WO2019052128A1 - Impression 4d et impression de céramiques à partir de métaux, avec oxydation sélective - Google Patents

Impression 4d et impression de céramiques à partir de métaux, avec oxydation sélective Download PDF

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Publication number
WO2019052128A1
WO2019052128A1 PCT/CN2018/077950 CN2018077950W WO2019052128A1 WO 2019052128 A1 WO2019052128 A1 WO 2019052128A1 CN 2018077950 W CN2018077950 W CN 2018077950W WO 2019052128 A1 WO2019052128 A1 WO 2019052128A1
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WIPO (PCT)
Prior art keywords
laser
scanning
oxidation
selectively
layer
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PCT/CN2018/077950
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English (en)
Inventor
Asif UR REHMAN
Tingting Liu
Wenhe LIAO
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Nanjing University Of Science And Technology (Njust)
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Publication of WO2019052128A1 publication Critical patent/WO2019052128A1/fr

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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
    • 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
    • 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
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
    • 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
    • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C04B35/111—Fine ceramics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/45—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on copper oxide or solid solutions thereof with other oxides
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/64—Burning or sintering processes
    • 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
    • B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/602—Making the green bodies or pre-forms by moulding
    • C04B2235/6026—Computer aided shaping, e.g. rapid prototyping
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/658—Atmosphere during thermal treatment
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/66—Specific sintering techniques, e.g. centrifugal sintering
    • C04B2235/661—Multi-step sintering
    • C04B2235/662—Annealing after sintering
    • C04B2235/663—Oxidative annealing
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/66—Specific sintering techniques, e.g. centrifugal sintering
    • C04B2235/665—Local sintering, e.g. laser sintering
    • 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 method for manufacturing and selectively oxidizing the material at the same time with the help of energy or laser beam to get the desired material in the presence of oxygen environment.
  • the invention relates to 3D printing of articles with selective laser melting (SLM) and selective laser sintering (SLS) with an additional dimension of selective oxidation within material in the broader field of Additive Manufacturing (AM)
  • AM additive manufacturing
  • SLM selective laser melting
  • SLS selective laser sintering
  • each manufacturing layer is mathematically sliced in 2D layers according to the requirement of the part.
  • Parts with ultimately complex shapes and intricate geometries will be manufactured with the ease of 2D layer powder fusion with sintering or melting of powder bed using a laser beam.
  • Aerospace and biomedical industries are one of the key beneficiaries of SLS/SLM because it has cut down the cost of manufacturing of different moulds and prototypes, researchers can generate the same model they designed on a computer with ease and low cost compared to the conventional manufacturing methods.
  • Article manufacturing quality in SLS, SLM is dependent on many parameters e.g. material powder, laser energy density, laser scanning strategy, laser speed, laser spot size and laser overlap.
  • Laser speed during the scanning is controlled according to the requirements if the laser speed is slow, it means the material powder will get energy beam for more time and vice versa.
  • scanning speed also defines melting and sintering of the material powder, if the scanning speed is too fast laser beam will not effectively melt or sinter the powder completely which can lead to many undesired features like pores and poorly melted powder.
  • the laser scanning speed is too slow, then it might melt material powder for too long time and also can increase thermal stresses which will lead to warping and cracking like manufacturing defects.
  • the overlap between two adjacent lines of laser scanning is named as laser overlap.
  • the laser spot lines are partially overlapping with each other it also has importance because overlap causes the scanning lines of the laser to merge with each other, but too much overlap can also cause re-melting of powder material thus increasing the time and decreasing the efficiency. Similarly, too small overlap can cause the lines to not merge with the adjacent line.
  • Laser energy density is critical considering the manufacturability of the material powder. To completely melt the material powder a high energy density of the laser is desired, as we decrease or increase the energy density of the laser power, it is directly affecting the temperature produced with laser energy density.
  • an inert gas environment is usually provided to prevent the materials from oxidation in open air.
  • the material chemical reaction is a process that may lead to one set of chemical substances to another set of chemicals.
  • Chemical reactions are usually described with the change in positions of electrons in breaking of chemical bonds and formation of new chemical bonds between atoms or molecules, with usually no change in the nuclei.
  • a chemical change which is described in scientific notation, called chemical equation, where reactants involve a chemical change that results in one or more chemical products.
  • a specific chemical reaction can sometimes under certain reaction characteristics convert into intermediate products before the final products.
