pm, et généralement supérieure au micron. Preferably, when the copper alloy composition is in the form of a powder, this copper alloy powder has a particle size of less than 150 μm, for example less than 100 μm, and generally greater than one micron.
La composition d’alliage de cuivre est par exemple fabriquée à partir de plusieurs matériaux précurseurs contenant du cuivre, de l’oxyde d’aluminium, du zirconium et optionnellement du chrome. The copper alloy composition is for example made from several precursor materials containing copper, aluminum oxide, zirconium and optionally chromium.
Le procédé de préparation de la composition d’alliage de cuivre comprend par exemple : The process for preparing the copper alloy composition includes, for example:
- une étape de fourniture des matériaux précurseurs, et - a step of supplying precursor materials, and
- une étape de combinaison des matériaux précurseurs pour former la composition d’alliage de cuivre.
Les teneurs des différents matériaux précurseurs sont choisies en fonction de la composition finale de la composition d’alliage de cuivre souhaitée, en tenant bien entendu compte de l’effet de dilution résultant du mélange des matériaux précurseurs. - a step of combining the precursor materials to form the copper alloy composition. The contents of the various precursor materials are chosen as a function of the final composition of the desired copper alloy composition, of course taking into account the dilution effect resulting from the mixing of the precursor materials.
Les matériaux précurseurs sont par exemple fournis sous la forme de plusieurs poudres, appelées ci-après poudres de précurseurs d’alliage. The precursor materials are for example supplied in the form of several powders, hereinafter referred to as alloy precursor powders.
En variante, les matériaux précurseurs sous fournis sous la forme de solides qui sont ensuite broyés sous forme de poudres. Alternatively, the precursor materials are provided as solids which are then ground into powders.
Le procédé de préparation de la poudre d’alliage comprend ainsi : The process for preparing the alloy powder thus comprises:
- une étape de fourniture de poudres de précurseur d’alliage, comprenant du cuivre, de l’oxyde d’aluminium, du zirconium et optionnellement du chrome, et - a step of supplying alloy precursor powders, comprising copper, aluminum oxide, zirconium and optionally chromium, and
- une étape de combinaison des poudres de précurseur d’alliage. - a step of combining the alloy precursor powders.
Les teneurs des différents éléments de la poudre de précurseur sont choisies en fonction de la composition finale de la poudre d’alliage souhaitée. The contents of the various elements of the precursor powder are chosen according to the final composition of the desired alloy powder.
Selon un premier mode de réalisation, les poudres de précurseur d’alliage sont combinées par mélange mécanique, de manière à obtenir une poudre d'alliage homogène de granulométrie comprise entre 1 pm et 100 pm. Le mélange mécanique est par exemple réalisé par broyage et malaxage. According to a first embodiment, the alloy precursor powders are combined by mechanical mixing, so as to obtain a homogeneous alloy powder with a particle size between 1 μm and 100 μm. The mechanical mixing is for example carried out by grinding and kneading.
Selon un deuxième mode de réalisation, les poudres de précurseurs d’alliage sont combinées dans un creuset puis atomisées, de préférence sous atmosphère de gaz neutre. According to a second embodiment, the alloy precursor powders are combined in a crucible then atomized, preferably under an inert gas atmosphere.
Dans ce mode de réalisation, les matériaux précurseurs sont par exemple fournis sous forme de poudre ou de barreaux pré-alliés. In this embodiment, the precursor materials are for example provided in the form of powder or pre-alloyed bars.
Dans ce mode de réalisation, l’étape de combinaison des matériaux précurseurs comprend par exemple : In this embodiment, the step of combining the precursor materials includes, for example:
- une étape de fusion des matériaux précurseurs jusqu’à atteindre un bain homogène en composition chimique ; - a step of melting the precursor materials until a bath with a homogeneous chemical composition is reached;
- une étape d’atomisation sous gaz neutre du mélange fondu sous forme de particules de poudre de granulométrie inférieure à 150 pm. - an atomization step under inert gas of the molten mixture in the form of powder particles with a particle size of less than 150 μm.
