US20170182557A1 - Metal powder, method of producing additively-manufactured article, and additively-manufactured article - Google Patents

Metal powder, method of producing additively-manufactured article, and additively-manufactured article Download PDF

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Publication number
US20170182557A1
US20170182557A1 US15/379,621 US201615379621A US2017182557A1 US 20170182557 A1 US20170182557 A1 US 20170182557A1 US 201615379621 A US201615379621 A US 201615379621A US 2017182557 A1 US2017182557 A1 US 2017182557A1
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United States
Prior art keywords
additively
manufactured article
powder
metal powder
mass
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Abandoned
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US15/379,621
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English (en)
Inventor
Ryusuke Tsubota
Junichi Tanaka
Yohei Oka
Akira Okamoto
Masato Kikukawa
Hiroaki OKUBO
Yoshito Nishizawa
Takeshi Maruyama
Motonori Nishida
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Fukuda Metal Foil and Powder Co Ltd
Daihen Corp
Original Assignee
Fukuda Metal Foil and Powder Co Ltd
Daihen Corp
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Application filed by Fukuda Metal Foil and Powder Co Ltd, Daihen Corp filed Critical Fukuda Metal Foil and Powder Co Ltd
Assigned to DAIHEN CORPORATION, FUKUDA METAL FOIL & POWDER CO., LTD. reassignment DAIHEN CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KIKUKAWA, MASATO, MARUYAMA, TAKESHI, NISHIDA, MOTONORI, NISHIZAWA, YOSHITO, OKUBO, HIROAKI, OKA, YOHEI, OKAMOTO, AKIRA, TANAKA, JUNICHI, TSUBOTA, RYUSUKE
Publication of US20170182557A1 publication Critical patent/US20170182557A1/en
Priority to US16/268,691 priority Critical patent/US11185924B2/en
Priority to US16/268,797 priority patent/US10967431B2/en
Abandoned legal-status Critical Current

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    • B22F3/1055—
    • 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
    • C22C1/0425—Copper-based alloys
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/0003—
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/09—Mixtures of metallic powders
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • 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
    • 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
    • B22F3/24—After-treatment of workpieces or articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • 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
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • 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
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C9/00—Alloys based on copper
    • C22C9/01—Alloys based on copper with aluminium as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/08—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of copper or alloys based thereon
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/64—Treatment of workpieces or articles after build-up by thermal means
    • 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
    • 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
    • B22F12/40—Radiation means
    • B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
    • 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
    • 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
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/248—Thermal after-treatment
    • 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
    • B22F2301/00—Metallic composition of the powder or its coating
    • B22F2301/05—Light metals
    • B22F2301/052—Aluminium
    • 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
    • B22F2301/00—Metallic composition of the powder or its coating
    • B22F2301/10—Copper
    • 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
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • 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
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present invention relates to a metal powder, a method of producing an additively-manufactured article, and an additively-manufactured article.
  • Japanese Patent Laying-Open No. 2011-021218 discloses a laser additive-manufacturing apparatus (so-called “3D printer”) for metal powder.
  • the additive manufacturing method for metal powder is of interest as a processing technology for metal products.
  • An advantage of this method is that complicated shapes which have been impossible by cutting work can be produced. Examples of additively-manufactured articles produced from iron-based alloy powder, aluminum alloy powder, titanium alloy powder, and the like have heretofore been reported.
  • the kinds of metals available for additive manufacturing are limited, and there is a certain restriction on metal products to which additive manufacturing is applicable.
  • An object of the present invention is to provide a metal powder for additive manufacturing, made up of a copper alloy and enabling both an adequate mechanical strength and an adequate electrical conductivity to be achieved, provide a method of producing an additively-manufactured article, and provide an additively manufactured article.
  • the metal powder is a metal powder for additive manufacturing.
  • the metal powder contains: not less than 0.2 mass % and not more than 1.3 mass % of aluminum; and a balance including copper and an incidental impurity.
  • the method of producing an additively-manufactured article includes: a first step of forming a powder layer including a metal powder of the above [ 1 ]; and a second step of forming a shaped layer by solidifying the metal powder at a predetermined position in the powder layer.
