WO2020093085A1 - A method of spray forming an object. - Google Patents
A method of spray forming an object. Download PDFInfo
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- WO2020093085A1 WO2020093085A1 PCT/AU2019/051148 AU2019051148W WO2020093085A1 WO 2020093085 A1 WO2020093085 A1 WO 2020093085A1 AU 2019051148 W AU2019051148 W AU 2019051148W WO 2020093085 A1 WO2020093085 A1 WO 2020093085A1
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- powder
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- copper
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
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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
- 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
- B22F3/115—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by spraying molten metal, i.e. spray sintering, spray casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—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
- B29C64/10—Processes of additive manufacturing
- B29C64/141—Processes of additive manufacturing using only solid materials
- B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
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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
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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
- B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
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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
- B22F10/60—Treatment of workpieces or articles after build-up
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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
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/64—Treatment of workpieces or articles after build-up by thermal means
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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
- 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
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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
- 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
- B22F12/20—Cooling means
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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
- 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
- B22F3/1035—Liquid phase sintering
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- 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
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0408—Light metal alloys
- C22C1/0416—Aluminium-based alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/082—Coating starting from inorganic powder by application of heat or pressure and heat without intermediate formation of a liquid in the layer
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/082—Coating starting from inorganic powder by application of heat or pressure and heat without intermediate formation of a liquid in the layer
- C23C24/085—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/082—Coating starting from inorganic powder by application of heat or pressure and heat without intermediate formation of a liquid in the layer
- C23C24/085—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
- C23C24/087—Coating with metal alloys or metal elements only
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
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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
- 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
- B22F12/50—Means for feeding of material, e.g. heads
- B22F12/53—Nozzles
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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
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
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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
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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- 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
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- 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
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- 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
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- 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
- This invention relates to a method of spray forming an object, for example by way of cold sprayed powder.
- Cold spraying metallic powders for forming 3D products is known.
- the process may be regarded as a type of 3D printing.
- the powders are typically entrained in an accelerant gas and sprayed through the nozzle of a hand help gun or a robotic device to create or repair products or parts thereof.
- a problem with at least many cold spray processes is that imperfect bonding of the deposited metallic particles results in the finished product having inadequate strength. It is believed that this can be attributed to metallurgical discontinuity between the bonded sections of sprayed particles. For example excessive gaps or unfilled voids may be left between deposited particles. Further, excessive portions of the surface of particles may fail to bond with neighboring particles.
- the powders may be sprayed more aggressively, for example by increasing the speed, temperature or by compression of the sprayed powder via a hot isostatic press. While these measures may ameliorate defects, they can also increase manufacturing costs to an unacceptable level.
- Another problem is that alloys with favourable mechanical hardness can be very difficult to deposit with cold spray, with low retention of powders (ie low deposition efficiencies) because the powders themselves are very hard. This problem can sometimes be rectified by annealing the powders, but this is time consuming and expensive.
- cold spraying refers to spraying powder through a nozzle at temperatures below the powder melting point and at speeds high enough to create bonding when the powder impacts a target.
- a method of forming a 3- dimensional solid object comprising the steps:
- the sprayed powder comprises a blend of at least a majority powder being a main matrix forming powder and at least a minority powder being a sintering powder.
- the majority powder and/or the minority powder each comprise alloy.
- step b) the item is heated to a temperature above the lowest melting temperature of an alloy formed by the matrix forming powder and the sintering powder.
- the item is heated and held at one or more temperature below the lowest melting temperature of an alloy formed by the matrix powder and the sintering powder, prior to exceeding such temperature.
- the shape of the item when formed is substantially determined by the matrix forming powder.
- the matrix forming powder has an additional metallic content of: a) less than 3% by weight;
- the matrix forming powder comprises primarily one or more of aluminium, copper, nickel, iron and/or a 6000 series aluminium alloy.
- the matrix forming powder comprises a ceramic substance.
- the sintering at step b) is by a sintering powder comprising a majority of one or more of aluminium, copper, nickel, tin and zinc.
- the sintering at step b) is by a sintering powder that is: a) less than 15% by weight of the sprayed powder;
- the combination of the matrix forming powder and the sintering powder has a minority of elements that provide sintering at step b), the minority comprising one or more of magnesium, silicon, carbon, nickel, copper, zinc, tin, aluminium, lithium, chrome, iron and manganese.
- the sprayed powder consists of or comprises Aluminium (eg in a 6000 Series Alloy), Al-Si-Mg and copper, and, at step b), the item is:
- the sprayed powder consists of or comprises Aluminium (eg in a 6000 Series Alloy), Al-Si-Mg and copper and, at step b), the item is:
- the sprayed powder consists of or comprises copper, and aluminium (up to about 15% by weight aluminium), and, at step b), the item is held at 850-1000°C optionally for at least 8 to 16 hours.
