Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/08—Ferrous alloys, e.g. steel alloys containing nickel
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
  • B21C1/00—Manufacture of metal sheets, wire, rods, tubes or like semi-manufactured products by drawing
  • B21C1/003—Drawing materials of special alloys so far as the composition of the alloy requires or permits special drawing methods or sequences
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/20—Direct sintering or melting
  • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• • 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
  • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
• • 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
  • 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
  • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
  • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
  • B23K35/24—Selection of soldering or welding materials proper
  • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
  • B23K35/3053—Fe as the principal constituent
• • 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
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D 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 [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y70/00—Materials specially adapted for additive manufacturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y80/00—Products made by additive manufacturing
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/004—Very low carbon steels, i.e. having a carbon content of less than 0,01%
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/005—Ferrous alloys, e.g. steel alloys containing rare earths, i.e. Sc, Y, Lanthanides
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/10—Ferrous alloys, e.g. steel alloys containing cobalt
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/10—Ferrous alloys, e.g. steel alloys containing cobalt
  • C22C38/105—Ferrous alloys, e.g. steel alloys containing cobalt containing Co and Ni
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys
  • C22C38/14—Ferrous alloys, e.g. steel alloys containing titanium or zirconium
• • 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
  • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
  • B22F2005/002—Tools other than cutting tools
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2301/00—Metallic composition of the powder or its coating
  • B22F2301/35—Iron
  • B22F2301/355—Rare Earth - Fe intermetallic alloys
• • 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
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P10/00—Technologies related to metal processing
  • Y02P10/25—Process efficiency

Definitions

• the present invention relates to an alloy for the manufacture of tools, in particular molds or mold parts, intended for the manufacture of aeronautical parts made of composite material.
• composite materials generally include a polymer matrix, in which reinforcing fibers are embedded.
• the polymer matrix is for example formed by a thermosetting resin, in particular by an epoxy, polyester, vinyl ester, polyamide or phenol resin.
• the reinforcing fibers are for example chosen from glass, carbon, Kevlar, aluminum or titanium fibers. In some cases, the fibers are woven with the aim of further improving the mechanical properties of the part.
• a Prepreg is usually used as a starting material, that is to say a composite in the form of a strip comprising the reinforcing fibers embedded in the polymer matrix.
• the part is then manufactured from this starting material by one of the following two processes:
• (a) Lamination and crosslinking under autoclave comprising the following successive steps: a. Deposition of the starting material, in successive layers, on a metal mold of convex or concave shape to obtain stratification on the metal mold, b. Vacuum encapsulation of the lamination to eliminate air bubbles and adhere the lamination to the more or less complex shapes of the mold, i.e. Crosslinking of the polymer matrix of the composite by heat treatment of the assembly including the mold with lamination in an autoclave, under pressure, at temperatures between 120°C and 180°C, for several hundred minutes;
• Invar M93 has a thermal expansion coefficient suitable for the manufacture of such tools. Furthermore, it also has advantageous properties for such an application, in particular in terms of resistance to shocks and scratches, increased tool life compared to non-metallic molds, possibility of producing a tool structure or mechanically welded mold and possibility of machining the tools from a mechanically welded structure.
• An aim of the invention is to propose an alloy allowing the additive manufacturing of tools intended for the manufacture of aeronautical parts made of composite material with improved productivity.
• the invention relates to an alloy for the manufacture of tools intended for the manufacture of aeronautical parts made of composite material, the alloy comprising, by weight:
• Ni% designates the Ni content as a percentage by weight in the alloy
• Ni% designates the Ni content as a percentage by weight in the alloy
• the impurities resulting from the preparation include, by weight: Ca ⁇ 0.0015% Mg ⁇ 0.0035% Al ⁇ 0.0085% O ⁇ 0.0025% S ⁇ 0.0035% P ⁇ 0.0100 % B ⁇ 0.0005% Mo ⁇ 0.1% Cr ⁇ 0.1% Cu ⁇ 0.1%
• the part is a tool, in particular a mold, intended for the manufacture of an aeronautical part made of composite material.
• the invention also relates to a metal powder made from an alloy as defined above.