Lors de cette atomisation, le mélange fondu est pulvérisé en fines gouttelettes grâce à un jet de gaz sous haute pression. Les gouttelettes se solidifient alors sous forme de particules de poudre d’alliage de cuivre. During this atomization, the molten mixture is sprayed into fine droplets thanks to a jet of gas under high pressure. The droplets then solidify as particles of copper alloy powder.
Le jet de gaz est par exemple un jet de gaz neutre, par exemple de l’azote, de l’hélium, de l’argon ou un mélange de plusieurs de ces gaz. The gas jet is for example a neutral gas jet, for example nitrogen, helium, argon or a mixture of several of these gases.
On a illustré à titre d’exemple sur la Figure 1 un dispositif d’atomisation gazeuse 1.There is illustrated by way of example in Figure 1 a gas atomization device 1.
Ce dispositif d’atomisation gazeuse 1 comprend une chambre de fusion ou autoclave 3, dans laquelle sont introduits les éléments d’alliages qui y sont fondues pour produire un mélange fondu, sous une couverture d’air ou de gaz neutre, ou bien sous vide.
Le dispositif d’atomisation gazeuse 1 comporte en outre une enceinte 5 d’atomisation, une buse 7 d’atomisation et une source gazeuse 9. This gaseous atomization device 1 comprises a melting chamber or autoclave 3, into which are introduced the alloy elements which are melted therein to produce a molten mixture, under a blanket of air or neutral gas, or else under vacuum. . The gas atomization device 1 further comprises an atomization chamber 5, an atomization nozzle 7 and a gas source 9.
La buse 7 d’atomisation est propre à pulvériser le mélange fondu issu de la chambre de fusion 3 sous formes de fines gouttelettes dans l’enceinte 5 d’atomisation grâce à un jet de gaz sous haute pression fourni par la source gazeuse 9. The atomization nozzle 7 is suitable for spraying the molten mixture from the melting chamber 3 in the form of fine droplets in the atomization enclosure 5 thanks to a high-pressure gas jet supplied by the gaseous source 9.
L’enceinte 5 d’atomisation comprend, dans sa partie inférieure, une chambre de collecte 1 1 dans laquelle sont collectées les particules de poudre d’alliage de cuivre résultant de la solidification des gouttelettes. The atomization chamber 5 comprises, in its lower part, a collection chamber 11 in which the particles of copper alloy powder resulting from the solidification of the droplets are collected.
La source gazeuse 9 est munie de préférence d’une pompe (non représentée) propre à collecter le gaz injecté dans l’enceinte pour le réinjecter via la buse 7 d’atomisation. The gaseous source 9 is preferably fitted with a pump (not shown) capable of collecting the gas injected into the enclosure in order to reinject it via the atomization nozzle 7.
L’enceinte 5 d’atomisation comprend en outre une chambre de collecte annexe 13 destinée à la collecte des particules de poudre entrainées par la pompe lors de la collecte du gaz. The atomization enclosure 5 further comprises an annex collection chamber 13 intended for the collection of the powder particles entrained by the pump during the collection of the gas.
La poudre d’alliage de cuivre selon l’invention est utilisée pour la fabrication de pièces par fabrication additive, par fusion ou frittage de particules de la poudre d’alliage de cuivre au moyen d'un faisceau de haute énergie. The copper alloy powder according to the invention is used for the manufacture of parts by additive manufacturing, by melting or sintering particles of the copper alloy powder by means of a high energy beam.
Le faisceau de haute énergie est par exemple un faisceau laser à haute densité d’énergie, par exemple développant une puissance spécifique de l’ordre de 105 W/cm2. The high energy beam is for example a high energy density laser beam, for example developing a specific power of the order of 10 5 W/cm 2 .
Le procédé de fabrication additive met par exemple en œuvre une technique de fusion ou de frittage sélective par laser sur lit de poudre, ou une technique de projection laser. The additive manufacturing process uses, for example, a selective laser melting or sintering technique on a powder bed, or a laser projection technique.