  • the first step and the second step of this production method are successively repeated to stack the shaped layers and produce an additively-manufactured article.
  • the method of producing an additively-manufactured article of the above [2] may further include a heat treatment step of heat-treating the additively-manufactured article.
  • the additively-manufactured article is an additively-manufactured article made from a copper alloy.
  • the copper alloy contains: not less than 0.2 mass % and not more than 1.3 mass % of aluminum; and a balance including copper and an incidental impurity.
  • the additively-manufactured article has a relative density of not less than 96% and not more than 100% with respect to a theoretical density of the copper alloy, and has an electrical conductivity of not less than 30% IACS.
  • the electrical conductivity may be not less than 50% IACS.
  • FIG. 1 is a flowchart generally showing a method of producing an additively-manufactured article according to an embodiment of the present invention.
  • FIG. 2 is a schematic diagram showing an example of STL data.
  • FIG. 3 is a schematic diagram showing an example of slice data.
  • FIG. 4 is a first schematic diagram illustrating a process of producing an additively-manufactured article.
  • FIG. 5 is a second schematic diagram illustrating the process of producing an additively-manufactured article.
  • FIG. 6 is a third schematic diagram illustrating the process of producing an additively-manufactured article.
  • FIG. 7 is a fourth schematic diagram illustrating the process of producing an additively-manufactured article.
  • FIG. 8 is a plan view showing a test specimen used for a tensile test.
  • an additively-manufactured article made from a copper alloy and having both an adequate mechanical strength and an adequate electrical conductivity is provided.
  • the present embodiment an embodiment of the present invention (hereinafter referred to as “the present embodiment”) will be described.
  • the present invention is not limited thereto.
  • the inventors atomized an ingot of pure copper to thereby obtain a copper powder, and tried to produce an additively-manufactured article from this copper powder.
  • a desired additively-manufactured article could not be obtained by this method.
  • the produced article had many voids and the density of the article was significantly decreased relative to that of the original ingot.
  • the electrical conductivity of the article was also significantly decreased relative to that of the original ingot. The decrease of the density is considered as inevitably resulting in decrease of the mechanical strength.
  • the inventors then studied copper alloys. As a result, the inventors found that a copper alloy powder having a specific alloy composition could be used to produce an additively-manufactured article having both an adequate mechanical strength and an adequate electrical conductivity.
  • the tensile strength is approximately equal to or more than 130 MPa. This tensile strength is almost close to the value of the tensile strength of an ingot of oxygen-free copper (JIS alloy No.: C1020) as pure copper. Therefore, the additively-manufactured article is expected to be applicable to various uses. Preferably, the tensile strength is approximately equal to or more than 195 MPa. This tensile strength is equivalent to or more than the tensile strength of an ingot of oxygen-free copper.
  • the tensile strength is measured through the following procedure.
  • a tension testing machine of Grade one or more under “JIS B 7721: Tension/compression testing machines—verification and calibration of the force-measuring system” is used.
  • a dumbbell-shaped test specimen 20 is manufactured as an additively-manufactured article to be tested. As shown in FIG.
  • dumbbell-shaped test specimen 20 has a shape like a dumbbell made up of a columnar parallel portion 21 , tapered shoulder portions 23 expanding gradually from respective opposite ends of this parallel portion 21 , and columnar grip portions 22 extending from shoulder portions 23 to serve as a grip device of the tensile testing machine or serve as a part to be gripped by a jig.
  • dumbbell-shaped test specimen 20 is tensioned at a rate of 2 mm/min by using the tension testing machine until the test specimen is broken.
  • a gripping tool or jig any tool appropriate for the shape of dumbbell-shaped test specimen 20 is used. Adjustments are further made so that a force is applied in the axial direction of dumbbell-shaped test specimen 20 .
  • the maximum tensile stress detected before the test specimen is broken is measured.
  • the maximum tensile stress is divided by the cross-sectional area of parallel portion 21 to thereby calculate the tensile stress.
  • the dimensions of respective parts of dumbbell-shaped test specimen 20 shown in FIG. 8 are as follows.
  • diameter D 2 of grip portion 22 6.0 mm
  • the theoretical density of an alloy is herein represented by the density of a cast material having the same composition as the alloy.