  • a response may also contain a sequence of sub reactions, which is also a part of reaction.
  • a chemical reaction At a specific temperature, a chemical reaction has specific reaction rate with specific chemical concentration, which can change with increase or decrease in the temperature. Reaction rates may increase with the temperature in endothermic reaction and may decrease with increase in temperature in exothermic reactions.
  • the reaction can continue in the forward or reverse direction until they are complete or reach equilibrium.
  • Forward-moving responses are often described as spontaneous, so no input of free energy is needed to advance.
  • Non-spontaneous responses require the input of free energy to forward (for example, charging a battery by applying an external power source, or photosynthesis powered by absorption of electromagnetic radiation in the form of sunlight).
  • SLS/SLM works on the fundamental principle of layer-by layer manufacturing.
  • the material powder which is heat fusible, is deposited uniformly on the platform and then the laser beam selectively melts or sinters the specific areas according to the geometry of the article being manufactured, which is sliced into 2D layer, in an inert gas environment (usually Argon, Nitrogen and Hellium in special cases).
  • the material has been selectively oxidized by providing oxygen environment, in SLS/SLM, to control the oxidation at the same time systematically.
  • the said method can print oxide ceramics from metals partially as well as completely.
  • the powder material is deposited with the desired thickness, and then the laser energy beam with specific energy density will scan the material powder bed in oxygen gas environment or open air during selective oxidation of laser sintering.
  • the laser energy density change controls the change in the amount of selective oxidation of the material.
  • the object of the invention to provide a method which can provide sintering and melting with a gradual oxidation in the material.
  • the change in the material ‘X’ to ‘Y’ can be increased and controlled with the increase in laser energy density e.g the change in the material with the increase in the laser power changes the Aluminum (Al) material into Alumina (Al 2 O 3 ) which is oxidised state of Al in an open air environment or oxygen environment, before the application of laser beam the material was Al but during the SLM the material has been changed into Al 2 O 3 , systematically.
  • Al 2 O 3 articles for example there are several composition which will have different thermal stresses during additive manufacturing. e.g. 80% Al 2 O 3 and 20% Al composition can also be used for slectively oxidising the Al into Al 2 O 3 to get 100% of Al 2 O 3 articles, 90% Al 2 O 3 and 10% Al composition can also be used for slectively oxidising the Al into Al 2 O 3 to get 100% of Al 2 O 3 articles, 95% Al 2 O 3 and 5% Al composition can also be used for slectively oxidising the Al into Al 2 O 3 to get 100% of Al 2 O 3 articles.
  • 80% Al 2 O 3 and 20% Al composition can also be used for slectively oxidising the Al into Al 2 O 3 to get 100% of Al 2 O 3 articles
  • 90% Al 2 O 3 and 10% Al composition can also be used for slectively oxidising the Al into Al 2 O 3 to get 100% of Al 2 O 3 articles
  • 95% Al 2 O 3 and 5% Al composition can also be used for slectively oxidising the Al into Al 2 O 3
  • the change in the material ‘X’ to ‘Y’ can be increased and controlled with the increase in laser energy density e.g the change in the material with the increase in the laser power changes the Cu 2 O material into CuO which is more oxidised state of Cu 2 O in an open air environment or oxygen environment, before the application of laser beam the material was Cu 2 O but during the SLM the material has been changed into CuO, systematically.
  • the X a O b will be taken as the most oxidised state of ‘X’, from all the oxidised states of the material ‘X’ then by changing the laser parameters the change in the material will be in such a way that at certain minimum laser power or energy density (depending on the laser power of the laser being used) ‘P min ’ the oxidation ‘X a O b ’ is supposed to be 0% and at the specific laser power or energy density ‘P max ’ the material will be completely changed in ‘X a O b ’. In between the P min ’ and ‘P max ’ the change in oxidation states for the different material may differ. There are differences in change of oxidation while oxidizing different materials.
  • the material X changes its oxidation state to ‘X c O d ’ which is is less oxidised states and then to ‘X a O b ’ which is a chemically more oxidised state.
  • ‘X a O b ’ may coexist with several other oxidised states like ‘X c O d ‘ and ‘X e O f ’ and so on, but the quantity of ‘X a O b ’ will keep on increasing with the increase in power of the laser.
  • the material X changes its oxidation state to several oxidation states ‘X c O d ‘ and ‘X e O f ’ and so on and then changes its oxidation state to ‘X a O b ’ which is the completely oxidized state
  • CuO has been taken as ‘X a O b ’ because it is in the most oxidised state of X.
  • the change in the material ‘X’ to ‘X a O b ’ can be increased and controlled with the increase in laser energy density.
  • the change in the material with the increase in the laser power changes the Cu (copper metal) material into Cu 2 O and CuO in an oxygen gas environment or open-air environment, before the application of laser beam the material was Cu, but during the SLM the material has been changed into Cu 2 O and CuO.
  • the quantity of CuO will keep on increasing with the increase in laser power or energy density, systematically.
  • FeO molecular structure have been depicted during selective oxidation of Fe have been depicted.
  • Particle have been printed with controlled oxidation as well as controlled molecular structure. Larger atom (bluish color) depicts the Fe and amaller atom (redish color) depicts the O molecules respectively.