• the invention also relates to a process for manufacturing a metal powder as defined above, said process comprising a step of supplying a filler wire as defined above, as well as an atomization step. plasma from this filler wire to obtain the metal powder.
• FIG. 1 is a graph illustrating the range of authorized contents for cobalt in the alloy according to the invention as a function of the nickel content of the alloy, the contents being expressed as a percentage by weight;
• FIG. 2 is a schematic perspective view of a part obtained by additive manufacturing according to the invention.
• the alloy according to the invention comprises, by weight:
• Ni% designates the Ni content as a percentage by weight in the alloy
• Ni% designates the Ni content as a percentage by weight in the alloy
• impurities resulting from the production we mean elements which are present in the raw materials used to produce the alloy or which come from the devices used for its production, and for example from the refractories of the furnaces. These residual elements have no metallurgical effect on the alloy.
• the impurities resulting from the production include in particular, by weight:
• the alloy according to the invention is an austenitic alloy at a temperature equal to ambient temperature (approximately 20°C).
• the cobalt content is between 0.80% by weight and 4.20% by weight, and also respects the following conditions: Co > -1.00 x Ni% + 36.80% and Co ⁇ -1.63 x Ni% + 62.72%.
• Ni% denotes the nickel content as a percentage by weight in the alloy
• Co denotes the cobalt content as a percentage by weight in the alloy.
• the domain according to the invention corresponds to the domain delimited by the rights C1, C2, CJnf and C_sup.
• a cobalt content included in this range makes it possible to obtain an average coefficient of thermal expansion between 20°C and 200°C comprised between 2.2.10 -6 °C -1 and 2.9.10' 6o C' 1 .
• the titanium content of between 1.0% by weight and 2.0% by weight makes it possible to obtain good resistance to the collapse of the liquid bath during the additive manufacturing of parts produced in the alloy according to the invention by arc-wire additive manufacturing and therefore makes it possible in particular to avoid the formation of drips in the part.
• the titanium content is less than 1.0% by weight, the resistance to collapse of the liquid bath during the additive manufacturing of parts made in the alloy according to the invention, in particular by arc-wire additive manufacturing, is insufficient and high manufacturing productivity, in particular a deposition rate greater than or equal to 450 cm 3 /h during additive manufacturing, generates undesirable drips.
• the titanium content is greater than 2.0% by weight, the average coefficient of thermal expansion between 20°C and 200°C risks being greater than the upper limit of 2.9.10 -6o C' 1 desired for the application mentioned above.
• the rare earth content is between 0.0010% and 0.0500%.
• the addition of rare earths at the mentioned contents makes it possible to reinforce the role of titanium, and thus to improve the resistance to collapse of the liquid bath during the additive manufacturing of parts made from the alloy according to the invention, in particular by arc-wire additive manufacturing.
• the rare earths are in particular chosen from yttrium, cerium, lanthanum, neodymium and praseodymium or their mixtures.
• a carbon content greater than 0.04% risks leading to hot cracking problems upon solidification, due to the precipitation of titanium carbides, and thus to poor solidification behavior during welding.
• the alloy according to the invention is advantageous. Indeed, it allows the manufacture, by additive manufacturing, of tools or parts of tools intended for the manufacture of aeronautical parts in composite material, comprising in particular a matrix made of epoxy resin in which carbon fibers are embedded as as reinforcing fibers, of good quality, in a simple and flexible way and with high productivity. Indeed, it presents the desired properties for such alloys mentioned above, and in particular an average coefficient of thermal expansion between 20°C and 100°C between 2.2.10 -6 °C -1 and 2.9.10 -6o C -1 , resulting in satisfactory compatibility between the tooling and the part to be manufactured, and good resistance to the collapse of the liquid bath during the additive manufacturing of parts, which allows the manufacture of parts of good quality. quality with high manufacturing productivity, especially with a deposition rate greater than or equal to 450 cm 3 /h during additive manufacturing.
• the alloy according to the invention can be produced by any suitable method known to those skilled in the art.