La mise en œuvre du procédé de fabrication selon ces techniques comprend dans tous les cas une étape de fourniture de la poudre d’alliage de cuivre, et la mise en œuvre des étapes (b) à (d) successives suivantes : The implementation of the manufacturing process according to these techniques includes in all cases a step of supplying the copper alloy powder, and the implementation of the following successive steps (b) to (d):
(b) chauffage d’une région de la poudre, à une température qui peut être supérieure ou inférieure à la température de fusion de la poudre d’alliage de cuivre, au moyen du faisceau à haute densité d’énergie, (b) heating a region of the powder, to a temperature which may be higher or lower than the melting temperature of the copper alloy powder, by means of the high energy density beam,
(c) retrait du faisceau à haute densité d’énergie de ladite région de poudre d’alliage de cuivre, (c) removing the high energy density beam from said region of copper alloy powder,
(d) refroidissement de ladite région de poudre d’alliage de cuivre à une vitesse de refroidissement supérieure ou égale à 104 oC/s. (d) cooling said region of copper alloy powder at a cooling rate greater than or equal to 10 4 o C/s.
Le refroidissement, lors de l’étape (d), de la région de la poudre d’alliage survient par exemple en conséquence du retrait lors de l’étape (c) du faisceau à haute densité d’énergie. The cooling, during step (d), of the region of the alloy powder occurs for example as a consequence of the withdrawal during step (c) of the high energy density beam.
Lors de l’étape (d), la région de poudre d’alliage de cuivre chauffée se solidifie pour former ainsi une couche de la pièce.
Les étapes (b) à (d) peuvent être à nouveau être mises en œuvre de manière itérative pour former des couches successives de la pièce. In step (d), the region of heated copper alloy powder solidifies to thereby form a layer of the part. Steps (b) to (d) can again be implemented iteratively to form successive layers of the part.
La fusion sélective par laser est une technique de fabrication additive permettant la production de pièces à partir d’une poudre d’alliage de cuivre en faisant fusionner sélectivement, c’est-à-dire localement, une région d’une couche de poudre d’alliage déposée sur un support. Selective laser melting is an additive manufacturing technique for producing parts from copper alloy powder by selectively, i.e. locally, melting a region of a layer of copper powder. alloy deposited on a support.
La technique de frittage sélectif par laser, ou SLS pour « Selective Laser Sintering » en anglais, diffère de la technique de fusion sélective par laser essentiellement en ce que la région de la couche de poudre d’alliage de cuivre n’est pas portée à une température supérieure à la température de fusion, mais frittée. The technique of selective laser sintering, or SLS for "Selective Laser Sintering" in English, differs from the technique of selective laser melting essentially in that the region of the layer of copper alloy powder is not brought to a temperature above the melting point, but sintered.
La mise en œuvre du procédé de fabrication par frittage ou fusion sélectif par laser comprend en outre, avant l’étape (b) ou avant chaque étape (b), une étape (a) de dépôt d’une couche de la poudre d’alliage sur un support. The implementation of the manufacturing process by sintering or selective laser melting further comprises, before step (b) or before each step (b), a step (a) of depositing a layer of the powder of alloy on a support.
Le support est par exemple une plateforme de fabrication, ou une couche de la pièce, de poudre préalablement déposée ou projetée. The support is for example a manufacturing platform, or a layer of the part, of powder previously deposited or projected.
Lors de l’étape (a), la couche de poudre d’alliage de cuivre est ainsi par exemple déposée sur la plateforme de fabrication, ou sur une couche de la pièce préalablement fabriquée par la mise en œuvre des étapes (a) à (d). During step (a), the layer of copper alloy powder is thus for example deposited on the manufacturing platform, or on a layer of the part previously manufactured by implementing steps (a) to ( d).
Lors de l’étape (b), le faisceau laser est dirigé sur une région de la couche de poudre d’alliage de cuivre déposée. La région de poudre mentionnée en référence aux étapes (b) et (d) correspond alors à la région de la couche de poudre sur laquelle est dirigé le faisceau laser. In step (b), the laser beam is directed onto a region of the deposited copper alloy powder layer. The region of powder mentioned with reference to steps (b) and (d) then corresponds to the region of the layer of powder onto which the laser beam is directed.