Abstract

L'invention concerne un procédé d'impression 4D utilisant un faisceau laser. Le procédé selon l'invention permet de fritter/faire fondre sélectivement chaque couche d'un lit de poudre, tout en changeant sélectivement le matériau par oxydation. Le procédé selon l'invention réalise un frittage ou une fusion au laser en oxydant le matériau, afin d'obtenir des propriétés souhaitées pour l'article constitué du matériau dans un environnement d'oxygène sous pression ou non sous pression. Dans ledit procédé, la puissance du laser ou la densité d'énergie du laser sont utilisées pour commander l'oxydation à l'intérieur de l'article constitué du matériau dans l'environnement d'oxygène. Ledit procédé permet également d'obtenir un état complètement oxydé du matériau pendant la fabrication de géométries 3D. Ce procédé peut être utilisé avec plusieurs matériaux, notamment mais sans s'y limiter, des céramiques, des composites et des semi-conducteurs, pour lesquels on souhaite une oxydation chimique conjointement à des géométries complexes, en vue de diverses applications allant de l'auto-cicatrisation à des propriétés de catalyse et électromagnétiques personnalisées.
PCT/CN2018/077950 2017-09-12 2018-03-04 Impression 4d et impression de céramiques à partir de métaux, avec oxydation sélective WO2019052128A1 (fr)

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PK0047017 2017-09-12
PK470 2017-09-12

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11305355B2 (en) 2020-05-21 2022-04-19 Kilncore Inc. High temperature, high pressure, powder-based, 3D printed object manufacturing

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CN102863224A (zh) * 2011-07-06 2013-01-09 赢创德固赛有限公司 包含用聚合物涂覆的含金属、金属氧化物、金属氮化物或半金属氮化物的芯颗粒的粉末
CN103008657A (zh) * 2013-01-13 2013-04-03 北京科技大学 一种快速成形制备氧化物弥散强化合金的方法
CN104439243A (zh) * 2015-01-06 2015-03-25 彭晓领 金属梯度材料的激光3d打印制备方法
US20150093279A1 (en) * 2013-10-02 2015-04-02 Honywell International Inc. Methods for forming oxide dispersion-strengthened alloys
CN106077641A (zh) * 2016-07-07 2016-11-09 四川三阳永年增材制造技术有限公司 一种陶瓷颗粒增强金属零件的制备方法
CN106282721A (zh) * 2015-06-11 2017-01-04 优克材料科技股份有限公司 成型粉末及陶瓷立体物件的制造方法

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102863224A (zh) * 2011-07-06 2013-01-09 赢创德固赛有限公司 包含用聚合物涂覆的含金属、金属氧化物、金属氮化物或半金属氮化物的芯颗粒的粉末
CN103008657A (zh) * 2013-01-13 2013-04-03 北京科技大学 一种快速成形制备氧化物弥散强化合金的方法
US20150093279A1 (en) * 2013-10-02 2015-04-02 Honywell International Inc. Methods for forming oxide dispersion-strengthened alloys
CN104439243A (zh) * 2015-01-06 2015-03-25 彭晓领 金属梯度材料的激光3d打印制备方法
CN106282721A (zh) * 2015-06-11 2017-01-04 优克材料科技股份有限公司 成型粉末及陶瓷立体物件的制造方法
CN106077641A (zh) * 2016-07-07 2016-11-09 四川三阳永年增材制造技术有限公司 一种陶瓷颗粒增强金属零件的制备方法

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11305355B2 (en) 2020-05-21 2022-04-19 Kilncore Inc. High temperature, high pressure, powder-based, 3D printed object manufacturing

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