Classifications

• • 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
  • C22C38/08—Ferrous alloys, e.g. steel alloys containing nickel
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y70/00—Materials specially adapted for additive manufacturing
• • 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
  • 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
• • 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
  • B22F10/10—Formation of a green body
• • 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
  • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
• • 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
  • 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
• • 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
  • 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
  • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
  • B22F7/008—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression characterised by the composition
• • 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
  • B22F9/00—Making metallic powder or suspensions thereof
  • B22F9/02—Making metallic powder or suspensions thereof using physical processes
  • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
  • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
  • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D 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 [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D 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
  • C22C33/00—Making ferrous alloys
  • C22C33/02—Making ferrous alloys by powder metallurgy
  • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
  • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
  • C22C33/0285—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with Cr, Co, or Ni having a minimum content higher than 5%
• • 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
• • 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
  • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
• • 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
  • C22C38/10—Ferrous alloys, e.g. steel alloys containing cobalt
  • C22C38/105—Ferrous alloys, e.g. steel alloys containing cobalt containing Co and Ni
• • 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
  • C22C38/12—Ferrous alloys, e.g. steel alloys containing tungsten, tantalum, molybdenum, vanadium, or niobium
• • 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
  • C22C38/14—Ferrous alloys, e.g. steel alloys containing titanium or zirconium
• • 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
  • B22F3/24—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
  • B22F2301/35—Iron
• • 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
  • B22F2304/00—Physical aspects of the powder
  • B22F2304/10—Micron size particles, i.e. above 1 micrometer up to 500 micrometer
• • 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 used in a rapid melting and quenching process such as three-dimensional additive manufacturing, thermal spraying, laser coating and overlaying.
• the present invention relates to a powder whose material is an Fe-based alloy.
• a 3D printer is used to manufacture a shaped object made of metal.
• a three-dimensional object is manufactured by the additive manufacturing method.
• the packed metal powder is irradiated with a laser beam or an electron beam.
• the irradiation causes the powder metal particles to melt.
• the particles then solidify.
• the melting and solidification bond the particles together.
• Irradiation is selectively applied to a portion of the metal powder.
• the portion of the powder which has not been irradiated does not melt.
• the bonding layer is formed only at the irradiated part.
• Metal powder is further spread over the bonding layer.
• the metal powder is irradiated with a laser beam or an electron beam.
• the irradiation melts the metal particles.
• the metal then solidifies.
• the melting and solidification combine the particles in the powder to form a new bonding layer.
• the new bonding layer is also bonded to the existing bonding layer.
• Patent Document 1 Japanese Patent No. 4661842.
• Patent Document 2 Japanese Patent Application Laid-Open No. 2013-253277 discloses a maraging steel which contains Fe as its main component and contains Ni, Co and Mo. The content of Co in this maraging steel is 7% by mass or more. This maraging steel contains W. This maraging steel does not contain Ti.
• Patent Document 3 Japanese Unexamined Patent Publication No. 2008-185183 discloses a maraging steel containing Ni, Cr, Mo and Co. The maraging steel is nitrided.
• Patent No. 4661842 gazette JP, 2013-253277, A JP, 2008-185183, A
• the metal material is rapidly melted and rapidly cooled to solidify.
• Conventional maraging steels are unsuitable for powders used in processes involving such rapid melting and quenching.
• an Fe-based alloy that is suitable for additive manufacturing and that provides a shaped article having excellent mechanical properties. Such alloys are also useful in injection, laser coating, overlaying, and the like.
• An object of the present invention is to provide a Fe-based metal powder that is suitable for a process involving rapid melt quench solidification and that a shaped article with excellent properties is obtained.
• [Item 5] A method for producing a shaped product using Fe-based metal powder as a raw material, (1) Ni: 15.0% by mass or more and 21.0% by mass or less, Co: 0% by mass or more and 10.0% by mass or less, Mo: 0% by mass or more and 7.0% by mass or less, Fe-based metal made of Fe-based alloy including Ti: 0.1% by mass to 6.0% by mass, and Al: 0.1% by mass to 3.0% by mass, with the balance being Fe and unavoidable impurities Preparing a powder, (2) a step of melting and solidifying the Fe-based metal powder to obtain a non-heat-treated shaped article; A method of producing a shaped article, including: [Item 6] The manufacturing method according to Item 5, wherein the Rockwell hardness of the unheat-treated shaped article is 30 or more and 40 or less.