• starting materials are placed in an electric arc furnace. Then, these starting materials are subjected to fusion in the electric arc furnace, then refining is carried out in a new pouch (VOD) by usual methods, in order to obtain:
• VOD new pouch
• the invention also relates to a filler wire made from an alloy having a composition as described above.
• Such a filler wire is particularly suitable for use as a filler wire in the context of a metal additive manufacturing process.
• the additive manufacturing process is for example an additive manufacturing process using an electric arc, a laser beam and/or an electron beam as an energy source to achieve fusion of the filler wire.
• the additive manufacturing process is in particular an additive manufacturing process by directed energy deposition (“Directed Energy Deposition” in English).
• the filler material is deposited, in particular by a nozzle, and immediately fused by concentrated thermal energy, in particular a laser beam, an electron beam and/or an electric arc.
• the additive manufacturing process is an arc-wire process (“WAAM” or “Wire arc additive manufacturing” in English), Laser-wire, electron beam-wire (“Electron Beam Free Form Fabrication” or “Electron beam additive manufacturing” in English) or a hybrid additive manufacturing process combining arc-wire and Laser-powder or arc-wire and Laser-wire technologies.
• the powder used has the same composition as the wire.
• Such a powder, whose particle size after sieving is between 20 pm and 150 pm, is for example obtained from the filler wire according to the invention, by means of plasma atomization technology.
• the filler wire used to manufacture the powder has a diameter of approximately 3 mm.
• the particle size of the powders is in particular determined by the following measurement method. Powder batches are separated into multiple powder size distributions using ultrasonic vibrating stainless steel sieves. The analysis of the size distribution of powders resulting from sieving is carried out according to the ASTM B214-07 standard. Sieving makes it possible to obtain 5 size classes: ⁇ 20pm - 20pm to 45pm - 45pm to 75pm - 75pm to 105pm - >105pm.
• the plasma atomization technology for making a powder from a wire is known per se, and is therefore not described in further detail.
• the invention also relates to a method of manufacturing a filler wire made from the alloy as described above.
• This process comprises, in a first step, the supply of a semi-finished product made from this alloy.
• the alloy is either cast into ingots or cast directly in the form of billets, in particular by means of continuous casting, in particular rotary casting.
• the semi-products obtained at the end of this step are therefore advantageously ingots or billets, and have for example a diameter of between 130 and 230 mm, and more particularly equal to approximately 150 mm.
• the semi-finished products are transformed by hot processing to form an intermediate yarn.
• the semi-products that is to say in particular the ingots or billets, are reheated, in particular in a gas oven, up to a temperature of between 1180° C and 1220°C.
• the reduced section semi-finished products are then transformed again hot, at a temperature between 950°C and 1150°C, to obtain the intermediate wire.
• the intermediate wire may in particular be a machine wire. It has, for example, a diameter of between 5 mm and 21 mm, and in particular approximately equal to 5.5 mm.
• the intermediate wire is produced by hot rolling on a wire train.
• the intermediate wire is then subjected to hyperquenching in a swimming pool, after heat treatment in a gas oven at a temperature between 1150°C and 1220°C for a period of between 60 minutes and 120 minutes.
• the intermediate wire is then stripped and wound into a coil.
• the intermediate wire thus obtained is drawn using a drawing installation of known type to obtain the filler wire.
• This filler wire has a diameter smaller than that of the starting wire. Its diameter is notably between 0.5 mm and 3.5 mm. It is advantageously between 0.8 mm and 2.4 mm.
• the drawing passes are carried out cold.
• the invention also relates to a method of manufacturing a part or part of a part 1 as shown schematically in Figure 2, made in an alloy as described above, comprising:
• the part 1 or part of a part is preferably a tool or part of a tool intended to be used for the manufacture of aeronautical parts made from composite materials, the composite material comprising, in particular, an epoxy resin matrix in which are embedded with reinforcing fibers in the form of carbon fibers.
• part 1 is a mold or part of a mold intended to be used for the manufacture of aeronautical parts made from composite materials, the composite material comprising, in particular, an epoxy resin matrix in which are embedded reinforcing fibers in the form of carbon fibers.
• part 1 defines a molding surface of a tool intended to be used for the manufacture of aeronautical parts made from composite materials and further comprises, optionally, a support structure for said molding surface.