- the sprayed powder consists of or comprises copper and aluminium (up to about 15% by weight aluminium) and, at step b), the item is:
- the sprayed powder consists of or comprises copper and aluminium (optionally up to about 15% by weight aluminium) and, at step b), the item is:
- the sprayed powder consists of or comprises copper and aluminium (optionally up to about 15% by weight aluminium) with up to 4% iron, and up to 3% nickel or silicon
- the sprayed powder consists of or comprises copper and zinc (optionally up to about 15% by weight zinc) and, at step b), the item is held at 850-950°C, optionally for at least 8-14 hours.
- the sprayed powder consists of or comprises copper and zinc (optionally up to about 15% by weight zinc) and, at step b), the item is:
- the sprayed powder consists of or comprises copper and zinc (optionally up to about 15% by weight zinc) and, at step b), the item is:
- the sprayed powder consists of or comprises copper and tin (optionally up to about 10% by weight tin) and, at step b), the item is held at 850-950°C, optionally for at least 8 to 14 hours.
- the sprayed powder consists of or comprises copper and tin (optionally up to about 10% by weight tin) and, at step b), the item is:
- the sprayed powder consists of or comprises copper and tin (optionally up to about 10% by weight tin) and, at step b), the item is:
- the sprayed powder consists of or comprises iron and copper (optionally up to about 5% by weight copper) and, at step b), the item is held at 1 ,096-1 ,200°C optionally for at least 8-14 hours.
- the sprayed powder consists of or comprises iron and copper (optionally up to about 5% by weight copper) and, at step b), the item is:
- the sprayed powder consists of or comprises iron and copper (optionally up to about 5% by weight copper) and, at step b), the item is:
- the sprayed powder consists of or comprises iron and nickel (optionally up to about 5% by weight nickel) and, at step b), the item is held at 1 ,455-1 ,490°C, optionally for at least 8-14 hours.
- the sprayed powder consists of or comprises iron and nickel (up to about 5% by weight nickel) and, at step b), the item is:
- the sprayed powder consists of or comprises iron and nickel (up to about 5% by weight nickel) and, at step b), the item is:
- the sprayed powder consists of or comprises nickel and copper (up to about 15% by weight copper) and, at step b), the item is held at 1 ,100-1 ,300°C, , optionally for at least 8-14 hours.
- the sprayed powder consists of or comprises nickel and copper (up to about 15% by weight copper) and, at step b), the item is:
- the sprayed powder at step a) consists of or comprises spheroidal particles, eg spheres or oblate spheroids.
- the sprayed powder at step a) consists or comprises particles that are not irregular, spiky or rough.
- the sprayed powder at step a) consists or comprises particles, at least 90% of which are 15-80 pm in span (eg in diameter).
- the sprayed powder at step a) consists or comprises particles, at least Optionally the matrix forming powder has a hardness of less than 200HV.
- the matrix forming powder has a hardness of less than 150 HV.
- the matrix forming powder has a hardness of less than 100 HV.
- Figure 1 is a phase diagram for copper
- Figure 2 illustrates, photographically, a series of blocks prepared by cold spraying a blend of Al-Si10-Mg powder + 3% Cu powder;
- Figure 3 is a phase diagram for AI-SM 0-Mg .
- Figure 4 illustrates, photographically, a further block prepared by cold spraying a blend AI-SM 0-Mg + 3% Cu.
- Aluminum Alloy 6061 is a commercially available product, for example as described at https://en.wikipedia.org/wiki/6061 aluminium alloy.
- Aluminum Alloy 6061 is sometimes used as a solid“wrought” product having a density of about 2.7 g/cm 3 , a melting pint of approximately 580°C, a modulus of elasticity of about 70-80 GPa, a Poissons ratio of about 0.33, a thermal conductivity of about 173 W/m.K and an electrical resistivity of about 3.7-4.0 x10-6 Q.cm.
- Aluminum Alloy 6061 is available in Australia as a powder from Ecka Granules Germany, a subsidiary of Kymera International
- Cold sprayed powdered Aluminum Alloy 6061 is often substandard to the wrought version in terms of the tensile strength of the finished product. This is believed to be attributable to incomplete bonding of particles within a layer, and/or between sprayed layers, in the microstructure of a cold sprayed item.
- Aluminum Alloy 6061 powder was cold sprayed using compressed air at 30 bar and 500°C to produce a series of standard tensile test bars. These were heat treated as follows:
- Copper particles were found to deposit well when cold sprayed. However pure copper appears to have no or insufficient ability for thermal hardening and so is generally believed to be of limited use for structural applications. It was an unlikely candidate for cold spraying items that need to have significant strength.
- Copper powder can be combined with Aluminum Alloy 6061 powder and cold sprayed to good effect.
- the copper powder was found to form a liquid phase above 548°C in the resulting 3D product (as illustrated in Figure 1). It was surprisingly discovered that that the copper gave rise to a finished item significantly harder than for Aluminum Alloy 6061 powder alone.
- the copper was found to have moderate diffusivity in the aluminum, making the copper able to form a ready sintering liquid phase and less likely to simply dissolve into the aluminum matrix.