Dans la technique de fusion sélective par laser, lors de l’étape (b), la région de la couche de poudre d’alliage de cuivre est portée à une température supérieure à la température de fusion de cette poudre d’alliage, pour former une région fondue. In the selective laser melting technique, during step (b), the region of the layer of copper alloy powder is brought to a temperature higher than the melting temperature of this alloy powder, to form a molten region.
Dans la technique de frittage sélectif par laser, lors de l’étape (b), la région de la couche de poudre d’alliage de cuivre n’est pas portée à une température supérieure à la température de fusion, mais frittée. In the selective laser sintering technique, during step (b), the region of the copper alloy powder layer is not brought to a temperature higher than the melting temperature, but sintered.
La forme de la région sur laquelle est dirigée le faisceau laser, qui n’est pas nécessairement convexe, correspond à une couche de la pièce fabriquée. The shape of the region on which the laser beam is directed, which is not necessarily convex, corresponds to a layer of the manufactured part.
Seule cette région est chauffée, de manière sélective, par le faisceau laser. La couche de poudre déposée lors de l’étape (a) comprend ainsi une région fondue ou frittée, et une ou plusieurs régions de poudre non fondues et non frittées. Only this region is heated, selectively, by the laser beam. The layer of powder deposited during step (a) thus comprises a melted or sintered region, and one or more regions of unmelted and unsintered powder.
Lors de l’étape (d), la région fondue ou frittée se solidifie pour former ainsi une couche de la pièce.
Les étapes (a) à (d) peuvent être à nouveau être mises en œuvre de manière itérative pour former des couches successives ou adjacentes de la pièce. During step (d), the molten or sintered region solidifies to thereby form a layer of the part. Steps (a) to (d) can again be implemented iteratively to form successive or adjacent layers of the part.
Par exemple, lors de chaque étape (a), chaque nouvelle couche de poudre d’alliage de cuivre peut être déposée sur la couche de poudre déposée lors de l’itération précédente, ou à l’écart de cette couche précédente. For example, during each step (a), each new layer of copper alloy powder can be deposited on the layer of powder deposited during the previous iteration, or away from this previous layer.
L’excédent de poudre d’alliage de cuivre, correspondant aux portions non fondues de la couche de poudre d’alliage de cuivre, peut alors être récupéré, soit à l’issue du procédé de fabrication, soit à l’issue de chaque succession d’étapes (a) à (d), ou encore à l’issue de certaines des successions d’étapes (a) à (d). The excess copper alloy powder, corresponding to the unmelted portions of the layer of copper alloy powder, can then be recovered, either at the end of the manufacturing process, or at the end of each succession of steps (a) to (d), or even at the end of some of the successions of steps (a) to (d).
On a illustré à titre d’exemple sur la Figure 2 un dispositif de fabrication additive 15 comprenant une enceinte 17 à l’intérieur de laquelle se situent un support 19 pour recevoir des couches successives de poudre d’alliage pour la fabrication d’une pièce et un laser 21 pour générer un faisceau laser 23 orientable de manière à diriger le faisceau laser 23 sur une région à solidifier de la dernière couche de poudre 25 déposée pour former une pièce 27 résultant de la superposition des régions solidifiées des couches superposées. There is illustrated by way of example in Figure 2 an additive manufacturing device 15 comprising an enclosure 17 inside which are located a support 19 to receive successive layers of alloy powder for the manufacture of a part and a laser 21 for generating a laser beam 23 that can be steered so as to direct the laser beam 23 onto a region to be solidified of the last layer of powder 25 deposited to form a part 27 resulting from the superposition of the solidified regions of the superimposed layers.
La technique de projection laser, ou DMD pour « Direct Metal Deposition » en anglais, consiste à émettre un faisceau laser à haute densité d’énergie sur un substrat tout en projetant de la poudre d’alliage au moyen d’une buse de projection coaxiale au faisceau laser. La poudre d’alliage est chauffée par le faisceau laser lors de son transport jusqu’au substrat et se dépose, sous forme de poudre d’alliage fondue, sur ce substrat. La géométrie de la pièce est obtenue en déplaçant d’une part le substrat dans un plan, et d’autre part le faisceau laser orthogonalement à ce plan. La pièce est alors fabriquée couche par couche à partir des données de conception de cette pièce. The laser projection technique, or DMD for "Direct Metal Deposition" in English, consists of emitting a high energy density laser beam on a substrate while projecting alloy powder by means of a coaxial projection nozzle to the laser beam. The alloy powder is heated by the laser beam during its transport to the substrate and is deposited, in the form of molten alloy powder, on this substrate. The geometry of the part is obtained by moving on the one hand the substrate in a plane, and on the other hand the laser beam orthogonal to this plane. The part is then manufactured layer by layer from the design data of this part.