  • the relative density with respect to the theoretical density is represented by a value in percentage determined by dividing the actually measured density of the additively-manufactured article by the theoretical density of the alloy. Therefore, the upper limit of the relative density is 100%.
  • the electrical conductivity is 30% IACS (International Annealed Copper Standard) or more defined with respect to the electrical conductivity 100% IACS of an annealed copper standard.
  • the electrical conductivity may preferably be not less than 50% IACS.
  • the metal powder of the present embodiment is a metal powder for additive manufacturing.
  • the metal powder corresponds to toner/ink for a common two-dimensional printer.
  • the metal powder contains: not less than 0.2 mass % and not more than 1.3 mass % of aluminum (Al); and a balance including copper (Cu) and an incidental impurity.
  • the Cu content in the metal powder may for example be not less than 98.7 mass % or not more than 99.8 mass %.
  • the Cu content in the metal powder can be measured by a method complying with “JIS H 1051: Methods for determination of copper in copper and copper alloys.”
  • the Al content can be measured by an ICP emission spectrometry complying with “JIS H 1057: Methods for determination of aluminum in copper and copper alloys.”
  • the upper limit of the Al content in the metal powder may be 1.3 mass %.
  • the lower limit of the Al content may be 0.23 mass %.
  • the metal powder may contain an impurity element(s) besides Al.
  • the impurity element is an element (incidental impurity) incidentally mixed during production.
  • the balance includes Cu and an incidental impurity (impurities).
  • the impurity element may be oxygen (O), phosphorus (P), and the like.
  • the content of the impurity element(s) may for example be less than 0.1 mass %, or less than 0.05 mass %.
  • the metal powder of the present embodiment includes for example an aluminum-containing copper alloy powder as described below.
  • the aluminum-containing copper alloy powder includes: not less than 0.2 mass % and not more than 1.3 mass % of Al; and a balance including Cu and an incidental impurity.
  • the copper alloy powder having such a chemical composition enables the additively-manufactured article to have both an adequate mechanical strength and an adequate electrical conductivity. If the Al content is less than 0.2 mass %, this copper alloy powder's properties are close to those of pure copper (oxygen-free copper). Namely, if this copper alloy powder is used to produce an additively-manufactured article, the additively-manufactured article has many voids, and accordingly has a significantly lower density relative to an ingot of oxygen-free copper and a significantly lower electrical conductivity relative to an ingot of oxygen-free copper. If the Al content is more than 1.3 mass %, there is a possibility that an electrical conductivity of not less than 30% IACS cannot be ensured.
  • the Al content may for example be not less than 0.23 mass % and not more than 1.3 mass %. When the Al content falls in this range, the mechanical strength and the electrical conductivity may be well balanced.
  • the particle-size distribution of the metal powder is appropriately adjusted based on conditions for producing the powder, sizing, sieving, or the like.
  • the average particle size of the metal powder may be adjusted in accordance with the pitch at which layers are stacked to produce an additively-manufactured article.
  • the average particle size of the metal powder may for example be approximately 100 to 200 ⁇ m, approximately 50 to 100 ⁇ m, or approximately 5 to 50
  • the average particle size herein refers to a particle size at a cumulative value of 50% (so-called “d50”) in a particle-size distribution measured by the laser diffraction/scattering method.
  • the particle shape of the metal powder is not particularly limited.
  • the particle shape may be a substantially spherical shape or an irregular shape.
  • the metal powder of the present embodiment is produced for example by a gas atomization method or a water atomization method. Namely, while alloy components in the molten state are dropped from the bottom of a tundish, the alloy components are allowed to contact high-pressure gas or high-pressure water, and the alloy components are rapidly cooled to be solidified. In this way, the alloy components are formed into particles.
  • plasma atomization method, centrifugal atomization method, or the like may for example be used to produce the metal powder.
  • the metal powder obtained through these production methods tends to enable a dense additively-manufactured article to be obtained.
  • a method of producing an additively-manufactured article from the above-described metal powder will be described.
  • a description will be given of a powder bed fusion method using a laser as means for solidifying the metal powder.
  • This means is not limited to the laser as long as the means can solidify the metal powder.
  • the means may for example be electron beam, plasma, or the like.
