JP6861728B2 - サーメット又は超硬合金の三次元印刷 - Google Patents
サーメット又は超硬合金の三次元印刷 Download PDFInfo
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- JP6861728B2 JP6861728B2 JP2018554115A JP2018554115A JP6861728B2 JP 6861728 B2 JP6861728 B2 JP 6861728B2 JP 2018554115 A JP2018554115 A JP 2018554115A JP 2018554115 A JP2018554115 A JP 2018554115A JP 6861728 B2 JP6861728 B2 JP 6861728B2
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- 239000011195 cermet Substances 0.000 title claims description 53
- 238000010146 3D printing Methods 0.000 title claims description 23
- 239000000843 powder Substances 0.000 claims description 69
- 239000002245 particle Substances 0.000 claims description 66
- 238000005245 sintering Methods 0.000 claims description 43
- 238000000034 method Methods 0.000 claims description 37
- 239000011230 binding agent Substances 0.000 claims description 36
- 229910052751 metal Inorganic materials 0.000 claims description 35
- 239000002184 metal Substances 0.000 claims description 35
- 238000007639 printing Methods 0.000 claims description 24
- 238000005520 cutting process Methods 0.000 claims description 16
- 239000002994 raw material Substances 0.000 claims description 9
- 238000009826 distribution Methods 0.000 claims description 8
- 239000011148 porous material Substances 0.000 claims description 8
- 238000000227 grinding Methods 0.000 claims description 4
- 238000005065 mining Methods 0.000 claims description 3
- 238000001694 spray drying Methods 0.000 claims description 3
- 239000012298 atmosphere Substances 0.000 claims description 2
- 238000002156 mixing Methods 0.000 claims description 2
- 241000430525 Aurinia saxatilis Species 0.000 claims 1
- 239000002923 metal particle Substances 0.000 claims 1
- 229940098458 powder spray Drugs 0.000 claims 1
- 238000007873 sieving Methods 0.000 claims 1
- 239000012071 phase Substances 0.000 description 45
- 239000000463 material Substances 0.000 description 7
- 239000008187 granular material Substances 0.000 description 6
- 150000001247 metal acetylides Chemical class 0.000 description 6
- 229910052804 chromium Inorganic materials 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 239000010419 fine particle Substances 0.000 description 5
- 238000000177 wavelength dispersive X-ray spectroscopy Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 4
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 238000002149 energy-dispersive X-ray emission spectroscopy Methods 0.000 description 3
- 229910052750 molybdenum Inorganic materials 0.000 description 3
- 229910052759 nickel Inorganic materials 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 229910017052 cobalt Inorganic materials 0.000 description 2
- 239000010941 cobalt Substances 0.000 description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 2
- 229910000428 cobalt oxide Inorganic materials 0.000 description 2
- IVMYJDGYRUAWML-UHFFFAOYSA-N cobalt(ii) oxide Chemical compound [Co]=O IVMYJDGYRUAWML-UHFFFAOYSA-N 0.000 description 2
- 229910052735 hafnium Inorganic materials 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 229910052758 niobium Inorganic materials 0.000 description 2
- 238000012856 packing Methods 0.000 description 2
- 230000000737 periodic effect Effects 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 229910052715 tantalum Inorganic materials 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- 229910052720 vanadium Inorganic materials 0.000 description 2
- 229920001342 Bakelite® Polymers 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 239000012300 argon atmosphere Substances 0.000 description 1
- 239000004637 bakelite Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000004590 computer program Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000005115 demineralization Methods 0.000 description 1
- 230000002328 demineralizing effect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 238000010191 image analysis Methods 0.000 description 1
- 238000001095 inductively coupled plasma mass spectrometry Methods 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 238000003921 particle size analysis Methods 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 238000004846 x-ray emission Methods 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
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- 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
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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
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/06—Metallic powder characterised by the shape of the particles