Ainsi, lors de l’étape (b), la partie de poudre d’alliage est à la fois chauffée et projetée sur le support. Thus, during step (b), the part of alloy powder is both heated and projected onto the support.
La technique de fusion par faisceau d'électrons (ou EBM pour « Electron Beam Melting » en anglais) diffère de la fusion sélective par laser en ce qu’elle utilise un faisceau d'électrons de haute énergie comme source de chaleur pour faire fondre et fusionner la poudre. Electron Beam Melting (EBM) differs from Selective Laser Melting in that it uses a high-energy electron beam as a heat source to melt and merge the powder.
Dans un exemple de réalisation mettant en œuvre une fusion par faisceau d’électrons, lors de l’étape (b), la partie de poudre d’alliage est chauffée par un faisceau d’électrons. In an exemplary embodiment implementing electron beam melting, during step (b), the part of alloy powder is heated by an electron beam.
Dans un exemple de réalisation, la fabrication additive met en œuvre une technique de fabrication dite de dépôt de matière sous forme solide. In an exemplary embodiment, additive manufacturing implements a manufacturing technique known as material deposition in solid form.
Dans un exemple de réalisation, la fabrication additive est réalisée à partir de la composition d’alliage de cuivre sous forme « solide », par opposition à la composition de
cuivre sous forme de poudre qui peut s’écouler. On parle de fabrication additive par dépôt de matière sous forme solide. In an exemplary embodiment, the additive manufacturing is carried out using the copper alloy composition in "solid" form, as opposed to the composition of copper in the form of a powder which can flow. We are talking about additive manufacturing by depositing material in solid form.
La fabrication additive est dans ce cas effectuée, par exemple, à partir d’un fil réalisé dans la composition d’alliage de cuivre, en utilisant un arc électrique pour faire fondre le fil et le déposer à l’endroit désiré avant qu’il ne se solidifie à nouveau. La superposition de fils permet de créer une structure ou une forme tridimensionnelle. Additive manufacturing in this case is carried out, for example, from a wire made in the copper alloy composition, using an electric arc to melt the wire and deposit it in the desired place before it does not solidify again. The layering of threads makes it possible to create a three-dimensional structure or shape.
Dans un exemple de réalisation particulier, la fabrication additive est réalisée par fabrication additive arc-fil (ou WAAM pour « Wire Arc Additive Manufacturing » en anglais). In a particular exemplary embodiment, the additive manufacturing is carried out by wire arc additive manufacturing (or WAAM for “Wire Arc Additive Manufacturing”).
Le procédé de fabrication selon l’invention est de préférence mis en œuvre dans une enceinte fermée, i.e. isolée du milieu extérieur. The manufacturing process according to the invention is preferably implemented in a closed enclosure, i.e. isolated from the external environment.
En particulier, le procédé de fabrication est de préférence mis en œuvre dans une enceinte fermée sous atmosphère protectrice d’un gaz inerte, le pourcentage massique d’oxygène dans l’atmosphère étant inférieur à 10.000 ppm. In particular, the manufacturing process is preferably implemented in a closed enclosure under a protective atmosphere of an inert gas, the mass percentage of oxygen in the atmosphere being less than 10,000 ppm.
Cette atmosphère protectrice permet d’éviter la contamination de la pièce, notamment par de l’oxygène pouvant conduire à une oxydation, lors de la fabrication. This protective atmosphere makes it possible to avoid contamination of the part, in particular by oxygen which can lead to oxidation, during manufacture.
Le gaz inerte est par exemple de l’argon, du l’azote, de l’hélium ou un autre gaz neutre, ou un mélange de plusieurs de ces gaz. The inert gas is for example argon, nitrogen, helium or another neutral gas, or a mixture of several of these gases.