  • an additive manufacturing (AM) method other than the powder bed fusion method may be used.
  • the directed energy deposition method may also be used.
  • cutting may be performed during additive manufacturing.
  • FIG. 1 is a flowchart generally showing a method of producing an additively-manufactured article of the present embodiment.
  • This production method includes a data processing step (S 10 ) and an additive manufacturing step (S 20 ).
  • the production method may also include a heat treatment step (S 30 ) after the additive manufacturing step (S 20 ).
  • the additive manufacturing step (S 20 ) includes a first step (S 21 ) and a second step (S 22 ). According to this production method, the first step (S 21 ) and the second step (S 22 ) are successively repeated to thereby produce an additively-manufactured article.
  • the production method will be described hereinafter with reference to FIGS. 1 to 7 .
  • FIG. 2 is a schematic diagram showing an example of STL data.
  • STL data 10 d division into elements (meshing) is done by the finite-element method, for example.
  • FIG. 3 is a schematic diagram showing an example of slice data.
  • the STL data is divided into n layers, namely a first shaped layer p 1 to an n-th shaped layer pn.
  • the slice thickness d is approximately 10 to 150 ⁇ m for example.
  • the slice thickness d may be approximately 10 to 50 ⁇ m for example.
  • FIG. 4 is a first schematic diagram illustrating a process of producing an additively-manufactured article.
  • a laser additive-manufacturing apparatus 100 shown in FIG. 4 includes a piston 101 , a table 102 supported on piston 101 , and a laser emission unit 103 which is to serve as an emission unit of a laser beam solidifying metal powder.
  • This step and subsequent steps are carried out in an inert gas atmosphere for example for suppressing oxidation of the additively-manufactured article.
  • the inert gas may for example be argon (Ar), nitrogen (N 2 ), helium (He), or the like.
  • a reducing gas such as hydrogen (H 2 ) for example may be used.
  • a vacuum pump or the like may be used to produce a reduced-pressure atmosphere.
  • Piston 101 is configured to be capable of lifting and lowering table 102 . On table 102 , the additively-manufactured article is produced.
  • a powder layer including the metal powder is formed. Based on the slice data, piston 101 lowers table 102 by a distance corresponding to one layer. On table 102 , the metal powder corresponding to one layer is spread. In this way, a first powder layer 1 including the metal powder is formed. The surface of first powder layer 1 is smoothed by means of a squeezing blade or the like (not shown).
  • the powder layer may also include a laser absorber (resin powder for example) or the like, in addition to the metal powder.
  • the powder layer may be substantially made up of only the metal powder.
  • FIG. 5 is a second schematic diagram illustrating the process of producing an additively-manufactured article.
  • a shaped layer which is to form a part of the additively-manufactured article is formed.
  • Laser emission unit 103 applies a laser beam to a predetermined position in first powder layer 1 , based on the slice data. Before the laser beam is applied, the powder layer may be heated in advance. The metal powder irradiated with the laser beam is melted and sintered and accordingly solidified. In this way, the metal powder at a predetermined position in first powder layer 1 is solidified to thereby form first shaped layer p 1 .
  • a general-purpose laser device may be used.
  • a laser beam source a fiber laser, a YAG laser, a CO 2 laser, a semiconductor laser, or the like is used.
  • the laser beam output power may for example be approximately 100 to 1000 W, or approximately 200 to 500 W, or approximately 350 to 450 W.
  • the laser beam scanning velocity may be adjusted within a range for example of 100 to 1000 mm/s, or adjusted within a range of 200 to 600 mm/s.
  • the laser beam energy density may be adjusted within a range for example of 100 to 1000 J/mm 3 .
  • the laser beam energy density herein refers to a value calculated in accordance with the following expression (I):
  • E represents laser beam energy density [unit: J/mm 3 ]
  • P represents laser output power [unit: W]
  • v represents scanning velocity [unit: mm/s]
  • s represents scanning width [unit: mm]
  • d represents slice thickness [unit: mm].
  • FIG. 6 is a third schematic diagram illustrating the process of producing an additively-manufactured article.
  • piston 101 further lowers table 102 by a distance corresponding to one layer.
  • a second powder layer 2 is formed in a similar manner to the above-described one, and a second shaped layer p 2 is formed based on the slice data.
