JP2020513214A - 付加製造用の超硬合金粉末 - Google Patents
付加製造用の超硬合金粉末 Download PDFInfo
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- JP2020513214A JP2020513214A JP2019542515A JP2019542515A JP2020513214A JP 2020513214 A JP2020513214 A JP 2020513214A JP 2019542515 A JP2019542515 A JP 2019542515A JP 2019542515 A JP2019542515 A JP 2019542515A JP 2020513214 A JP2020513214 A JP 2020513214A
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- JP
- Japan
- Prior art keywords
- cemented carbide
- sintered
- carbide particles
- powder composition
- sintered cemented
- 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
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- 239000000843 powder Substances 0.000 title claims abstract description 57
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 32
- 239000000654 additive Substances 0.000 title claims abstract description 27
- 230000000996 additive effect Effects 0.000 title claims abstract description 24
- 239000002245 particle Substances 0.000 claims abstract description 126
- 238000000034 method Methods 0.000 claims abstract description 52
- 239000000203 mixture Substances 0.000 claims abstract description 41
- 229910052751 metal Inorganic materials 0.000 claims description 40
- 239000002184 metal Substances 0.000 claims description 40
- 239000011230 binding agent Substances 0.000 claims description 28
- 150000001247 metal acetylides Chemical class 0.000 claims description 26
- 238000005245 sintering Methods 0.000 claims description 18
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 11
- 239000010941 cobalt Substances 0.000 claims description 6
- 229910017052 cobalt Inorganic materials 0.000 claims description 6
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical group [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 4
- 229910045601 alloy Inorganic materials 0.000 claims description 3
- 239000000956 alloy Substances 0.000 claims description 3
- 239000012530 fluid Substances 0.000 claims description 3
- 229910052742 iron Inorganic materials 0.000 claims description 2
- 229910052759 nickel Inorganic materials 0.000 claims description 2
- 238000013461 design Methods 0.000 description 8
- 238000010146 3D printing Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 238000001878 scanning electron micrograph Methods 0.000 description 5
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 4
- 238000009826 distribution Methods 0.000 description 4
- 239000012071 phase Substances 0.000 description 4
- 229920001223 polyethylene glycol Polymers 0.000 description 4
- 238000007655 standard test method Methods 0.000 description 4
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- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- 239000002202 Polyethylene glycol Substances 0.000 description 2
- 238000000280 densification Methods 0.000 description 2
- 238000001513 hot isostatic pressing Methods 0.000 description 2
- 239000003112 inhibitor Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
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- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 229920000151 polyglycol Polymers 0.000 description 2
- 239000010695 polyglycol Substances 0.000 description 2
