Classifications

• • 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
• • 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
  • B22F3/10—Sintering only
  • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
• • 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
  • B22F3/12—Both compacting and sintering
  • B22F3/16—Both compacting and sintering in successive or repeated steps
• • 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
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C19/00—Alloys based on nickel or cobalt
  • C22C19/03—Alloys based on nickel or cobalt based on nickel
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C19/00—Alloys based on nickel or cobalt
  • C22C19/07—Alloys based on nickel or cobalt based on cobalt
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C33/00—Making ferrous alloys
  • C22C33/02—Making ferrous alloys by powder metallurgy
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C38/00—Ferrous alloys, e.g. steel alloys

Definitions

• the present invention relates to a metal powder for modeling used in a three-dimensional additive manufacturing method, a laser coating method, a thermal spraying method, a cladding method, and the like.
• 3D printers are used to produce metal objects.
• a model is manufactured by the additive manufacturing method.
• the spread metal powder is irradiated with a laser beam or an electron beam. Irradiation melts the metal. The metal then solidifies. Due to this melting and solidification, the particles in the powder are bonded to each other. Irradiation is selectively performed on a part of the metal powder. The part of the powder that has not been irradiated does not melt. Only in the irradiated part, a bonding layer is formed.
• the bonding powder may be obtained by irradiating a beam onto the metal powder that has been jetted from the nozzle and traveling.
• metal powder is spread on the bonding layer.
• This metal powder is irradiated with a laser beam or an electron beam. Irradiation melts the metal. The metal then solidifies. By this melting and solidification, particles in the powder are bonded to each other, and a new bonded layer is formed. The new bonding layer is also combined with the existing bonding layer.
• the laser coating method is used for forming the metal coating layer.
• a laser beam is irradiated onto metal powder spread on a base. Irradiation melts the metal. The metal then solidifies. Due to this melting and solidification, the particles in the powder are bonded to each other. The particles also bind to the substrate. By the bonding, a covering layer is formed.
• the beam may be applied to the metal powder that is being jetted from the nozzle.
• the metal coating layer may be formed by thermal spraying or overlaying.
• Metal powders used in additive manufacturing methods, laser coating methods, thermal spraying methods, overlaying methods, etc. are manufactured by water atomizing methods, gas atomizing methods and the like.
• the properties of the metal powder affect the handleability.
• the properties of the metal powder further affect the physical properties of the three-dimensional structure and the coating layer.
• Japanese Patent Application Laid-Open No. 2001-152204 discloses a metal product obtained by impregnating a modeled object obtained by the additive manufacturing method with a metal having a melting point lower than the melting point of the modeled object. Impregnation increases the density of the metal product.
• Japanese Patent Laid-Open No. 2006-321711 discloses a metal powder having an arithmetic average circularity of 0.7 or more.
• this powder the surface of the particles is covered with aggregation preventing particles. With this powder, aggregation is unlikely to occur.
• This powder is excellent in handleability.
• the density of the shaped object obtained from this powder is large. This shaped article is excellent in strength.
• Japanese Patent Application Laid-Open No. 2011-21218 discloses a powder containing a laser absorber. A shaped article obtained from this powder is excellent in strength.
• the objective of this invention exists in provision of the metal powder for modeling excellent in various performance.
• the particle comprises a large number of particles, and these particles contain at least one of Ni, Fe and Co, and the total content of Ni, Fe and Co is 50% by mass or more.
• a modeling metal powder The ratio P1 of the number of particles having a circularity of less than 0.80 to the total number of particles is 10% or less, A metal powder for modeling in which the ratio P3 of the number of particles having a circularity of 0.95 or more to the total number of particles is 50% or more is provided.
• This metal powder for modeling contains many particles with high circularity. This powder is excellent in handleability. A shaped article obtained from this powder has high strength. The coating layer obtained from this powder is excellent in wear resistance.
• the metal powder for modeling according to the present invention is a collection of a large number of particles.
• a molded article can be obtained from this powder by the additive manufacturing method.
