JP2020158850A - 粉末積層造形用粉末材料及び造形物の製造方法 - Google Patents
粉末積層造形用粉末材料及び造形物の製造方法 Download PDFInfo
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- JP2020158850A JP2020158850A JP2019060845A JP2019060845A JP2020158850A JP 2020158850 A JP2020158850 A JP 2020158850A JP 2019060845 A JP2019060845 A JP 2019060845A JP 2019060845 A JP2019060845 A JP 2019060845A JP 2020158850 A JP2020158850 A JP 2020158850A
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- 238000000034 method Methods 0.000 title claims abstract description 30
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- 229910003468 tantalcarbide Inorganic materials 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- JBQYATWDVHIOAR-UHFFFAOYSA-N tellanylidenegermanium Chemical compound [Te]=[Ge] JBQYATWDVHIOAR-UHFFFAOYSA-N 0.000 description 1
- 229910003470 tongbaite Inorganic materials 0.000 description 1
- 229910052723 transition metal Inorganic materials 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 229910001930 tungsten oxide Inorganic materials 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- 229910001935 vanadium oxide Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
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- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/16—Both compacting and sintering in successive or repeated steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/30—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
- C22C29/08—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds based on tungsten carbide
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
Description
また、例えば特許文献2には、減圧下において電子ビームで粉末材料を融解させて粉末積層造形法によって三次元的な造形物を製造する積層造形装置が開示されている。この積層造形装置においては、造形物にクラックが生じることを抑制するなど造形精度を向上させる目的で、造形前に粉末材料の予熱が行われる。
本発明は、造形前に予熱を行ってもガスが生成しにくく減圧下で粉末積層造形法によって造形物を製造することが可能な粉末積層造形用粉末材料及び造形物の製造方法を提供することを課題とする。
本発明の他の態様に係る造形物の製造方法は、上記の一態様に係る粉末積層造形用粉末材料を用いて粉末積層造形法によって造形物を製造することを要旨とする。
粉末積層造形用粉末材料は、例えば、セラミック粒子、金属粒子等の粒子にバインダーを添加して造粒することにより製造される場合があるが、前述した予熱などの加熱によりバインダーから熱分解ガス、揮発ガス等のガスが発生する場合がある。例えば、バインダーが分解して二酸化炭素、有機成分ガス等の熱分解ガスが発生する場合がある。
さらに、熱処理による質量減少率は低い方がより好ましいので、0.015質量%以下であることがより好ましく、0.01質量%以下であることがさらに好ましい。
さらに、熱処理時の圧力は特に限定されるものではなく、常圧下で熱処理を行ってもよいし、減圧下で熱処理を行ってもよい。
エレクトロンビームメルティング法とは、3D CADデータから作成したスライスデータを基に、電子ビームを用いて上記粉末層を選択的に溶融・凝固させ、積層することで、3次元的な構造体を造形する技術である。
酸化物系セラミックとしては、例えば、以下に示す金属の酸化物が挙げられる。すなわち、金属としては、B、Si、Ge、Sb、Bi等の半金属元素、Mg、Ca、Sr、Ba、Zn、Al、Ga、In、Sn、Pb等の典型元素、Sc、Y、Ti、Zr、Hf、V、Nb、Ta、Cr、Mo、W、Mn、Fe、Co、Ni、Cu、Ag、Au等の遷移金属元素、La、Ce、Pr、Nd、Sm、Er、Lu等のランタノイド元素から選択される1種又は2種以上の金属が挙げられる。これらの金属の中でも、Mg、Y、Ti、Zr、Cr、Mn、Fe、Zn、Al、Erから選択される1種又は2種以上の金属が好ましい。
これらのセラミックは、いずれか1種を単独で使用してもよいし、2種以上を組み合わせて使用してもよい。また、これらのセラミックの中では、炭化タングステンが特に好ましい。
これらの金属は、いずれか1種を単独で使用してもよいし、2種以上を組み合わせて使用してもよい。また、これらの金属の中では、コバルトが特に好ましい。
本実施形態の粉末積層造形用粉末材料の製造方法は、1100℃、2.5時間との条件で熱処理した場合の質量減少率が0.02質量%以下であるならば、特に限定されるものではないが、粉末積層造形用粉末材料の製造工程中のいずれかの工程(例えば最終工程)に焼成工程を有する方法により、使用時に加熱されてもガスが発生しにくい粉末積層造形用粉末材料を製造することができる。
あるいは、本実施形態の粉末積層造形用粉末材料が焼結により製造される場合には、焼結工程において、熱分解ガス、揮発ガス等のガスを発生させ得る物質を除去可能な条件(加熱温度及び加熱時間)で焼結を行うことにより、使用時に加熱されてもガスが発生しにくい粉末積層造形用粉末材料を製造することができる。
本実施形態の粉末積層造形用粉末材料を用いて粉末積層造形法によって三次元的な造形物を製造する方法は、例えば、次のような方法がある。図1は粉末積層造形のための積層造形装置の一例の簡略図を示しており、大まかな構成として、積層造形が行われる空間である積層エリア10と、粉末材料を貯留しておくストック12と、積層エリア10への粉末材料の供給を補助するワイパ11と、粉末材料を固化するための固化手段(電子銃、レーザー発振器等)13と、を備えている。
以下に実施例及び比較例を示し、本発明をさらに具体的に説明する。
平均一次粒子径2μmの炭化タングステン粒子と平均一次粒子径2μmのコバルト粒子の焼結体からなる焼結粒子の集合体である実施例及び比較例の粉末(粉末積層造形用粉末材料)を製造した。一次粒子の平均粒子径はレーザー回折・散乱法により測定することができる。例えば、株式会社堀場製作所製のレーザー回折/散乱式粒子径分布測定装置LA−300を用いて測定することができる。
20・・・粉末材料層
21・・・粉末固化層
Claims (5)
- 粉末積層造形法によって造形物を製造するための粉末材料であって、複数の一次粒子が結合してなる二次粒子を含有し、1100℃、2.5時間との条件で熱処理した場合の質量減少率が0.02質量%以下である粉末積層造形用粉末材料。
- 前記二次粒子が、セラミック粒子と金属粒子の焼結体からなる焼結粒子である請求項1に記載の粉末積層造形用粉末材料。
- 前記セラミック粒子が炭化タングステン粒子である請求項2に記載の粉末積層造形用粉末材料。
- 前記金属粒子がコバルト粒子である請求項2又は請求項3に記載の粉末積層造形用粉末材料。
- 請求項1〜4のいずれか一項に記載の粉末積層造形用粉末材料を用いて粉末積層造形法によって造形物を製造する造形物の製造方法。
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