L’enceinte et/ou le support de fabrication peuvent être chauffés afin de limiter les contraintes résiduelles dans la pièce et les déformations de la pièce lors du refroidissement. The enclosure and/or the manufacturing support can be heated in order to limit the residual stresses in the part and the deformations of the part during cooling.
La pièce produite par un tel procédé de fabrication a une composition correspondant à celle de la poudre d’alliage utilisée. The part produced by such a manufacturing process has a composition corresponding to that of the alloy powder used.
La composition d’alliage de cuivre permet la fabrication, par un procédé de fabrication additive, d’une pièce présentant des caractéristiques mécaniques satisfaisantes.
The copper alloy composition allows the manufacture, by an additive manufacturing process, of a part with satisfactory mechanical characteristics.
Claims
1. Composition d’alliage de cuivre de composition massique CuComp(AI2O3)aZrbCrc dans laquelle, en pourcentage massique : 1 ,5% < a < 5%, 0,01% < b < 5%, 0% < c < 5%, le complément étant constitué de cuivre et d’impuretés inévitables. 1. Composition of copper alloy of composition by mass Cu C omp (Al 2 O3) aZrbCrc in which, in mass percentage: 1.5% < a < 5%, 0.01% < b < 5%, 0% < c < 5%, the balance consisting of copper and unavoidable impurities.
2. Composition d’alliage de cuivre selon la revendication 1 , se présentant sous la forme d’une poudre. 2. Copper alloy composition according to claim 1, being in the form of a powder.
3. Composition d’alliage de cuivre selon la revendication 1 , se présentant sous la forme d’un solide, en particulier sous la forme d’un fil ou d’une plaque. 3. Copper alloy composition according to claim 1, being in the form of a solid, in particular in the form of a wire or a plate.
4. Procédé de fabrication d’une composition d’alliage de cuivre selon l’une quelconque des revendications 1 à 3, le procédé comprenant les étapes de : fourniture d’un ou plusieurs matériaux précurseurs comprenant du cuivre, de l’alumine, du zirconium et, optionnellement, du chrome ; combinaison des matériaux précurseurs pour former la composition d’alliage. 4. A method of making a copper alloy composition according to any one of claims 1 to 3, the method comprising the steps of: providing one or more precursor materials comprising copper, alumina, zirconium and, optionally, chromium; combination of the precursor materials to form the alloy composition.
5. Procédé de fabrication selon la revendication 4, dans lequel les matériaux précurseurs sont fournis sous forme de poudres de précurseur d’alliage, et l’étape de combinaison comprend un mélange mécanique des poudres de précurseur d’alliage pour obtenir la composition d’alliage de cuivre sous la forme d’une poudre. 5. A manufacturing method according to claim 4, wherein the precursor materials are provided in the form of alloy precursor powders, and the step of combining comprises mechanical mixing of the alloy precursor powders to obtain the composition of copper alloy in the form of a powder.
6. Procédé de fabrication selon la revendication 5, dans lequel les poudres de précurseurs d’alliage présentent chacune une granulométrie comprise entre 1 pm et 100 pm. 6. Manufacturing process according to claim 5, in which the powders of alloy precursors each have a particle size between 1 μm and 100 μm.
7. Procédé de fabrication selon la revendication 5 ou 6, dans lequel les matériaux précurseurs sont fournis sous la forme de solides, l’étape de combinaison des matériaux précurseurs comprenant un broyage des dits solides. 7. Manufacturing process according to claim 5 or 6, in which the precursor materials are provided in the form of solids, the step of combining the precursor materials comprising grinding said solids.
8. Procédé de fabrication selon l’une quelconque des revendications 4 à 7, dans lequel l’étape de combinaison des matériaux précurseurs comprend une étape de fusion d’un mélange des matériaux précurseurs, et une étape d’atomisation sous gaz neutre du mélange fondu sous forme de particules de poudre pour obtenir la composition d’alliage de cuivre sous forme de poudre. 8. Manufacturing process according to any one of claims 4 to 7, in which the step of combining the precursor materials comprises a step of melting a mixture of the precursor materials, and a step of atomizing the mixture under neutral gas. melted into powder particles to obtain the copper alloy composition in powder form.
