JP5330656B2 - 金属間化合物製の三次元製品の大量生産法 - Google Patents
金属間化合物製の三次元製品の大量生産法 Download PDFInfo
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- 229910000765 intermetallic Inorganic materials 0.000 title claims description 44
- 238000004519 manufacturing process Methods 0.000 title claims description 35
- 238000000034 method Methods 0.000 claims description 79
- 239000000843 powder Substances 0.000 claims description 65
- 238000002844 melting Methods 0.000 claims description 58
- 230000008018 melting Effects 0.000 claims description 58
- 238000010894 electron beam technology Methods 0.000 claims description 23
- 239000000203 mixture Substances 0.000 claims description 15
- 239000002245 particle Substances 0.000 claims description 13
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 10
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 10
- 239000011261 inert gas Substances 0.000 claims description 10
- 239000010936 titanium Substances 0.000 claims description 10
- 229910052719 titanium Inorganic materials 0.000 claims description 10
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- 238000013178 mathematical model Methods 0.000 claims description 8
- 239000000126 substance Substances 0.000 claims description 6
- 239000001307 helium Substances 0.000 claims description 4
- 229910052734 helium Inorganic materials 0.000 claims description 4
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 claims description 4
- 238000009689 gas atomisation Methods 0.000 claims description 3
- 238000005245 sintering Methods 0.000 claims description 3
- GNFTZDOKVXKIBK-UHFFFAOYSA-N 3-(2-methoxyethoxy)benzohydrazide Chemical compound COCCOC1=CC=CC(C(=O)NN)=C1 GNFTZDOKVXKIBK-UHFFFAOYSA-N 0.000 claims description 2
- 238000010438 heat treatment Methods 0.000 claims description 2
- 238000009751 slip forming Methods 0.000 claims description 2
- 239000010410 layer Substances 0.000 description 19
- 239000000463 material Substances 0.000 description 16
- 150000001875 compounds Chemical class 0.000 description 9
- 230000015572 biosynthetic process Effects 0.000 description 8
- 238000005755 formation reaction Methods 0.000 description 8
- 229910052751 metal Inorganic materials 0.000 description 8
- 239000007789 gas Substances 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- 238000003754 machining Methods 0.000 description 6
- 238000010309 melting process Methods 0.000 description 6
- 230000003647 oxidation Effects 0.000 description 6
- 238000007254 oxidation reaction Methods 0.000 description 6
- 229910045601 alloy Inorganic materials 0.000 description 5
- 239000000956 alloy Substances 0.000 description 5
- 238000001816 cooling Methods 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 4
- 230000008020 evaporation Effects 0.000 description 4
- 238000001704 evaporation Methods 0.000 description 4
- 239000013078 crystal Substances 0.000 description 3
- 229910001092 metal group alloy Inorganic materials 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229910010038 TiAl Inorganic materials 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 238000001465 metallisation Methods 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 241000894007 species Species 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 230000003746 surface roughness Effects 0.000 description 2
- OQPDWFJSZHWILH-UHFFFAOYSA-N [Al].[Al].[Al].[Ti] Chemical compound [Al].[Al].[Al].[Ti] OQPDWFJSZHWILH-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 229910021325 alpha 2-Ti3Al Inorganic materials 0.000 description 1