• step (3) Following the step (2), (3) The method according to item 5 or 6, further comprising the step of subjecting the unheat-treated shaped article to a heat treatment to obtain a shaped article.
• step (3) is (3-1) applying a solution to the unheat-treated shaped article; (3-2) Aging the unheat-treated molded article Item 8.
• the method according to item 7, comprising: [Item 9] The solution treatment (3-1) is performed at a treatment temperature of 700 ° C. or more and 900 ° C. or less for a treatment time of 1.0 hour or more and 3.0 hours or less, and Item 9.
• the method according to Item 8, wherein the aging (3-2) is performed at a treatment temperature of 450 ° C.
• the shaped article obtained through the step (3) has the following formulas (I) and (II): 1.5 ⁇ (A TH / A TR ) ⁇ (C TH / C TR ) ⁇ 3.5 (I) 1.5 ⁇ (B TH / B TR ) ⁇ (C TH / C TR ) ⁇ 3.5 (II) ( Wherein , A TH represents tensile strength at 400 ° C., A TR represents tensile strength at 25 ° C., B TH represents 0.2% proof stress at 400 ° C., and B TR represents 0. Item 11. The method according to any one of Items 7 to 10, which represents a 2% proof stress, C TH represents a breaking elongation at 400 ° C., and C TR represents a breaking elongation at 25 ° C.).
• a common maraging steel contains substantially no C, and contains alloying elements such as Ni, Mo, Ti, and Co.
• alloying elements such as Ni, Mo, Ti, and Co.
• intermetallic compounds such as Ni 3 Mo phase and Ni 3 Ti phase are precipitated in the matrix of martensite. This intermetallic compound contributes to the high hardness and strength of maraging steel.
• Co lowers the solid solubility limit of Mo. Accordingly, in martensite in which the amount of addition of Co is large, the amount of supersaturated Mo is also large. The addition of Co promotes the precipitation of the Ni 3 Mo phase into martensite.
• Co is an austenite-forming element
• addition of a large amount of Co inhibits martensitic transformation.
• the addition of a large amount of Co promotes the formation of the mu phase or the sigma phase, resulting in the embrittlement of the alloy.
• Co is a subject of the specified chemical substance disorder preventive regulation, and from the viewpoint of compliance with this regulation, addition of a large amount of Co to Fe is not preferable. From such a circumstance, it is preferable that the addition amount of Co be suppressed.
• the Ni 3 Mo phase is less likely to precipitate. In this steel, mechanical properties such as hardness and strength are insufficient.
• the present inventors have found that the addition of a predetermined amount of Ni, Ti and Al to Fe compensates for the small addition amount of Co.
• the present inventors have found that a shaped article having excellent mechanical properties can be obtained by a process involving rapid melting and quenching and solidification using the Fe-based metal powder according to the present invention as a raw material.
• the Fe-based metal powder for shaping according to the present invention is a collection of a large number of particles.
• the material of this particle is an Fe-based alloy.
• the structure of the matrix of this Fe-based alloy is martensite.
• This Fe-based alloy contains Ni, Mo, Ti and Al.
• the Fe-based alloy may contain Co.
• the balance in this alloy is Fe and unavoidable impurities. The role of each element in this alloy is described in detail below.
• Co is an optional element that inhibits martensitic transformation.
• Co is not added or, if added, the amount is set to a small amount. Incidentally, even when Co is not added, a trace amount of Co can be inevitably included in the alloy. 10.0 mass% or less is preferable, 5.0 mass% or less is more preferable, 0.5 mass% or less is more preferable, 0.3 mass% or less is especially preferable.
• the Co content may be substantially zero. Therefore, the preferable content of Co is 0% by mass or more and 10.0% by mass or less, more preferably 0% by mass or more and 5.0% by mass or less, and still more preferably 0% by mass or more and 0.3% by mass or less It is.
• Ni is an essential element forming an intermetallic compound with each of Mo, Ti and Al in an Fe-based alloy.
• Specific examples of the intermetallic compounds include Ni 3 Mo, Ni 3 Ti and Ni 3 Al. These intermetallic compounds strengthen the alloy. From the powder whose material is this alloy, in spite of the rapid melting and quenching process, a shaped article excellent in strength is obtained. From the viewpoint of the strength of the shaped article, the content of Ni in the alloy is preferably 15.0% by mass or more, more preferably 16.0% by mass or more, and particularly preferably 17.0% by mass or more. Ni is an austenite-forming element. The addition of a large amount of Ni inhibits martensitic transformation.
