JP2022501230A - 対向面の作製方法、および前記対向面を使用して複雑な形を有する部品の製造方法 - Google Patents
対向面の作製方法、および前記対向面を使用して複雑な形を有する部品の製造方法 Download PDFInfo
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- JP2022501230A JP2022501230A JP2021516738A JP2021516738A JP2022501230A JP 2022501230 A JP2022501230 A JP 2022501230A JP 2021516738 A JP2021516738 A JP 2021516738A JP 2021516738 A JP2021516738 A JP 2021516738A JP 2022501230 A JP2022501230 A JP 2022501230A
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Abstract
Description
・作製する対向面のプリントを形成し、残りの対向面が、部品製造のための成形型に適した形状面を有するよう、三次元アディティブプリントシステムの制御部により、作製部品の三次元原板をデジタル形成する。
・3Dアディティブプリント技術によって、対向面を作製する。対向面の大きさは、密度延伸倍率によって増加する。前記密度延伸倍率は、製造部品の焼結・高密度化中にかかる圧力の方向に沿った、製造部品(1;24d)の収縮を補うものである。
・焼結による、対向面(20;30a、30b)のアディティブプリントを完了させる。
・3Dアディティブプリント技術は、ステレオリソグラフィ、バインダジェット、制御押出成形、融合フィラメント加工、インクジェットプリント、そしてエアロゾルジェットプリントから選択され得る。
・対向面の作製に使用される多孔性材料は、セラミック、シリカ、金属珪酸塩、複合材から選択される。
・プリントは、5mm以下の厚さの壁を有する対向面に対して行われる。これにより、続く部品の焼結において、いかなる亀裂の発生も防ぐことができる。
・対向面は、後工程において、少なくとも二つの部位に分割される。前記二つの部位は、少なくとも一つのアンダーカットを排除するように、少なくとも一つの接合面に沿って接合される。複雑な形状を複数の部位に分割し、その部位の間の接合面は、成形型から直接取り出すことができる。
・加圧焼結を行う高密度化用成形型内に、対向面部を投入する。
・対向面部を通る、少なくとも一つのダクト内に、粉末状高密度化する材料を投入する。
・一軸圧力下で焼結することにより、高密度化対象の材料を高密度化する。
・部品を取り出すため、対向面部を分割する。これにより、部品が完成する。
・対向面の材料および製造部品の材料が、焼結時に同様の挙動を発揮するよう、対向面の材料を選択する。この挙動は、対向面の材料に対する従来の焼結と同様のものである。
・対向面のセラミックの、焼結開始時温度あるいは焼結終了時温度は、それぞれ、製造製品のセラミック以上、あるいはそれよりも高い。
・セラミックは、粉末状のYSZ(イットリア安定化ジルコニア)、ATZ(アルミナ強化ジルコニア)、ZTA(ジルコニア強化アルミナ)、40%〜80%の範囲の高密度化度合を発揮するアルミナから選択され得る。
・少なくとも一端が解放されているダクトが、対向面外側に設けられている。これにより、部品形成用の粉末状あるいは多孔性材料で対向面を満たし、余分な粉末を除去することができる。
・対向面のアディティブプリントは、対向面の焼結によってなされる。この焼結は、製造部品の焼結と同時に行われ得る。
Claims (18)
- 加圧焼結による高密度化によって、複雑な形を有する部品(1;24d)を製造するための対向面(20、30a、30b)を作製する方法であって、前記対向面(20;30a、30b)は、下記工程にしたがって、デジタル制御された三次元(3D)アディティブプリントにより作製された連続層からなり、
作製する前記対向面(20;30、30b)のプリントを形成し、前記対向面の残りが、前記部品(1;24d)を製造するための成形型に適した形状面を有するよう、三次元アディティブプリントシステムの制御部に、製造する前記部品(1;24d)の三次元原板(3)をデジタル記録する工程と、
3Dアディティブプリント技術によって、前記対向面(30a、30b)を作製する工程と、
焼結による、前記対向面(20;30a、30b)のアディティブプリントを完了される工程と、を含み、
前記対向面(20;30a、30b)の大きさは密度伸長倍率によって増加し、
前記密度延伸倍率は、加圧焼結によって製造する前記部品の高密度化をはかる際にかかる、一軸圧力(F)の方向に沿った、製造する前記部品(1;24d)の収縮を補うものである、ことを特徴とする、対向面を作製する方法。 - 前記3Dアディティブプリント技術は、ステレオリソグラフィ、バインダジェット、制御押出成形、融合フィラメント加工、インクジェットプリント、及び、エアロゾルジェットプリントから選択される、ことを特徴とする請求項1に記載の、対向面を作製する方法。