- UQZIWOQVLUASCR-UHFFFAOYSA-N alumane;titanium Chemical compound [AlH3].[Ti] UQZIWOQVLUASCR-UHFFFAOYSA-N 0.000 description 1
- 238000012512 characterization method Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000007730 finishing process Methods 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000004372 laser cladding Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 150000002736 metal compounds Chemical class 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000012768 molten material Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 239000012798 spherical particle Substances 0.000 description 1
- 230000000930 thermomechanical effect Effects 0.000 description 1
- 229910021324 titanium aluminide Inorganic materials 0.000 description 1
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- 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
- B23K15/00—Electron-beam welding or cutting
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- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/10—Auxiliary heating means
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- 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
- B23K15/00—Electron-beam welding or cutting
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- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/001—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass valves or valve housings
- B23P15/002—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass valves or valve housings poppet valves
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/02—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from one piece
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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
- C22C1/047—Making non-ferrous alloys by powder metallurgy comprising intermetallic compounds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B22F10/73—Recycling of powder
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- B22—CASTING; POWDER METALLURGY
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- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
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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
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- 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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/001—Turbines
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- 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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/006—Vehicles
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- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/10—Aluminium or alloys thereof
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- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/14—Titanium or alloys thereof
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- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
- B23K2103/52—Ceramics
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2220/00—Application
- F05B2220/40—Application in turbochargers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2230/00—Manufacture
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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
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- Y02P10/25—Process efficiency