• the content of Ni is preferably 21.0% by mass or less, more preferably 20.0% by mass or less, and particularly preferably 19.5% by mass or less. Therefore, the preferable content of Ni is 15.0% by mass or more and 21.0% by mass or less, more preferably 16.0% by mass or more and 20.0% by mass or less, still more preferably 17.0% by mass or more It is 19.5 mass% or less.
• Mo is an optional element that forms an intermetallic compound with Fe in a Fe-based alloy.
• An exemplary intermetallic compound is Fe 2 Mo.
• Mo further forms an intermetallic compound with Ni.
• An exemplary intermetallic compound is Ni 3 Mo.
• the preferable content of Mo is 0% by mass or more and 7.0% by mass or less, more preferably 2.0% by mass or more and 7.0% by mass or less, and still more preferably 2.5% by mass or more.
• the content is 0% by mass or less, particularly preferably 3.0% by mass or more and 5.0% by mass or less.
• Ti is an essential element that forms an intermetallic compound with Ni in an Fe-based alloy.
• An exemplary intermetallic compound is Ni 3 Ti. This intermetallic compound contributes to the creep rupture strength of the alloy. This intermetallic compound also contributes to the oxidation resistance of the alloy. From the powder of which the material is this alloy, a shaped article excellent in durability can be obtained despite the rapid melting and quenching process. From the viewpoint of the durability of the shaped article, the content of Ti in the alloy is preferably 0.1% by mass or more, more preferably 0.5% by mass or more, and particularly preferably 2.0% by mass or more. Large additions of Ti are prone to high temperature cracking in the rapid melt quench solidification process.
• the content of Ti is preferably 6.0% by mass or less, more preferably 5.0% by mass or less, and particularly preferably 4.0% by mass or less. Therefore, the preferred content of Ti is 0.1% by mass or more and 6.0% by mass or less, more preferably 0.5% by mass or more and 5.0% by mass or less, still more preferably 2.0% by mass or more. It is 0 mass% or less.
• Al is an essential element that forms an intermetallic compound with Ni in a Fe-based alloy.
• An exemplary intermetallic compound is Ni 3 Al. This intermetallic compound contributes to the creep rupture strength of the alloy. This intermetallic compound also contributes to the oxidation resistance of the alloy. From the powder of which the material is this alloy, a shaped article excellent in durability can be obtained despite the rapid melting and quenching process. From the viewpoint of the durability of the shaped article, the content of Al in the alloy is preferably 0.1% by mass or more, more preferably 0.3% by mass or more, and particularly preferably 0.5% by mass or more. Large additions of Al are prone to high temperature cracking in the rapid melt quench solidification process.
• the preferable content of Al is 0.1% by mass or more and 3.0% by mass or less, more preferably 0.3% by mass or more and 2.5% by mass or less, still more preferably 0.5% by mass or more. It is 0 mass% or less.
• the average particle diameter D50 of the metal powder is preferably 15 ⁇ m or more and 50 ⁇ m or less, and particularly preferably 20 ⁇ m or more and 30 ⁇ m or less from the viewpoint of easy production of a shaped article.
• the total volume of the powder is made 100%, and the cumulative curve is determined.
• the particle diameter of the point at which the cumulative volume is 50% on this curve is D50.
• the particle diameter D50 is measured by laser diffraction scattering.
• a laser diffraction / scattering type particle size distribution measuring apparatus “Microtrac MT 3000” manufactured by Nikkiso Co., Ltd. can be mentioned. Powder is poured into the cell of this device together with pure water, and the particle diameter is detected based on the light scattering information of the particles.
• the tap density TD of the metal powder is preferably 0.10 mg / m 3 or more 0.40 mg / m 3 or less, is 0.15 mg / m 3 or more 0.35 mg / m 3 or less Particularly preferred. The method of measuring the tap density TD will be described in detail later.
• the ratio (D50 / TD) of the average particle diameter D50 ( ⁇ m) to the tap density TD (Mg / m 3 ) is preferably 0.2 or more and 20 or less.
• the metal powder whose ratio (D50 / TD) is 0.2 or more is excellent in fluidity. A high density shaped object is obtained from this metal powder.
• the ratio (D50 / TD) is more preferably 2 or more, and particularly preferably 5 or more.
• the ratio (D50 / TD) is more preferably 15 or less, and particularly preferably 12 or less. Therefore, D50 / TD is preferably 0.2 or more and 20 or less, more preferably 2 or more and 15 or less, and further preferably 5 or more and 12 or less.
• Various shaped articles can be produced from the metal powder according to the present invention.