- 229920000036 polyvinylpyrrolidone Polymers 0.000 description 2
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- 235000013855 polyvinylpyrrolidone Nutrition 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- INZDTEICWPZYJM-UHFFFAOYSA-N 1-(chloromethyl)-4-[4-(chloromethyl)phenyl]benzene Chemical compound C1=CC(CCl)=CC=C1C1=CC=C(CCl)C=C1 INZDTEICWPZYJM-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- 229910026551 ZrC Inorganic materials 0.000 description 1
- OTCHGXYCWNXDOA-UHFFFAOYSA-N [C].[Zr] Chemical compound [C].[Zr] OTCHGXYCWNXDOA-UHFFFAOYSA-N 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 239000012300 argon atmosphere Substances 0.000 description 1
- 230000002902 bimodal effect Effects 0.000 description 1
- UFGZSIPAQKLCGR-UHFFFAOYSA-N chromium carbide Chemical compound [Cr]#C[Cr]C#[Cr] UFGZSIPAQKLCGR-UHFFFAOYSA-N 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- WHJFNYXPKGDKBB-UHFFFAOYSA-N hafnium;methane Chemical compound C.[Hf] WHJFNYXPKGDKBB-UHFFFAOYSA-N 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- UNASZPQZIFZUSI-UHFFFAOYSA-N methylidyneniobium Chemical compound [Nb]#C UNASZPQZIFZUSI-UHFFFAOYSA-N 0.000 description 1
- NFFIWVVINABMKP-UHFFFAOYSA-N methylidynetantalum Chemical compound [Ta]#C NFFIWVVINABMKP-UHFFFAOYSA-N 0.000 description 1
- 238000009862 microstructural analysis Methods 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 239000010970 precious metal Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 229910052702 rhenium Inorganic materials 0.000 description 1
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 238000004626 scanning electron microscopy Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 239000012798 spherical particle Substances 0.000 description 1
- 238000010561 standard procedure Methods 0.000 description 1
- 229910003468 tantalcarbide Inorganic materials 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 229910003470 tongbaite Inorganic materials 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
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Abstract
Description
本出願は、特許協力条約第8条及び米国特許法第120条に基づく2017年2月20日に出願された米国特許出願第15/437,153号の優先権を主張するものであり、その全体は参照により本明細書に組み入れられる。
本明細書に記載される実施形態は、以下の詳細な説明及び実施例、並びにその前及び後の説明を参照することによって、より容易に理解され得る。しかしながら、本明細書に記載される要素、装置、及び方法は、詳細な説明及び実施例で提示される特定の実施形態に限定されない。これらの実施形態が本発明の原理の例示にすぎないことが認識されるべきである。本発明の趣旨及び範囲から逸脱することなく、多くの修正例及び適応例が当業者に容易に明らかとなるであろう。
焼結超硬合金粒子を含む粉末組成物を以下のように調製した。炭化タングステン(WC)粒子を粉末コバルトと共に粉砕して、83重量パーセントのWC及び17重量パーセントのコバルトを含むグレード組成物(WC−17Co)を製造した。粉砕に続いて、WC−17Coグレードを噴霧乾燥し、−53μm〜+10μmの分布にふるいにかけた。ふるい分けされたグレードの粉末を、1〜2時間、1150〜1200℃で固体状態で真空焼結(<10−3トール)し、軽焼結体を形成した。この成形体をインパクトミルで粉砕して焼結超硬合金粒子を得た。焼結した超硬合金粒子を部分的な液体状態で1280〜1350℃で1〜2時間真空中(<10−3トール)で再焼結し、多孔質焼結体を得た。この多孔質焼結体をボールミル粉砕した後、インパクトミリングして、6.5g/cm3の見かけ密度を有する焼結超硬合金粒子を得た。X線回折(X-ray diffraction、XRD)による分析により、焼結超硬合金粒子中にイータ相を含む非化学量論的炭化物が存在しないことを確認した。
実施例1の焼結超硬合金粉末(WC−17%Co)を、N.Huntingdon,PAのExOne製の3D印刷システムのチャンバに入れた。3D印刷システムは、ビルドボックス内でWC−17%Co粉末を繰り返し散布した後、破断バー(rupture bar)の設計に従ってポリグリコールエーテル溶媒を含むPVP−PEG結合剤を塗布することによって、層状プロセスでグリーン横方向破断バーを生成した。ExOne装置内で焼結超硬合金粒子を結合剤噴射することにより、合計15本のグリーン横方向破断バーを製造した。続いてグリーンバーを空気中で200℃で4時間硬化させた。グリーン横方向破断バーは、良好な強度及び取り扱い特性を呈した。例えば、グリーン横方向破断バーは、欠けたりフレーク状になったりせず、ASTM E9に従って少なくとも10MPaの圧縮強度を呈した。グリーン横方向破断バーは、1460〜1500℃で0.5〜1時間真空焼結/HIPされ、理論密度の99.3%に等しい13.7g/cm3に緻密化された。次に、15本の焼結横方向破断バーを寸法に合わせて研削し、ASTM B406に従って試験した。バーの平均横方向破断強度は、3044MPaであった。微細構造分析は、イータ相がなく、誇張された大きな粒子が存在しないことを明らかにした。図2は、本実施例の焼結横方向破断バーの微細構造のSEMである。図2に示すように、微細構造は、実質的に均一である。