  • the first step (S 21 ) and the second step (S 22 ) are repeated.
  • FIG. 7 is a fourth schematic diagram illustrating the process of producing an additively-manufactured article. As shown in FIG. 7 , finally the n-th shaped layer pn is formed and thus an additively-manufactured article 10 is completed.
  • the additively-manufactured article is thereafter heat-treated.
  • the additively-manufactured article is heat-treated after additively manufactured.
  • the heat treatment can be expected to improve the mechanical properties and the electrical conductivity of the additively-manufactured article.
  • the atmosphere during the heat treatment may for example be an atmosphere of nitrogen, air, argon, hydrogen, vacuum, or the like.
  • the heat treatment temperature may for example be not less than 300° C. and not more than 400° C.
  • the time for heat treatment may for example be not less than two hours and not more than four hours.
  • the additively-manufactured article may have a complicated shape which cannot be obtained by cutting.
  • the additively-manufactured article of the present embodiment has both an adequate mechanical strength and an adequate electrical conductivity.
  • the additively-manufactured article of the present embodiment is applicable to a plasma torch by way of example.
  • the additively-manufactured article may have the following composition.
  • the additively-manufactured article of the present embodiment is an additively-manufactured article made from a specific copper alloy.
  • the copper alloy contains: not less than 0.2 mass % and not more than 1.3 mass % of Al; and a balance including Cu and an incidental impurity.
  • the balance of the copper alloy may include an incidental impurity.
  • the additively-manufactured article has a relative density of not less than 96% and not more than 100% with respect to the theoretical density, and has an electrical conductivity of not less than 30% IACS.
  • the upper limit of the Al content may be 1.3 mass %.
  • the lower limit thereof may be 0.23 mass %.
  • the density of the additively-manufactured article can for example be measured in accordance with the Archimedes method.
  • the density measurement in accordance with the Archimedes method may be done to comply with “JIS Z 2501: Sintered metal materials—Determination of density, oil content and open porosity.” Water may be used as the liquid.
  • the relative density of the additively-manufactured article may be not less than 96.5%, not less than 97.0%, not less than 97.5%, not less than 98.0%, not less than 98.5%, or not less than 99.0%.
  • the electrical conductivity can be measured by means of a commercially-available eddy-current conductivity meter. A higher electrical conductivity is also desired.
  • the electrical conductivity of the additively-manufactured article may be not less than 30% IACS, not less than 40% IACS, or not less than 50% IACS.
  • the additively-manufactured article may have the following composition.
  • the additively-manufactured article is an additively-manufactured article made from a specific aluminum-containing copper alloy.
  • the aluminum-containing copper alloy contains: not less than 0.2 mass % and not more than 1.3 mass % of Al; and a balance including Cu and an incidental impurity.
  • the balance of the copper alloy may include an incidental impurity.
  • the additively-manufactured article has a relative density of not less than 96% and not more than 100% with respect to the theoretical density of the aluminum-containing copper alloy, and has an electrical conductivity of not less than 30% IACS.
  • the additively-manufactured article can be expected to have both the mechanical strength based on a relative density of not less than 96.0% and an electrical conductivity of not less than 30% IACS (preferably not less than 50% IACS).
  • Metal powders E1, E2, E3, and E4 correspond to Examples.
  • the Cu content in metal powders E1, E2, E3, and E4 was measured by an electrogravimetric method for determining copper content (nitric acid-sulfuric acid method) complying with “JIS H 1051: Methods for determination of copper in copper and copper alloys.”
  • the Al content in metal powders E1, E2, E3, and E4 was measured by an ICP emission spectrometry complying with “JIS H 1057: Methods for determination of aluminum in copper and copper alloys.”
  • the oxygen content was measured in accordance with “JIS Z 2613: Inert gas fusion-infrared absorption method” and the phosphorus content was measured in accordance with “JIS H 1058: Absorption spectroscopy.”
  • Metal powder X was produced from an ingot (JIS alloy No.: C1020) of a commercially-available pure copper (so-called oxygen-free copper).
  • Metal powder Y was produced from an ingot of a commercially-available copper alloy (product name “AMPCO940”). Metal powder X and metal powder Y correspond to Comparative Examples.