- 前記対向面(20;30a、30b)は、セラミック、シリカ、金属珪酸塩、及び、複合材から選択される多孔性材料よりなる、ことを特徴とする請求項1または2に記載の、対向面を作製する方法。
- 前記プリントは、5mm以下の厚さの壁を有する、前記対向面(20;30a、30b)に対して行われる、ことを特徴とする請求項1〜3のいずれか一項に記載の、対向面を作製する方法。
- 3Dアディティブプリント実行時、200℃〜600℃の温度、かつ、0.1℃/分〜1℃/分の温度上昇率で熱処理を行うことによって、前記対向面(30a、30b)からバインダを取り出す工程を実施する、ことを特徴とする請求項1〜4のいずれか一項に記載の、対向面(20、30a、30b)を作製する方法。
- 前記バインダを取り出す工程に続き、600℃〜1,500℃の温度で、前記対向面(3a、30b)を熱処理することで、予備焼結工程を実施する、ことを特徴とする請求項5に記載の、対向面を作製する方法。
- 前記対向面は、後工程において、少なくとも一つの接合面(P)に沿って接合される、少なくとも二つの部位(30a、30b)に分割され、これにより、少なくとも一つのアンダーカットが排除され、
前記複雑な形を分離する前記部位(30a、30b)間の前記接合面(P)により、前記複雑な形を成形型から直接取り出すことができる、ことを特徴とする請求項1〜6のいずれか一項に記載の、対向面を作製する方法。 - 請求項7に記載の方法により作製した対向面(20;30a、30b)を使用し、焼結により、複雑な形を有する部品(1;24d)を製造する方法であって、
一軸圧力下で焼結を行う高密度化用成形型に、前記対向面部(20、30a、30b)をあわせて投入する工程と、
対向面部(30a)を通る、少なくとも一つのダクト(4)内に、高密度化前の粉末状あるいは多孔性材料を投入する工程と、
一軸圧力(F)下で焼結することにより、前記粉末状あるいは多孔性材料を高密度化する工程と、
前記対向面部(30a、30b)を分離させ、前記部品(1;24d)を取り出し、製造を完成させる工程と、を含む、ことを特徴とする、複雑な形を有する部品を製造する方法。 - 前記対向面(20;30a、30b)は、前記対向面(20;30a、30b)の材料および製造する前記部品(1;24d)の材料が、焼結に対して同様の挙動を示すように選択された多孔性材料からなる、ことを特徴とする請求項1〜8のいずれか一項に記載の、複雑な形を有する部品を製造する方法。
- 前記対向面(20;30a、30b)をなすセラミックの焼結開始温度は、製造する前記部品(1;24d)の焼結開始温度以上、あるいは前記対向面(20;30a、30b)をなすセラミックの焼結終了温度は、製造する前記部品(1;24d)の焼結終了温度よりも高い、ことを特徴とする請求項8に記載の、複雑な形を有する部品を製造する方法。
- 前記セラミックは、YSZ、ATZ、ZTA、及び、40%〜80%の範囲の高密度化度合を発揮するアルミナ粉末から選択される、ことを特徴とする請求項10に記載の、複雑な形を有する部品を製造する方法。
- 少なくとも一旦が解放されているダクト(4)が前記対向面(20;30a、30b)の外側に設けられ、前記ダクト(4)は、前記部品(1;24d)をなす粉末状あるいは多孔性材料を投入する、ことを特徴とする請求項8〜11のいずれか一項に記載の、複雑な形を有する部品を製造する方法。
- 前記対向面(20;30a、30b)の焼結は、製造する前記部品(1;24d)の焼結と同時に行われる、ことを特徴とする請求項8〜12のいずれか一項に記載の、複雑な形を有する部品を製造する方法。
- 製造する前記部品(1;24d)の前記粉末状あるいは多孔性材料は、セラミック、金属合金、ポリマー、及び、複合材から選択される、ことを特徴とする請求項8〜13のいずれか一項に記載の、複雑な形を有する部品を製造する方法。
- 前記対向面部(30a、30b)の、一つあるいはそれ以上の外側壁が開口しており、セラミック粉末で満たされ、前記セラミック粉末の焼結温度は、前記対向面部(30a、30b)の前記セラミックの焼結温度と同じである、ことを特徴とする請求項14に記載の、複雑な形を有する部品を製造する方法。
- 多孔性あるいは粉末状材料からなる界面層(22;42)が、前記対向面(20;30a、30b)と高密度化する前の材料(24)との間に配置される、ことを特徴とする請求項8〜15のいずれか一項に記載の、複雑な形を有する部品を製造する方法。
- 前記界面層(22;42)は、グラファイト、酸化イットリウム、及び、窒化ホウ素から選択される材料からなる、少なくとも一層から形成される、ことを特徴とする請求項16に記載の、複雑な形を有する部品を製造する方法。
- 前記界面層(22;42)は、吹き付け、粉末積層、および適切な形状を有するシートから選択される形で付与される、ことを特徴とする請求項17に記載の、複雑な形を有する部品を製造する方法。
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