• a coating layer can be obtained from this powder by a laser coating method. This powder is also suitable for thermal spraying and overlaying.
• Each particle contains at least one of Ni, Fe and Co.
• the particles may include only one of Ni, Fe, and Co.
• the particles may include Ni and Fe.
• the particles may contain Fe and Co.
• the particles may contain Co and Ni.
• the particles may contain Ni, Fe and Co.
• preferable materials for the particles include Fe-based alloys (SUS316, SUS630, etc.), Ni-based alloys (equivalent to ALLOYC276, ALLOY718, etc.), and Co-based alloys (equivalent to Stellite No. 6, equivalent to Stellite No. 20).
• the total content of Ni, Fe and Co in the particles is 50% by mass or more. This powder is suitable for applications requiring high strength, high wear resistance or corrosion resistance. The total content may be 100% by mass.
• the particles may contain other elements.
• Other elements include S, Mg, Al, Ti, V, Cr, Mn, Si, Cu, Zn, Ga, Ge, Zr, Nb, Mo, Hf, Ta, W, In, Sn, Sb, La, and Ce.
• Pr, Nb, Gd, Tb, Dy, Yb, Y, B, P, Bi, N, and C are exemplified.
• the ratios P1, P2 and P3 are defined as follows.
• P1 Ratio of the number of particles having a circularity of less than 0.80 to the total number of particles
• P2 Ratio of the number of particles having a circularity of 0.80 or more and less than 0.95 to the total number of particles
• P3 Circularity Ratio of the number of particles having a particle size of 0.95 or more to the total number of particles
• the ratio P1 is 10% or less. In other words, the sum of the ratio P2 and the ratio P3 exceeds 90%. Furthermore, in this powder, the ratio P3 is 50% or more.
• the fluidity and filling properties of this powder are high.
• this powder is subjected to an additive manufacturing method or a laser coating method, it can be spread smoothly and densely. This powder is excellent in handleability. Since the powder is densely spread, the shaped article and the coating layer obtained from this powder are excellent in strength.
• the ratio P1 is more preferably 7% or less, and particularly preferably 4% or less. Ideally, the ratio P1 is zero.
• the ratio P3 is more preferably 70% or more, and particularly preferably 80% or more. Ideally, the ratio P3 is 100%.
• this powder is excellent in fluidity, the aggregation preventing particles disclosed in JP-A-2006-321711 are not necessary. In a powder containing no aggregation preventing particles, the aggregation preventing particles do not hinder the bonding between the particles. Therefore, the molded article and the coating layer obtained from this powder are excellent in strength. Of course, this powder may contain anti-agglomeration particles.
• the shaped article and the coating layer obtained from this powder are excellent in strength, it is not necessary to mix the laser absorber disclosed in JP 2011-21218 A into this powder. Therefore, defects due to the laser absorber do not occur. Of course, a laser absorber may be mixed with this powder.
• this powder is excellent in fluidity and filling properties.
• This powder can be closely packed in a container or the like.
• the ratio (d1 / d2) between the bulk density d1 and the packing density d2 of this powder is 0.80 or more.
• This powder has a small volume shrinkage upon melting. In the shaped object obtained from this powder, there are few voids. From this powder, a molded article and a coating layer excellent in strength can be obtained.
• the ratio (d1 / d2) is more preferably equal to or greater than 0.85, and particularly preferably equal to or greater than 0.90.
• the ratio (d1 / d2) is 1.00.
• Bulk density d1 is measured in accordance with the provisions of “JIS Z 2504”.
• the packing density d2 is measured in accordance with the rules of “JIS Z 2512”.
• Y (D10 ⁇ D90) / D50 2 (In the above formula, D10 is the cumulative 10 volume% particle diameter, D50 is the cumulative 50 volume% particle diameter, and D90 is the cumulative 90 volume% particle diameter.)
• the value Y calculated by is from 0.80 to 1.20.
• the total volume of the powder is 100%, and a cumulative curve is obtained.
• the particle diameter at the point where the cumulative volume is 10% on this curve is D10.