  • a laser additive-manufacturing apparatus with the following specifications was prepared.
  • laser fiber laser, maximum output power 400 W
  • the above-described apparatus was used to produce an additively-manufactured article having a columnar shape (diameter 14 mm ⁇ height 15 mm).
  • the first step (S 21 ) of forming a powder layer including the metal powder, and the second step (S 22 ) of forming a shaped layer by applying a laser beam at a predetermined position in the powder layer to thereby solidify the metal powder were successively repeated. Accordingly, additively-manufactured articles of No. X-1 to No. X-40 were produced from the pure copper powder (metal powder X) which was produced from an ingot of a commercially-available pure copper.
  • the additively-manufactured articles produced from the pure copper powder significantly vary from one another in final physical properties even under the same conditions. “Unmeasurable” in Table 2 means that a highly reliable density could not be measured by the Archimedes method due to an excessively large number of voids.
  • the electrical conductivity of an ingot of the commercially-available pure copper may be considered as approximately 100% IACS.
  • the additively-manufactured article produced from metal powder X has a significantly lower electrical conductivity.
  • the additively-manufactured article produced from metal powder X has a significantly lower tensile strength value relative to the tensile strength (approximately 195 MPa) of the ingot of the commercially-available pure copper. Based on these results, it is considered difficult to produce a practically applicable mechanical part from the pure copper powder produced from an ingot of oxygen-free copper.
  • the first step (S 21 ) of forming a powder layer including the metal powder, and the second step (S 22 ) of forming a shaped layer by applying a laser beam at a predetermined position in the powder layer to thereby solidify the metal powder were successively repeated. Accordingly, additively-manufactured articles of No. Y-1 to No. Y-7 were produced from the copper alloy powder (metal powder Y) which was produced from an ingot of a commercially-available copper alloy (product name “AMPCO940”).
  • the additively-manufactured articles produced from the copper alloy powder had a higher relative density as compared with the additively-manufactured articles produced from metal powder X.
  • the electrical conductivity was significantly lower as compared with the original ingot (approximately 45.5% IACS). Based on these results, it is also considered difficult to produce a practically applicable mechanical part from the copper alloy powder having the composition different from the present invention.
  • the first step (S 21 ) of forming a powder layer including the metal powder, and the second step (S 22 ) of forming a shaped layer by applying a laser beam at a predetermined position in the powder layer to thereby solidify the metal powder were successively repeated. Accordingly, additively-manufactured articles of No. E1-1 to No. E1-9 were produced from the copper alloy powder (metal powder E1) containing 0.23 mass % of aluminum.
  • E1-1 E1 200 587.3 98.161 — 59.17 — E1-2
  • E1 300 391.5 96.335 — 56.63 — E1-3
  • E1 200 587.3 98.055 — 56.73 — E1-4
  • E1 300 391.5 98.021 — 59.05 — E1-5
  • E1 400 293.7 97.662 — 57.60 — E1-6
  • E1 500 234.9 97.511 — 56.74 — E1-7
  • the first step (S 21 ) of forming a powder layer including the metal powder, and the second step (S 22 ) of forming a shaped layer by applying a laser beam at a predetermined position in the powder layer to thereby solidify the metal powder were successively repeated. Accordingly, additively-manufactured articles of No. E2-1 to No. E2-15 were produced from the copper alloy powder (metal powder E2) containing 0.58 mass % of aluminum.
  • the first step (S 21 ) of forming a powder layer including the metal powder, and the second step (S 22 ) of forming a shaped layer by applying a laser beam at a predetermined position in the powder layer to thereby solidify the metal powder were successively repeated. Accordingly, additively-manufactured articles of No. E3-1 to No. E3-6 were produced from the copper alloy powder (metal powder E3) containing 0.81 mass % of aluminum.
  • the first step (S 21 ) of forming a powder layer including the metal powder, and the second step (S 22 ) of forming a shaped layer by applying a laser beam at a predetermined position in the powder layer to thereby solidify the metal powder were successively repeated. Accordingly, additively-manufactured articles of No. E4-1 to No. E4-6 were produced from the copper alloy powder (metal powder E4) containing 1.3 mass % of aluminum.

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