JP2021085063A - 三次元造形用合金粉末 - Google Patents
三次元造形用合金粉末 Download PDFInfo
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- 239000000843 powder Substances 0.000 title claims abstract description 87
- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 78
- 239000000956 alloy Substances 0.000 title claims abstract description 78
- 238000000465 moulding Methods 0.000 title abstract description 8
- 239000002245 particle Substances 0.000 claims abstract description 119
- 229910000640 Fe alloy Inorganic materials 0.000 claims abstract description 87
- 239000003575 carbonaceous material Substances 0.000 claims abstract description 56
- 239000011247 coating layer Substances 0.000 claims abstract description 33
- 125000004430 oxygen atom Chemical group O* 0.000 claims abstract description 10
- 238000010297 mechanical methods and process Methods 0.000 claims description 6
- 238000000034 method Methods 0.000 description 54
- 239000012298 atmosphere Substances 0.000 description 24
- 238000004519 manufacturing process Methods 0.000 description 22
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 19
- 239000011230 binding agent Substances 0.000 description 19
- 229910052799 carbon Inorganic materials 0.000 description 16
- 229910052751 metal Inorganic materials 0.000 description 13
- 239000002184 metal Substances 0.000 description 13
- 238000009692 water atomization Methods 0.000 description 13
- 238000010304 firing Methods 0.000 description 12
- 239000000463 material Substances 0.000 description 12
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 8
- 238000005238 degreasing Methods 0.000 description 8
- 238000002156 mixing Methods 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 6
- 239000012535 impurity Substances 0.000 description 6
- 229910052710 silicon Inorganic materials 0.000 description 6
- 239000010703 silicon Substances 0.000 description 6
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 5
- 229910002091 carbon monoxide Inorganic materials 0.000 description 5
- 239000011261 inert gas Substances 0.000 description 5
- 229910052814 silicon oxide Inorganic materials 0.000 description 5
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 229910052742 iron Inorganic materials 0.000 description 4
- 239000010410 layer Substances 0.000 description 4
- 229910052760 oxygen Inorganic materials 0.000 description 4
- 239000001301 oxygen Substances 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- 238000006722 reduction reaction Methods 0.000 description 4
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- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
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- 229910017061 Fe Co Inorganic materials 0.000 description 1
- 229910002060 Fe-Cr-Al alloy Inorganic materials 0.000 description 1
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- 229910001209 Low-carbon steel Inorganic materials 0.000 description 1
- 229910017709 Ni Co Inorganic materials 0.000 description 1
- 229910003267 Ni-Co Inorganic materials 0.000 description 1
- 229910003262 Ni‐Co Inorganic materials 0.000 description 1
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- 239000003522 acrylic cement Substances 0.000 description 1
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
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- 229910021529 ammonia Inorganic materials 0.000 description 1
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- 229910001566 austenite Inorganic materials 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 235000014121 butter Nutrition 0.000 description 1
- 150000001721 carbon Chemical group 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
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- 150000004706 metal oxides Chemical class 0.000 description 1
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
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- B33Y70/00—Materials specially adapted for additive manufacturing
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
- B22F1/054—Nanosized particles
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- B22F1/16—Metallic particles coated with a non-metal
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- 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
- B22F3/1003—Use of special medium during sintering, e.g. sintering aid
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- 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
- B22F3/115—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by spraying molten metal, i.e. spray sintering, spray casting
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- 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
- B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
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- B33Y70/00—Materials specially adapted for additive manufacturing
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- 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
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- 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
- B22F2009/0888—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 casting construction of the melt process, apparatus, intermediate reservoir, e.g. tundish, devices for temperature control
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- B22F2302/00—Metal Compound, non-Metallic compound or non-metal composition of the powder or its coating
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Abstract
Description
1.1.三次元造形用合金粉末
第1実施形態に係る三次元造形用合金粉末の構成について、図1を参照して説明する。なお、以下の各図においては、図示の便宜上、粒子の形状や各部材の尺度を実際とは異ならせている。
鉄合金粒子11は、鉄を含む合金であって、焼結性を有していれば特に限定されない。鉄合金粒子11の形成材料としては、例えば、オーステナイト系ステンレス鋼、マルテンサイト系ステンレス鋼、析出硬化系ステンレス鋼などのステンレス鋼、低炭素鋼、炭素鋼、耐熱鋼、ダイス鋼、高速度工具鋼、Fe−Ni合金、Fe−Ni−Co合金などが挙げられる。
炭素材料12は、鉄合金粒子11の表面に付着して被覆層13を形成する。炭素材料12の形成材料としては、例えば、グラファイト、カーボンブラック、活性炭、カーボンファイバー、カーボンナノチューブ、カーボンナノ粒子などが挙げられ、炭素材料12の形成材料として、これらのうちの1種類以上を用いる。炭素材料12には市販品を用いてもよい。鉄合金粒子11に対する被覆層13の形成方法、すなわち合金粉末1の製造方法は後述する。
合金粉末1の製造方法について、図2を参照して説明する。図2に示すように、本実施形態の合金粉末1の製造方法は、工程S1および工程S2を有している。なお、図2に示した工程フローは一例であって、これに限定されるものではない。
合金粉末1を用いた三次元造形物の製造方法には、上述した公知の方法が採用可能である。三次元造形物の製造方法は、例えば、三次元造形によって成形体を作製する成形工程、成形体に焼成処理を施して焼結体とする焼成工程、および焼結体の表面を研磨する研磨工程を有している。本実施形態では、三次元造形物の製造方法のうちの焼成工程について述べる。
2.1.三次元造形用合金粉末
第2実施形態に係る三次元造形用合金粉末の構成について、図3を参照して説明する。本実施形態の三次元造形用合金粉末は、第1実施形態の三次元造形用合金粉末1に対して、被覆層の形成方法を異ならせたものである。そのため、第1実施形態と同一の構成部位については、同一の符号を使用し、重複する説明は省略する。
合金粉末2の製造方法は、第1実施形態の図2と同様に工程S1および工程S2を有している。合金粉末2の製造方法のうち、工程S2に相当する被覆層23の形成方法について説明する。合金粉末2の製造方法のうち、工程S1に相当する鉄合金粒子11の作製は第1実施形態と同様にして行う。
Claims (5)
- 鉄合金粒子を含む三次元造形用合金粉末であって、
前記鉄合金粒子の表面には、炭素材料を含む被覆層が形成され、
前記鉄合金粒子は、前記鉄合金粒子の全量に対して0.1質量%以上0.7質量%以下の濃度の酸素原子を含み、
前記三次元造形用合金粉末の100グラムあたりに含まれる、前記炭素材料の質量yグラムは、前記酸素原子の質量xグラムと、補正質量zグラムとの間に式y=0.75×x−zの関係を有し、
前記補正質量zは、0.0グラムを超え、0.4グラムより小さいことを特徴とする三次元造形用合金粉末。 - 前記補正質量zは、0.00グラムを超え、0.05グラムより小さいことを特徴とする、請求項1に記載の三次元造形用合金粉末。
- 前記鉄合金粒子の平均粒子径は、0.1μm以上20.0μm以下であることを特徴とする請求項1または請求項2に記載の三次元造形用合金粉末。
- 前記被覆層は、前記炭素材料の粉末を機械的手法にて、前記鉄合金粒子の表面に固着させることにより形成されることを特徴とする、請求項1から請求項3のいずれか1項に記載の三次元造形用合金粉末。
- 前記炭素材料の粉末は、平均粒子径が3nm以上100nm以下であることを特徴とする、請求項1から請求項4のいずれか1項に記載の三次元造形用合金粉末。
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