• the particle diameter at the point where the cumulative volume is 50% on this curve is D50.
• the particle diameter at the point where the cumulative volume is 90% on this curve is D90.
• the particle diameters D10, D50, and D90 are measured by a laser diffraction scattering method.
• An apparatus suitable for this measurement is Nikkiso Co., Ltd.'s laser diffraction / scattering particle size distribution measuring apparatus “Microtrack MT3000”.
• the powder is poured into the cell of this apparatus together with pure water, and the particle diameter is detected based on the light scattering information of the particles. Ten measurements are made and an average value is calculated.
• the powder whose value Y is 0.80 or more and 1.20 or less has a particle size distribution close to a lognormal distribution. This powder is excellent in fluidity and filling properties. This powder has a small volume shrinkage upon melting. In the shaped object obtained from this powder, there are few voids. From this powder, a molded article and a coating layer excellent in strength can be obtained. From the viewpoint of strength, the value Y is more preferably 0.85 or more, and particularly preferably 0.90 or more. From the viewpoint of strength, the value Y is more preferably 1.15 or less, and particularly preferably 1.10 or less.
• the particle diameter D10 is preferably 1 ⁇ m or more, more preferably 5 ⁇ m or more, and particularly preferably 10 ⁇ m or more.
• the particle diameter D50 is preferably 15 ⁇ m or more and 50 ⁇ m or less, and particularly preferably 20 ⁇ m or more and 30 m or less.
• This powder can be produced by various methods.
• Specific examples of the production method include a water atomization method, a gas atomization method, a plasma atomization method, a rotating electrode method, a disk atomization method, a melt spinning method, a mechanical grinding method, and a chemical reduction method.
• a plurality of manufacturing methods may be combined.
• particles obtained by the water atomization method may be mechanically pulverized.
• a water atomizing method and a gas atomizing method are exemplified.
• raw materials are put into a crucible having pores at the bottom. This raw material is heated and melted by a high frequency induction furnace in the atmosphere of air, argon gas or nitrogen gas. Water is jetted onto the raw material flowing out from the pores. The raw material is rapidly cooled and solidified to obtain a powder.
• raw materials are put into a crucible having pores at the bottom. This raw material is heated and melted by a high frequency induction furnace in the atmosphere of air, argon gas or nitrogen gas. Helium gas, argon gas or nitrogen gas is injected into the raw material flowing out from the pores. The raw material is rapidly cooled and solidified to obtain a powder.
• a powder containing many particles with high circularity By adjusting the atomizing conditions, a powder containing many particles with high circularity can be obtained. Particles having a high degree of circularity may be selected from the powder obtained by atomization.
• One example of the selection method is sieving with a mesh.
• Another means of selection is an image analysis method. In the image analysis method, the circularity of particles is measured by an analysis device. Particles whose circularity is within a predetermined range are automatically selected.
• the powder was spread and irradiated with a laser beam. Irradiation bonded the particles to form a bonded layer. A powder was spread on the bonding layer and irradiated with a laser beam. Such laying and irradiation were repeated to obtain a shaped object with a predetermined shape.
• the powder was spread on a plate made of pure Fe and irradiated with a laser beam. Irradiation bonded the particles to form a coating layer.
• the powder according to the present invention is also suitable for a 3D printer of a type in which powder is ejected from a nozzle.
• This powder is also suitable for a laser coating method in which the powder is sprayed from a nozzle.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Materials Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Manufacturing & Machinery (AREA)
• Physics & Mathematics (AREA)
• Optics & Photonics (AREA)
• Powder Metallurgy (AREA)

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• 2014
  • 2014-11-27 JP JP2014240312A patent/JP6475478B2/ja active Active
• 2015
  • 2015-11-25 KR KR1020187029725A patent/KR102266771B1/ko active IP Right Grant
  • 2015-11-25 CN CN201580054354.7A patent/CN106794515A/zh active Pending
  • 2015-11-25 KR KR1020177008137A patent/KR20170048438A/ko active Application Filing
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