• the additive manufacturing process is for example an additive manufacturing process using an electric arc, a laser beam and/or an electron beam as an energy source to achieve fusion of the filler material.
• the additive manufacturing process is in particular an additive manufacturing process by directed energy deposition (“Directed Energy Deposition” in English).
• the filler material is deposited, in particular by a nozzle, and immediately fused by concentrated thermal energy, in particular a laser beam, an electron beam and/or an electric arc.
• the additive manufacturing process is an arc-wire, laser-wire, electron beam-wire process (“Electron Beam Free Form Fabrication” or “Electron beam additive manufacturing” in English) or a process of hybrid additive manufacturing combining arc-wire and laser-powder or arc-wire and laser-wire technologies.
• the powder and the filler wire are made in the alloy as described below. above.
• the additive manufacturing process comprises several passes, each pass corresponding to the formation of a layer of the part 1 or part of the part to be manufactured, the duration between two successive passes being defined by the minimum time necessary so that the tool, and in particular the tool for melting the filler material, for example the laser beam, the electron beam and/or the electric arc, returns to the start of the deposition zone.
• this manufacturing process makes it possible to flexibly manufacture high quality parts 1 or parts of parts with high productivity, and in particular with a higher deposition rate. or equal to 450 cm 3 /h.
• the process also comprises, prior to the manufacture of the part 1 or part of a part, a step of supply of a powder made from the alloy as described above.
• This powder whose particle size after sieving is between 20 pm and 150 pm, is for example manufactured by plasma atomization from a wire made of an alloy as described above, the wire having in particular a diameter of approximately 3 mm.
• the plasma atomization process is known per se, and is therefore not described in detail.
• the invention also relates to a part 1 or part of a part made from an alloy as described above obtained by metal additive manufacturing.
• the part 1 or part of a part is preferably a tool or part of a tool intended to be used for the manufacture of aeronautical parts made from composite materials, the composite material comprising, in particular, an epoxy resin matrix in which are embedded with reinforcing fibers in the form of carbon fibers.
• part 1 is a mold or part of a mold intended to be used for the manufacture of aeronautical parts made from composite materials, the composite material comprising, in particular, an epoxy resin matrix in which are embedded reinforcing fibers in the form of carbon fibers.
• part 1 defines a molding surface of a tool intended to be used for the manufacture of aeronautical parts made from composite materials and further comprises, optionally, a support structure for said molding surface.
• the metal additive manufacturing process uses in particular, as filler material, a filler wire made from the alloy as described above and/or a powder made from the alloy as described above. .
• the additive manufacturing process is for example an additive manufacturing process using an electric arc, a laser beam and/or an electron beam as an energy source to achieve the fusion of the filler material.
• the additive manufacturing process is in particular an additive manufacturing process by directed energy deposition (“Directed Energy Deposition” in English).
• the filler material is deposited, in particular by a nozzle, and immediately fused by concentrated thermal energy, in particular a laser beam, an electron beam and/or an electric arc.
• the additive manufacturing process is an arc-wire, laser-wire, electron beam-wire process (“Electron Beam Free Form Fabrication” or “Electron beam additive manufacturing” in English) or a process of hybrid additive manufacturing combining arc-wire and laser-powder or arc-wire and laser-wire technologies.
• the powder and the filler wire are made in the alloy as described below. above.
• a part 1 or part of a part obtained by a metal additive manufacturing process is as solidified. It therefore presents a solidification microstructure typical of the nickel alloy considered, such a microstructure typically comprising columnar dendrites which grow epitaxically on top of each other and whose orientation depends on the width and height of the metal wall manufactured. Furthermore, a part 1 obtained by an additive manufacturing process presents, due to its additive manufacturing process, a succession of superimposed solidification strata. Each stratum, obtained by solidifying drops of molten metal deposited, remelts the skin of the previous stratum in order to generate metallurgical continuity, and subsequently heats the rest of the lower strata. The reheating temperature is all the lower the further the stratum in question is from the zone being melted and solidified. This particular microstructure can be observed by metallographic observation on metallographic sections of the parts 1.