- Example 2 item ie with copper in the blend, was significantly stronger than the Example 1 item, and also compared very well against the wrought item.
- WQ Water Quench.
- Sample A did not show any visible porosity.
- Samples B and C displayed substantial gross porosity during the heat treatment, lowering their density and making the finished item unsuitable for many mechanical applications.
- Sample D displayed no visible porosity, making it a candidate for mechanical applications.
- a common powdery alloy for 3D printing (eg Selective Laser Melting) is AI-10Si-Mg.
- AI-10Si-Mg alloy is designed to fuse and was thought to be suitable for liquid phase sintering in a cold spray context. As illustrated in Figure 3, it has a large two-phase region (eg a large temperature zone in which it can be solid or liquid) suitable for liquid formation. Furthermore, it is able to be hardened in a similar manner to sprayed Aluminum Alloy 6061 . The addition of Cu was thought to be sufficient for lowering the temperature at which sintering liquid is first present, to as little as 524°C (Fig X). It was thought that this would promote the action of liquid phase sintering, as well as augmenting hardening response on final heat treatment as described above.
- Example 5 6061 + 5%AI-10Si-Mg + 1 % Cu with Pre-sintering Treatment Gives Surprising Performance
- the 6061 alloy powder of Examples 1 and 2 was blended with 5% AI-10Si-Mg and 1 % Cu, then cold sprayed.
- the sprayed part was then subjected to an unusual heat treatment, including a“pre-sintering” treatment, as follows:
- Example 6 Application of Pre-Sintering to Aluminium Bronze
- pre-sintering treatment in Example 5 may improve the penetration of liquid along poorly-bonded interfaces, and act to reduce porosity. This effect may be generalized to various alloy systems, for example, aluminium bronze.
- a pure copper powder was blended with the 10% 6061 powder of Examples 1 and 2. This was cold sprayed into parts and then heat treated in 2 ways, then tested, as per the table below. Additionally, a fully alloyed aluminium bronze powder (ie without a sintering agent) was cold sprayed and tested for comparison. The blended powder with 2 pre-sintering steps performed remarkably well.
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- Mechanical Engineering (AREA)
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- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
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- Civil Engineering (AREA)
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- Structural Engineering (AREA)
- Powder Metallurgy (AREA)
Abstract
Description
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Priority Applications (6)
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BR112021008599-8A BR112021008599A2 (en) | 2018-11-09 | 2019-10-22 | A THREE-DIMENSIONAL FORMATION METHOD OF AN OBJECT BY SPRAYING |
EP19882889.9A EP3877106A4 (en) | 2018-11-09 | 2019-10-22 | A method of spray forming an object |
US17/292,181 US11623387B2 (en) | 2018-11-09 | 2019-10-22 | Method of spray forming an object |
JP2021523616A JP2022512869A (en) | 2018-11-09 | 2019-10-22 | How to spray form an object |
CN201980073969.2A CN112996614B (en) | 2018-11-09 | 2019-10-22 | Method for forming object by spraying |
KR1020217017684A KR20210090672A (en) | 2018-11-09 | 2019-10-22 | Product injection molding method |
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AU2018904269A AU2018904269A0 (en) | 2018-11-09 | A Method of Spray Forming an Object | |
AU2018904269 | 2018-11-09 |
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WO2020093085A1 true WO2020093085A1 (en) | 2020-05-14 |
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PCT/AU2019/051148 WO2020093085A1 (en) | 2018-11-09 | 2019-10-22 | A method of spray forming an object. |
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US (1) | US11623387B2 (en) |
EP (1) | EP3877106A4 (en) |
JP (1) | JP2022512869A (en) |
KR (1) | KR20210090672A (en) |
CN (1) | CN112996614B (en) |
BR (1) | BR112021008599A2 (en) |
WO (1) | WO2020093085A1 (en) |
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- 2019-10-22 JP JP2021523616A patent/JP2022512869A/en active Pending
- 2019-10-22 WO PCT/AU2019/051148 patent/WO2020093085A1/en active Search and Examination
- 2019-10-22 EP EP19882889.9A patent/EP3877106A4/en active Pending
- 2019-10-22 US US17/292,181 patent/US11623387B2/en active Active
- 2019-10-22 CN CN201980073969.2A patent/CN112996614B/en active Active
- 2019-10-22 KR KR1020217017684A patent/KR20210090672A/en unknown
- 2019-10-22 BR BR112021008599-8A patent/BR112021008599A2/en active Search and Examination
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Also Published As
Publication number | Publication date |
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CN112996614B (en) | 2024-02-06 |
BR112021008599A2 (en) | 2021-09-08 |
KR20210090672A (en) | 2021-07-20 |
US20210370587A1 (en) | 2021-12-02 |
EP3877106A1 (en) | 2021-09-15 |
US11623387B2 (en) | 2023-04-11 |
JP2022512869A (en) | 2022-02-07 |
CN112996614A (en) | 2021-06-18 |
EP3877106A4 (en) | 2022-08-03 |
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