炭化タングステン(WC)粒子を粉末コバルトと共に粉砕して、83重量パーセントのWC及び17重量パーセントのコバルトを含むグレード組成物(WC−17Co)を製造した。粉砕に続いて、WC−17Coグレードを噴霧乾燥し、−53μm〜+10μmの分布にふるいにかけた。ふるい分けされたグレードの粉末を、1〜2時間、1150〜1200℃で固体状態で真空焼結(<10−3トール)し、軽焼結体を形成した。この成形体をインパクトミルで粉砕して、4.5g/cm3の見かけ密度を有する焼結超硬合金粒子を得た。
Claims (33)
- 6g/cm3以上の見掛け密度を有する焼結超硬合金粒子を含む粒子成分、を含む粉末組成物。
- 前記焼結超硬合金粒子の見掛け密度は、7g/cm3〜11g/cm3である、請求項1に記載の粉末組成物。
- 前記焼結超硬合金粒子は、平均個別粒子密度が理論密度の80%以上である、請求項1に記載の粉末組成物。
- 前記焼結超硬合金粒子は、平均個別粒子密度が理論密度の90%以上である、請求項1に記載の粉末組成物。
- 前記焼結超硬合金粒子は、平均個別粒子密度がが理論密度の80〜95%である、請求項1に記載の粉末組成物。
- 前記焼結超硬合金粒子は、1μm〜100μmの平均粒径を有する、請求項1に記載の粉末組成物。
- 前記焼結超硬合金粒子は、球形又は実質的に球形である、請求項6に記載の粉末組成物。
- 前記焼結超硬合金粒子は、IVB族金属炭化物、VB族金属炭化物、及びVIB族金属炭化物からなる群から選択される1つ以上の金属炭化物を含む、請求項1に記載の粉末組成物。
- 前記焼結超硬合金粒子は、炭化タングステンを含む、請求項8に記載の粉末組成物。
- 前記焼結超硬合金粒子は、少なくとも1種のVB族金属炭化物を更に含む、請求項9に記載の粉末組成物。
- 前記焼結超硬合金粒子は、非化学量論的金属炭化物を含まない、請求項9に記載の粉末組成物。
- 前記非化学量論的金属炭化物は、イータ相を含む、請求項11に記載の粉末組成物。
- 前記焼結超硬合金粒子は、0.1〜35重量パーセントの量の金属結合剤を含む、請求項1に記載の粉末組成物。
- 前記金属結合剤は、コバルト、ニッケル、鉄、及びそれらの合金からなる群から選択される、請求項13に記載の粉末組成物。
- 6g/cm3以上の見掛け密度を有する焼結超硬合金粒子を含む粒子成分を含む粉末組成物を提供することと、
前記粉末組成物を1つ以上の付加製造技術によってグリーン物品に成形することと、
前記グリーン物品を焼結して焼結物品を提供することと、を含む、物品を製造する方法。 - 前記焼結物品は、理論密度の95%を超える、請求項15に記載の方法。
- 前記焼結物品は、理論密度の99%を超える、請求項15に記載の方法。
- 前記焼結物品は、完全密度(fully dense)を有する、請求項15に記載の方法。
- 前記グリーン物品は、前記粉末組成物に加えて有機結合剤を含む、請求項15に記載の方法。
- 前記グリーン物品は、10MPa以上の圧縮強度を有する、請求項15に記載の方法。
- 前記焼結物品は、2.5GPa以上の横方向破断強度を有する、請求項15に記載の方法。
- 前記焼結物品は、前記グリーン物品に対して1つ以上の寸法値において20%未満の収縮率を呈する、請求項15に記載の方法。
- 前記焼結超硬合金粒子の見掛け密度は、7g/cm3〜11g/cm3である、請求項15に記載の方法。
- 前記焼結超硬合金粒子は、平均個別粒子密度が理論密度の80%以上である、請求項15に記載の方法。
- 前記焼結超硬合金粒子は、IVB族金属炭化物、VB族金属炭化物、及びVIB族金属炭化物からなる群から選択される1種以上の金属炭化物を含む、請求項15に記載の方法。
- 前記焼結超硬合金粒子は、炭化タングステンを含む、請求項25に記載の方法。
- 前記焼結超硬合金粒子は、少なくとも1種のVB族金属炭化物を更に含む、請求項26に記載の方法。
- 前記焼結超硬合金粒子は、実質的に均一な微細構造を呈する、請求項26に記載の方法。
- 前記焼結超硬合金粒子は、0.1〜35重量パーセントの量の金属結合剤を含む、請求項15に記載の方法。
- 前記付加製造技術は、バインダージェッティングである、請求項15に記載の方法。
- 前記焼結物品は、油及びガス用途のためのフロー制御部品である、請求項15に記載の方法。
- 前記焼結物品は、油及びガス用途のためのポンプ部品である、請求項15に記載の方法。
- 前記焼結物品は、前記付加製造技術によって形成された1つ以上の内部流体流路を含む、請求項15に記載の方法。
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US15/437,153 US11065863B2 (en) | 2017-02-20 | 2017-02-20 | Cemented carbide powders for additive manufacturing |
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PCT/US2018/018553 WO2018152448A1 (en) | 2017-02-20 | 2018-02-17 | Cemented carbide powders for additive manufacturing |
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WO2018152448A1 (en) | 2018-08-23 |
AT521303B1 (de) | 2020-12-15 |
ES2732648A2 (es) | 2019-11-25 |
US11065863B2 (en) | 2021-07-20 |
KR20190111027A (ko) | 2019-10-01 |
KR102592186B1 (ko) | 2023-10-20 |
ES2732648R1 (es) | 2020-04-13 |
GB2573445B (en) | 2022-01-26 |
AT521303A2 (de) | 2019-12-15 |
KR20230150889A (ko) | 2023-10-31 |
CN110199043A (zh) | 2019-09-03 |
GB2573445A (en) | 2019-11-06 |
GB201909911D0 (en) | 2019-08-21 |
ES2732648B2 (es) | 2022-06-27 |
AT521303A5 (de) | 2020-12-15 |
DE112018000911T5 (de) | 2019-11-07 |
US20180236687A1 (en) | 2018-08-23 |
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