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/105—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing inorganic lubricating or binding agents, e.g. metal salts
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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
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- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
- B23B27/14—Cutting tools of which the bits or tips or cutting inserts are of special material
- B23B27/148—Composition of the cutting inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C5/00—Milling-cutters
- B23C5/16—Milling-cutters characterised by physical features other than shape
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/008—Abrasive bodies without external bonding agent
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- B33Y10/00—Processes of additive manufacturing
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- 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
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B33Y70/00—Materials specially adapted for additive manufacturing
- B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B33Y80/00—Products made by additive manufacturing
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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
- C22C1/05—Mixtures of metal powder with non-metallic powder
- C22C1/051—Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
- E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21C—MINING OR QUARRYING
- E21C35/00—Details of, or accessories for, machines for slitting or completely freeing the mineral from the seam, not provided for in groups E21C25/00 - E21C33/00, E21C37/00 or E21C39/00
- E21C35/18—Mining picks; Holders therefor
- E21C35/183—Mining picks; Holders therefor with inserts or layers of wear-resisting material
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21C—MINING OR QUARRYING
- E21C35/00—Details of, or accessories for, machines for slitting or completely freeing the mineral from the seam, not provided for in groups E21C25/00 - E21C33/00, E21C37/00 or E21C39/00
- E21C35/18—Mining picks; Holders therefor
- E21C35/183—Mining picks; Holders therefor with inserts or layers of wear-resisting material
- E21C35/1835—Chemical composition or specific material
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- B22F10/60—Treatment of workpieces or articles after build-up
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- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F2207/00—Aspects of the compositions, gradients
- B22F2207/01—Composition gradients
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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
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Description
− サーメット又は超硬合金原料粉末と有機バインダー、例えばPEGを混合する工程、
− 前記原料粉末を噴霧乾燥することにより、粒状原料粉末を形成する工程、
− 前記噴霧乾燥させた原料粉末を予備焼結して有機バインダーを除去することにより、直径20μm以上のサーメット及び/又は超硬合金粒子の平均気孔率が10−40vol%、好ましくは15−30vol%、より好ましくは20−25vol%である予備焼結された粒状粉末を形成する工程、
− 前記予備焼結された粒状粉末を粒子の20−70vol%、好ましくは45−65vol%が直径10μm未満となるまで粉砕することにより、粉末を形成する工程、
− 前記粉末を印刷バインダーと共に用いて物体を3D印刷することにより、3D印刷されたサーメット又は超硬合金グリーン体を形成する工程、
− 前記グリーン体を焼結することにより、3D印刷されたサーメット又は超硬合金物体を形成する工程
を含む、方法に関する。
− 3D印刷された物体を不活性雰囲気中150−230℃で硬化させる工程、及び
− 3D印刷された物体を脱粉して物体の表面から結合していない粒子を除去する工程を更に含む。
「サーメット」という用語は、本明細書において、金属結合相中に硬質成分を含む材料を意味することを意図しており、硬質成分は、Ta、Ti、Nb、Cr、Hf、V、Mo及びZrのうちの一又は複数の炭化物又は炭窒化物、例えばTiN、TiC及び/又はTiCNを含む。
Claims (13)
- 超硬合金又はサーメット物体の三次元印刷用の粉末であって、前記粉末は、D90が15−35μmの超硬合金及び/又はサーメット粒子からなり、前記サーメット及び/又は超硬合金粒子が金属結合相を含み、直径20μm以上のサーメット及び/又は超硬合金粒子の平均気孔率が10−40vol%であり、粒子の30−70vol%が直径10μm未満である、粉末。
- 超硬合金及び/又はサーメット粒子のD50が5−20μmである、請求項1に記載の粉末。
- 超硬合金及び/又はサーメット粒子のD10が1−5μmである、請求項1又は2に記載の粉末。
- 粉末における超硬合金及び/又はサーメット粒子の粒度分布が単峰性である、請求項1から3の何れか一項に記載の粉末。
- 粉末における金属結合相の平均含有量が8−14wt%である、請求項1から4の何れか一項に記載の粉末。
- 前記金属結合相がCoを含む、請求項1から5の何れか一項に記載の粉末。
- 3D印刷されたサーメット又は超硬合金物体を製造する方法であって、
− サーメット又は超硬合金粉末と有機バインダーを混合する工程、
− 前記粉末を噴霧乾燥することにより、粒状原料粉末を形成する工程、
− 前記噴霧乾燥させた原料粉末を予備焼結して前記有機バインダーを除去することにより、直径20μm以上のサーメット及び/又は超硬合金粒子の平均気孔率が10−40vol%である、予備焼結された粒状粉末の脆弱なケーキを形成する工程、
− 前記予備焼結された粒状粉末の脆弱なケーキを粒子の30−70vol%が直径10μm未満となるまで粉砕することにより、粉末を形成する工程、
− 前記粉末を印刷バインダーと共に用いて物体を3D印刷することにより、3D印刷されたサーメット又は超硬合金グリーン体を形成する工程、
− 前記グリーン体を焼結することにより、3D印刷されたサーメット又は超硬合金物体を形成する工程
を含む、方法。 - 3D印刷する工程の後であって焼結する工程の前に、
− 3D印刷された物体を不活性雰囲気中150−230℃で硬化させる工程、及び
− 3D印刷された物体を脱粉して物体の表面から結合していない粒子を除去する工程を更に含む、請求項7に記載の方法。 - 焼結する工程が、印刷バインダーを燃焼除去する脱バインダー工程を含む、請求項7又は8に記載の方法。
- 予備焼結する工程の前に、噴霧乾燥させた粉末を篩い分けし、直径42μmを超える粒子を除去する、請求項7から9の何れか一項に記載の方法。
- 焼結する工程に続いて又は組み入れて、サーメット又は超硬合金物体を焼結HIPする工程を更に含む、請求項7から10の何れか一項に記載の方法。
- 三次元印刷がバインダージェッティングである、請求項7から11の何れか一項に記載の方法。
- 物体が金属切削用の切削工具、又は鉱業用途用の切削工具、又は摩耗部品である、請求項7から12の何れか一項に記載の方法。
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