9. Procédé de fabrication d’une pièce en alliage de cuivre par fabrication additive au moyen d’une composition d’alliage de cuivre selon l’une quelconque des revendications 1 à 3. 9. A method of manufacturing a copper alloy part by additive manufacturing using a copper alloy composition according to any one of claims 1 to 3.
10. Procédé de fabrication selon la revendication 9, dans lequel la composition d’alliage de cuivre se présente sous la forme de poudre et la fabrication additive est réalisée par fusion ou frittage de particules de la composition d’alliage de cuivre sous forme de
poudre, au moyen d'un faisceau à haute densité d’énergie, notamment un faisceau laser à haute densité d’énergie. 10. Manufacturing process according to claim 9, in which the copper alloy composition is in the form of powder and the additive manufacturing is carried out by melting or sintering particles of the copper alloy composition in the form of powder, by means of a high energy density beam, in particular a high energy density laser beam.
11. Procédé de fabrication selon la revendication 10, dans lequel la fabrication additive comprend la mise en œuvre, sur la composition d’alliage de cuivre, d’au moins une technique de fabrication additive choisie parmi la technique de projection laser, la technique de fusion sélective par laser, la technique de frittage sélectif par laser et la fusion par faisceau d’électrons 11. Manufacturing process according to claim 10, in which the additive manufacturing comprises the implementation, on the copper alloy composition, of at least one additive manufacturing technique chosen from among the laser projection technique, the selective laser melting, selective laser sintering technique and electron beam melting
12. Procédé de fabrication selon l’une quelconque des revendications 9 à 11 , comprenant la fourniture de la composition d’alliage de cuivre sous forme de poudre et la mise en œuvre de la succession des étapes (b) à (d) suivantes : 12. Manufacturing process according to any one of claims 9 to 11, comprising the supply of the copper alloy composition in powder form and the implementation of the following succession of steps (b) to (d):
(b) chauffage, au moyen du faisceau à haute densité d’énergie, d’une partie de la composition d’alliage de cuivre sous forme de poudre, (b) heating, by means of the high energy density beam, a part of the copper alloy composition in powder form,
(c) retrait du faisceau à haute densité d’énergie de la partie de composition d’alliage de cuivre, (c) removing the high energy density beam from the copper alloy composition part,
(d) refroidissement de la partie de la composition d’alliage de cuivre. (d) cooling part of the copper alloy composition.
13. Procédé de fabrication selon la revendication 12, comprenant en outre, avant l’étape (b), une étape (a) de dépôt d’une couche de la composition d’alliage de cuivre sous forme de poudre sur un support, et en ce que l’étape (b) de chauffage de la partie de la composition d’alliage sous forme de poudre est mise en œuvre en dirigeant le faisceau à haute densité d’énergie sur une région de la couche de composition d’alliage de cuivre sous forme de poudre déposée formant ladite partie de composition d’alliage de cuivre sous forme de poudre. 13. Manufacturing process according to claim 12, further comprising, before step (b), a step (a) of depositing a layer of the copper alloy composition in powder form on a support, and in that the step (b) of heating the part of the alloy composition in powder form is carried out by directing the high energy density beam onto a region of the layer of alloy composition of powdered copper deposited forming said powdered copper alloy composition part.
14. Procédé de fabrication selon la revendication 12 ou 13, dans lequel le refroidissement de la partie de la composition d’alliage de cuivre survient en conséquence de l’étape (c) de retrait du faisceau à haute densité d’énergie. 14. A manufacturing method according to claim 12 or 13, wherein the cooling of the part of the copper alloy composition occurs as a consequence of step (c) of withdrawing the high energy density beam.
15. Procédé de fabrication selon l’une quelconque des revendications 12 à 14, dans lequel les étapes (b) à (d) sont mises en œuvre dans une enceinte fermée chauffée et/ou sous atmosphère protectrice d’un gaz inerte, notamment d’argon, le pourcentage massique d’oxygène dans ladite atmosphère étant inférieur à 10.000 ppm. 15. Manufacturing process according to any one of claims 12 to 14, in which steps (b) to (d) are implemented in a heated closed enclosure and/or under a protective atmosphere of an inert gas, in particular d argon, the mass percentage of oxygen in said atmosphere being less than 10,000 ppm.