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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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12014—All metal or with adjacent metals having metal particles
Description
G. Sauthoff, "Intermetallics(金属間化合物)", Weinheim, New Yark (1995);及び
H. Clemens, F. Appel, A. Baur, R. Gerling, V. Guther, H. Kestler, "エンジニアリングg-TiAl系合金の加工及び適用", Ti-2003 Science and Technology, Vo. IV, Wiley-VCH
"レーザーを使用する直接金属付着に関する実用的な検討及び可能性", G.K. Lewisら;
"レーザー成形チタン部材", D.H. Abbotら;
"レーザー成形を使用する粉末からのチタン航空宇宙産業用部材の製造", F.G. Arcellaら;及び
"直接レーザー製造TiAl合金部材のミクロ構造の加工パラメーターの最適化及び特徴付け", D. Srivastavaら
a)製品の三次元数学的モデルを作製し、これをコントロールユニットに保存する工程;
b)前記製品を構成する最終の金属間化合物と同じ化学組成を持つ粒径20〜150μmの金属間化合物の粉末を調製する工程;
c)溶融チャンバー内において前記粉末を敷設して、一定かつ実質的に均一な厚さを持つ粉末層を形成する工程;
d)前記溶融チャンバー内において敷設した前記粉末層を、少なくとも700℃で、かつ前記粉末の融点より低い温度に予熱する工程;
e)前記コントロールユニットに保存した三次元数学的モデルに従って、製品の断面部分に相当する区域において集束電子ビームにて高真空条件下で走査することによって溶融を行う工程;
f)前記工程c)〜e)により形成された前記製品の直近の断面部分の上面の高さ位置が、前記工程c)で形成した粉末層の厚さに相当する分だけ下がるように、前記製品の既に形成された部分及びその周囲に敷設された前記粉末の位置を下げる工程;
g)前記工程c)〜f)を、前記コントロールユニットに保存した三次元数学的モデルに従って、製品の最終の断面部分に達成するまで繰り返す工程;及び
h)前記工程g)で得られた前記製品の温度が1200℃以下に下がった後、前記溶融チャンバーに不活性ガスを供給することにより、前記製品を不活性ガス雰囲気中で冷却する最終工程
を包含することを特徴とする金属間化合物製の三次元製品の大量生産法に関する。
低圧ガスタービンブレードを製造するために、General Electric Aviation(米国)によって供給された仕様に従って、金属間化合物γTiAl 48Al-2Cr-2Nbの粉末を調製した。使用する金属間化合物は、融点約1550℃を有する。
この粉末を、EBM装置A2(ARCAM AB(スウェーデン)製)の溶融チャンバー内に配置したディストリビューターに入れた。
集束電子ビームのみを使用し、粉末が温度約900℃となるまで、予熱工程を行った。
使用した数学的モデルは、タービンブレード30個(すべてが、幾何学的形状及び寸法について同じ特性を持つ)の同時生産用に構成されている。
高真空下で行われる製造法は、製造完了に計約30時間及びヘリウム雰囲気中での冷却を必要とする。
ついで、ブレード30個を分離し、約0.2mmの表面層(取り代)を除去するためにブレードを表面仕上げ加工操作に供する前に、支持部分(図3における羽根車についての例によって示されるもの)を除去する。本発明による方法を使用する場合、γTiAl金属間化合物製のガスタービン用ブレードの大量生産のコストが、従来技術の方法を使用する場合の大量生産のコストと比べて、約4倍低減されることが予測される。
2 層
10 タービンブレード
11 固定脚
12 ベースフランジ
13 翼
20 可動性支持表面
30 ディストリビューター
40 集束電子ビーム発生装置
50 羽根車
55 支持部分
56 スロット
Claims (14)
- 電子ビーム溶融によって、チタン及びアルミニウムを基材とする金属間化合物製の三次元製品を大量生産する方法であって、
a)前記製品の三次元数学的モデルを作製し、これをコントロールユニットに保存する工程;
b)前記製品を構成する最終の金属間化合物と同じ化学組成を持つ粒径20〜150μmの金属間化合物の粉末を調製する工程;
c)溶融チャンバー内において、前記粉末を敷設して、一定かつ実質的に均一な厚さを持つ粉末層を形成する工程;
d)前記溶融チャンバー内において、敷設した前記粉末層を、少なくとも700℃で、かつ前記粉末の融点より低い温度に予熱する工程;
e)前記コントロールユニットに保存した三次元数学的モデルに従って、前記製品の断面部分に相当する区域において集束電子ビームにて高真空条件下で走査することによって溶融を行う工程;
f)前記工程c)〜e)により形成された前記製品の直近の断面部分の上面の高さ位置が、前記工程c)で形成した粉末層の厚さに相当する分だけ下がるように、前記製品の既に形成された部分及びその周囲に敷設された前記粉末の位置を下げる工程;
g)前記工程c)〜f)を、前記コントロールユニットに保存した三次元数学的モデルに従って、前記製品の最終の断面部分に達成するまで繰り返す工程;及び
h)前記工程g)で得られた前記製品の温度が1200℃以下に下がった後、前記溶融チャンバーに不活性ガスを供給することにより、前記製品を不活性ガス雰囲気中で冷却する最終工程
を包含することを特徴とする金属間化合物製の三次元製品の大量生産法。 - 前記粉末及び製品がγTiAl金属間化合物製である請求項1に記載の方法。
- 前記不活性ガスがヘリウム又はその混合物である請求項1又は2に記載の方法。
- 前記予熱工程d)を、完全に又は部分的に、集束電子ビームにて走査することによって行う請求項1〜3のいずれか1項に記載の方法。
- 前記予熱工程d)を、完全に又は部分的に、電気抵抗を使用して溶融チャンバーを加熱することによって行う請求項1〜3のいずれか1項に記載の方法。
- 前記予熱工程d)を、充分に高い温度で行って、少なくとも製品の各断面部分の区域において、前記粉末の弱い焼結を生じさせる請求項1〜5のいずれか1項に記載の方法。
- 前記工程e)を、下方の断面部分の溶融工程を行った際の走査経路に対して60〜90°の角度で交差する走査経路に沿って集束エネルギービームを移動させることによって行う請求項1〜6のいずれか1項に記載の方法。
- 前記溶融工程e)が、初めに、製品の断面部分に相当する区域の周囲に沿って集束電子ビームにて溶融することを含むものである請求項1〜7のいずれか1項に記載の方法。
- 前記工程e)における集束電子ビームでの溶融を、少なくとも、溶融チャンバーを高真空条件に維持して行う請求項1〜8のいずれか1項に記載の方法。
- 前記工程c)〜f)の各繰返しの間に、連続して形成される電面部分を支持するために、1以上の部分を形成する請求項1〜9のいずれか1項に記載の方法。
- 製品が形成された後、1以上の支持部分を除去する請求項10に記載の方法。
- 前記工程b)で調製する粉末の粒径が約70μmである請求項1〜11のいずれか1項に記載の方法。
- 前記工程b)で調製する粉末がガスアトマイゼーション法によって得られたものである請求項1〜12のいずれか1項に記載の方法。
- 前記工程c)〜f)の各繰返しサイクル時、厚さ20〜150μmを持つ製品の断面部分を形成する請求項1〜13のいずれか1項に記載の方法。
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