• the method of manufacturing this shaped object is (1) preparing a metal powder, and (2) melting and solidifying the metal powder to obtain an unheat-treated shaped article.
• the process of melting and solidifying the metal powder includes a rapid melting and quenching process. Specific examples of this process include three-dimensional additive manufacturing, thermal spraying, laser coating and overlaying. In particular, this metal powder is suitable for three-dimensional additive manufacturing.
• a 3D printer can be used for this additive manufacturing method.
• the padded metal powder is irradiated with a laser beam or an electron beam.
• the radiation causes the particles to heat rapidly and melt rapidly.
• the particles then solidify rapidly.
• the melting and solidification bond the particles together.
• Irradiation is selectively applied to a portion of the metal powder.
• the portion of the powder which has not been irradiated does not melt.
• the bonding layer is formed only at the irradiated part.
• Metal powder is further spread over the bonding layer.
• the metal powder is irradiated with a laser beam or an electron beam.
• the irradiation causes the particles to melt rapidly.
• the particles then solidify rapidly.
• the melting and solidification combine the particles in the powder to form a new bonding layer.
• the new bonding layer is also bonded to the existing bonding layer.
• the Rockwell hardness HRC of the shaped article after shaping is preferably 30 or more and 40 or less.
• the shaped article having a Rockwell hardness HRC of 30 or more is excellent in strength.
• the Rockwell hardness HRC is particularly preferably 32 or more.
• Shaped articles having a Rockwell hardness HRC of 40 or less have few internal defects such as cracks.
• the Rockwell hardness HRC is particularly preferably 38 or less. Therefore, the preferred Rockwell hardness HRC of the non-heat-treated shaped article is 30 or more and 40 or less, and more preferably 32 or more and 38 or less. The method of measuring the Rockwell hardness HRC will be described in detail later.
• the method for producing a shaped article is (3)
• the method further includes a step of subjecting the unheat-treated shaped article obtained in the step (2) to a heat treatment to obtain a shaped article.
• this step (3) (3-1) a step of subjecting the unheat-treated shaped article to solution treatment; (3-2) Aging the unheat-treated shaped article including.
• the temperature for solution treatment is preferably 700 ° C. or more and 900 ° C. or less.
• the temperature is more preferably 730 ° C. or more, particularly preferably 750 ° C. or more.
• the temperature is more preferably 870 ° C. or less, particularly preferably 850 ° C. or less. Therefore, a preferable solution temperature is 700 ° C. or more and 900 ° C. or less, more preferably 730 ° C. or more and 870 ° C. or less, and further preferably 750 ° C. or more and 850 ° C. or less.
• the solutioning time is preferably 1.0 hour or more and 3.0 hours or less.
• solution treatment which is 1.0 hour or more, a martensitic structure in which alloy elements are sufficiently dissolved is obtained.
• the time is more preferably 1.3 hours or more, and particularly preferably 1.5 hours or more.
• Solution costs which are less than 3.0 hours, reduce energy costs.
• the time is more preferably equal to or less than 2.7 hours, and particularly preferably equal to or less than 2.5 hours. Therefore, the preferred solutioning time is 1.0 hour to 3.0 hours, more preferably 1.3 hours to 2.7 hours, and still more preferably 1.5 hours to 2.5 hours. .
• the temperature of aging is preferably 450 ° C. or more and 550 ° C. or less.
• the temperature is more preferably 460 ° C. or more, particularly preferably 470 ° C. or more.
• the temperature is more preferably 540 ° C. or less, particularly preferably 530 ° C. or less. Therefore, the preferable temperature of aging is 450 ° C. or more and 550 ° C. or less, more preferably 460 ° C. or more and 540 ° C. or less, and still more preferably 470 ° C. or more and 530 ° C. or less.
• the time of aging is preferably 3.0 hours or more and 6.0 hours or less. Aging for 3.0 hours or more gives a structure in which Ni 3 Mo, Ni 3 Ti and Ni 3 Al are sufficiently precipitated. In this respect, the time is more preferably 3.3 hours or more, and particularly preferably 3.5 hours or more. Aging that is less than 6.0 hours reduces energy costs. In this respect, the time is more preferably 5.7 hours or less, particularly preferably 5.5 hours or less. Therefore, the preferable aging time is 3.0 hours to 6.0 hours, more preferably 3.3 hours to 5.7 hours, and still more preferably 3.5 hours to 5.5 hours.
• the Rockwell hardness HRC of the shaped article after heat treatment is preferably 50 or more and 60 or less.