16. Procédé de fabrication selon l’une quelconque des revendications 12 à 15, dans lequel l’étape de fourniture de la poudre d’alliage comprend la mise en œuvre du procédé de fabrication d’une composition d’alliage de cuivre selon l’une quelconque des revendications 4 à 8. 16. Manufacturing process according to any one of claims 12 to 15, in which the step of supplying the alloy powder comprises implementing the process for manufacturing a copper alloy composition according to any of claims 4 to 8.
17. Procédé de fabrication selon la revendication 9, dans lequel la fabrication additive comprend la mise en œuvre d’un dépôt de matière sous forme solide à partir de la
composition d’alliage de cuivre sous forme solide, en particulier une fabrication additive arc- fil. 17. Manufacturing process according to claim 9, in which the additive manufacturing comprises the implementation of a deposition of material in solid form from the copper alloy composition in solid form, in particular arc-wire additive manufacturing.
18. Pièce en alliage de cuivre obtenue par un procédé de fabrication selon l’une quelconque des revendications 9 à 17, ledit alliage de cuivre ayant la composition massique CuComp(AI2O3)aZrbCrc dans laquelle, en pourcentage massique : 1 ,5% < a < 5%, 0,01% < b < 5%, 0% < c < 5%, le complément étant constitué de cuivre et d’impuretés inévitables.
18. Copper alloy part obtained by a manufacturing process according to any one of claims 9 to 17, said copper alloy having the mass composition Cu C o m p (Al 2 O 3 ) aZrbCrc in which, in mass percentage : 1.5% < a < 5%, 0.01% < b < 5%, 0% < c < 5%, the balance being made up of copper and inevitable impurities.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR2109686A FR3126997A1 (en) | 2021-09-15 | 2021-09-15 | Copper alloy composition and method of making same, method of making a part from the copper alloy composition |
| PCT/EP2022/075438 WO2023041537A1 (en) | 2021-09-15 | 2022-09-13 | Copper alloy composition and method for manufacturing same, method for manufacturing a part from the copper alloy composition |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| EP4402296A1 true EP4402296A1 (en) | 2024-07-24 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP22786893.2A Pending EP4402296A1 (en) | 2021-09-15 | 2022-09-13 | Copper alloy composition and method for manufacturing same, method for manufacturing a part from the copper alloy composition |
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| Country | Link |
|---|---|
| EP (1) | EP4402296A1 (en) |
| CN (1) | CN117999372A (en) |
| FR (1) | FR3126997A1 (en) |
| WO (1) | WO2023041537A1 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| FR2985521B1 (en) * | 2012-01-09 | 2015-05-15 | Le Bronze Ind | PROCESS FOR OBTAINING A COPPER ALLOY HAVING A VERY HIGH LEVEL OF MECHANICAL CHARACTERISTICS |
| FR3075828B1 (en) * | 2017-12-26 | 2022-04-29 | Thales Sa | ALUMINUM ALLOY POWDER FOR ADDITIVE MANUFACTURING, AND METHOD FOR MAKING A PART BY MANUFACTURING FROM THIS POWDER |
| CN110202133A (en) * | 2019-07-01 | 2019-09-06 | 有研粉末新材料股份有限公司 | A kind of nano aluminum oxide dispersion strengthens the preparation method and application of copper-based composite powder |
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2021
- 2021-09-15 FR FR2109686A patent/FR3126997A1/en active Pending
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2022
- 2022-09-13 CN CN202280062077.4A patent/CN117999372A/en active Pending
- 2022-09-13 WO PCT/EP2022/075438 patent/WO2023041537A1/en active Application Filing
- 2022-09-13 EP EP22786893.2A patent/EP4402296A1/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| WO2023041537A1 (en) | 2023-03-23 |
| FR3126997A1 (en) | 2023-03-17 |
| CN117999372A (en) | 2024-05-07 |
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