• a part 1 or part of a part obtained by a metal additive manufacturing process can thus be distinguished from parts obtained by other processes, and in particular from a part obtained by conventional metallurgy which produces a recrystallized structure with homogeneous grains.
• the ingots thus obtained were hot forged to obtain bars 100 mm in diameter and 500 mm long, which were then surface machined to remove the scale and forged using a rotary forge marketed by the company GFM to produce bars 30 mm in diameter and 3 m long. These bars were then cold drawn to produce a wire with a diameter of 5.5 mm and a length of 15 meters.
• the cold drawing step comprises a plurality of successive drawings with recrystallization heat treatments at a temperature of 1000°C for one hour interspersed between two successive drawings.
• the wire underwent annealing at a temperature of 1150°C for one hour in a gas oven, then was pickled and finally drawn on an industrial wire drawing machine to produce a wire of laboratory intake of 1.2 mm in diameter, wound in 15 kg reels.
• This manufacturing process is conventionally used to manufacture filler wire in the laboratory and makes it possible to obtain a filler wire having the same composition, surface cleanliness and suitability for use as filler wire as the process described previously for the manufacture of filler wire.
• the walls thus manufactured have a length of 150 mm, a width of 150 mm and a height of 70 mm.
• the inventors determined the number of sags occurring during the manufacture of the wall, as well as the average coefficient of thermal expansion of the alloy between 20°C and 200°C.
• the number of drips is observed visually on the walls during manufacture.
• the average coefficient of thermal expansion between 20°C and 200°C was measured as follows. The expansion of AL alloys was measured on heating between 20°C and 200°C, then the average coefficient of thermal expansion a[20°C_200°C] between 20°C and A I
• Table 2 summarizes the results of the tests carried out using wires made in alloys No. 1 to 22, as well as Invar M93 in Table 1.
• Alloys No. 1 to 4 in Table 1 above have titanium and/or rare earth contents lower than the lower limits of the corresponding ranges of the alloy according to the invention.
• the inventors noted that the walls made from wires made from these alloys also had a non-zero number of sags, respectively equal to 7, 5, 3 and 1. These alloys are therefore also not satisfactory for manufacturing tools or tools. parts of tools intended for the manufacture of aeronautical parts in composite material with improved productivity.
• alloy No. 1 also has an average coefficient of thermal expansion between 20°C and 200°C lower than the lower limit desired for this application.
• Alloy No. 9 has a titanium content greater than the upper limit of the corresponding range of the alloy according to the invention. This wall does not have any sags. On the other hand, its average coefficient of thermal expansion between 20°C and 200°C is 3.3.10 -6o C' 1 and is too high for the application considered.
• Alloys No. 10, 11, 14 and 18 have cobalt contents less than - 1.00 x Ni% + 36.80% and/or less than 0.80% by weight. Walls made from wires made from these alloys do not show sags. However, the average thermal expansion coefficients between 20°C and 200°C of these alloys are too high for the application considered.
• Alloys No. 16 and 21 have cobalt contents greater than -1.63 x Ni% + 62.72%. Walls made from wires made from these alloys do not show sags. However, the average coefficients of thermal expansion between 20°C and 200°C of these alloys are respectively 3.1.10 -6o C -1 and 3.5.10 -6o C -1 and are too high for the application considered.
• Alloy No. 22 has a cobalt content greater than 4.20% by weight. Walls made from wires made of this alloy do not show sags. However, the average coefficient of thermal expansion between 20°C and 200°C of this alloy is 2.0.10 -6o C' 1 and is too low for the application considered.
• the walls made from the alloy according to the invention corresponding to compositions No. 5, 6, 7, 8, 12, 13, 15, 17, 19 and 20 do not show any sags.
• these alloys have average coefficients of thermal expansion between 20°C and 200°C between 2.2.10 -6 °C -1 and 2.9.10 -6o C -1 , and therefore allow the manufacture of tools or parts of tools intended for the manufacture of aeronautical parts made of composite material with improved productivity, that is to say with a relatively short interpass duration as used in the context of the tests.

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• 2022
  • 2022-05-27 JP JP2024569822A patent/JP2025519161A/ja active Pending
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