• a shaped article having a Rockwell hardness HRC of 50 or more is excellent in strength.
• the Rockwell hardness HRC is particularly preferably 52 or more.
• a shaped article having a Rockwell hardness HRC of 60 or less is excellent in toughness.
• the product obtained from this shaped article is excellent in durability.
• the Rockwell hardness HRC is particularly preferably 58 or less. Therefore, the preferred Rockwell hardness HRC of the shaped article after heat treatment is 50 or more and 60 or less, and particularly preferably 52 or more and 58 or less.
• V1 and the value V2 are respectively calculated by the following formulas.
• V1 (A TH / A TR ) ⁇ (C TH / C TR )
• V2 (B TH / B TR ) ⁇ (C TH / C TR )
• a TH represents tensile strength at 400 ° C.
• a TR represents tensile strength at 25 ° C.
• B TH represents 0.2% proof stress at 400 ° C.
• B TR represents 0 at 25 ° C. represent .2% yield strength
• C TH represents the elongation at break 400 ° C.
• C TR denotes the elongation at break at 25 ° C..
• the value V1 is preferably 1.5 or more and 3.5 or less, and the value V2 is preferably 1.5 or more and 3.5 or less.
• the three-dimensional object satisfy the following formulas (I) and (II). 1.5 ⁇ (A TH / A TR ) ⁇ (C TH / C TR ) ⁇ 3.5 (I) 1.5 ⁇ (B TH / B TR ) ⁇ (C TH / C TR ) ⁇ 3.5 (II)
• a shaped article having a value V1 of 1.5 or more and a value V2 of 1.5 or more is excellent in strength and durability under a high temperature environment.
• the value V1 and the value V2 are more preferably equal to or greater than 1.8, and particularly preferably equal to or greater than 2.0.
• a shaped article having a value V1 and a value V2 of 3.5 or less can be easily manufactured.
• the values V1 and V2 are particularly preferably 3.3 or less. Therefore, preferable values V1 and V2 are 1.5 or more and 3.5 or less, more preferably 1.8 or more and 3.5 or less, and particularly preferably 2.0 or more and 3.3 or less.
• Raw materials having the compositions shown in Tables 1 to 3 below were prepared. Each raw material was heated by high frequency induction in an alumina crucible to obtain a molten alloy. The molten alloy was dropped from a nozzle formed at the bottom of the crucible and having a diameter of 5 mm, to which high pressure argon gas was injected. The jets refined and quenched the molten metal to form a powder. This powder was classified so that the diameter of each particle was 63 ⁇ m or less, to obtain Fe-based metal powder of each example and each comparative example.
• a three-dimensional additive manufacturing apparatus (trade name "EOS-M280") was used to manufacture a three-dimensional object.
• the unheat-treated shaped article was subjected to heat treatment under the conditions shown in Tables 1 to 3 below.
• Tap density The tap density was measured in accordance with the "JIS Z 2512". In the measurement, about 50 g of metal powder was filled in a cylinder of 100 cm 3 in volume, and the density was measured. The measurement conditions are as follows. Drop height: 10 mm The number of taps: 200. The results are shown in Tables 1 to 3 below.
• the symbol “-" in the column of component composition represents an unavoidable impurity.
• the symbol “-” in the hardness column after shaping represents that it is smaller than 30 HRC or larger than 40 HRC.
• the symbol “-” in the hardness row after heat treatment represents less than 50 HRC or greater than 60 HRC.
• the symbol “-” in the column of value V1 represents less than 1.5 or greater than 3.5.
• the symbol “-” in the column of value V2 represents less than 1.5 or greater than 3.5.
• the symbol “-” in the column of solution heat treatment temperature represents that the temperature is lower than 700 ° C or higher than 900 ° C.
• the symbol “-" in the column of solution heat treatment time represents that the time is shorter than 1 hour or longer than 3 hours.
• the symbol “-” in the aging heat treatment temperature column represents that the temperature is lower than 450 ° C or higher than 550 ° C.
• the symbol “-” in the aging heat treatment time column represents that the time is shorter than 3 hours or longer than 6 hours.
• the symbol “-” in the column D50 / TD indicates that the ratio is less than 0.2 or greater than 20.
• the powder according to the invention is also suitable for 3D printers of the type in which the powder is jetted from a nozzle.
• the powder is also suitable for laser coating processes in which the powder is sprayed from a nozzle.

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• 2017
  • 2017-10-27 JP JP2017207885A patent/JP6703511B2/ja active Active
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