Metal powder composed of spherical particles

• US 10,350,680 B2
• Filed: 03/24/2016
• Issued: 07/16/2019
• Est. Priority Date: 03/31/2015
• Status: Active Grant

• Current Assignee: Sanyo Special Steel Company Limited (Nippon Steel Corporation)
• Original Assignee: Sanyo Special Steel Company Limited (Nippon Steel Corporation)
• Inventors: Yamamoto, Takahisa, Kariya, Tetsuro
• Primary Examiner(s): Ferre, Alexandre F
• Application Number:
  US15/562,600
• Publication Number:
  US 20180104740A1
• Time in Patent Office: 1,209 Days
• Field of Search: None
• CPC Class Codes: B22F 1/05 Metallic powder characterised by the size or surface area of the particles
• CPC Class Codes: B22F 1/065 Spherical particles
• CPC Class Codes: B22F 10/20 Direct sintering or melting
• CPC Class Codes: B22F 10/34 of powder characteristics, e.g. density, oxidation or flowability
• CPC Class Codes: B22F 2301/15 Nickel or cobalt
• CPC Class Codes: B22F 2301/35 Iron
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 9/082 atomising using a fluid using centrifugal force B22F9/10
• CPC Class Codes: B22F 9/18 with reduction of metal compounds
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: C22C 1/0433 Nickel- or cobalt-based alloys
• CPC Class Codes: C22C 19/03 based on nickel
• CPC Class Codes: C22C 19/05 with chromium
• CPC Class Codes: C22C 19/056 with the maximum Cr content being at least 10% but less than 20%
• CPC Class Codes: C22C 19/07 based on cobalt
• CPC Class Codes: C22C 30/02 containing copper
• CPC Class Codes: C22C 33/02 by powder metallurgy working metallic powder B22F
• CPC Class Codes: C22C 38/00 Ferrous alloys, e.g. steel alloys cast-iron alloys C22C37/00
• CPC Class Codes: C22C 38/007 containing silver
• CPC Class Codes: C22C 38/008 : containing tin
• CPC Class Codes: C22C 38/02 : containing silicon
• CPC Class Codes: C22C 38/06 : containing aluminium
• CPC Class Codes: C22C 38/105 : containing Co and Ni
• CPC Class Codes: C22C 38/12 : containing tungsten, tantalum, molybdenum, vanadium, or niobium
• CPC Class Codes: C22C 38/14 : containing titanium or zirconium
• CPC Class Codes: C22C 38/16 : containing copper
• CPC Class Codes: C22C 38/46 : with vanadium
• CPC Class Codes: C22C 38/48 : with niobium or tantalum
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A problem to be solved is to provide a metal powder having a variety of excellent performances, and, in order to solve such a problem, the present invention provides a metal powder that is composed of many spherical particles; that includes at least one of Ni, Fe, and Co, in which the total content (T.C.) of the Ni, the Fe, and the Co is 50 mass % or more; that has a cumulative 10 vol % particle size D10 of 1.0 μm or more; and in which a value Y is 7.5 to 24.0 as calculated by the following mathematical equation: Y=D50×ρ×S, where D50 represents a cumulative 50 vol % particle size of the powder, ρ represents a true density of the powder, and S represents a specific surface area of the powder.

Claims

1. A metal powder composed of many spherical particles, the metal powder comprising at least one of Ni, Fe, and Co,

wherein the total content (T.C.) of the Ni, the Fe, and the Co is 50 mass % or more,

wherein the metal powder has a cumulative 10 vol % particle size D10 of 1.0 μ

m or more,

wherein a ratio P2 of the number of particles having a circularity of 0.95 or more to the total number of the particles is 50% or more, and

wherein a value Y is 7.5 to 24.0 as calculated by the following mathematical equation;

Y=D50 (m)×

ρ

(kg/m³)×

S (m²/kg)

wherein D50 (m) represents a cumulative 50 vol % particle size of the powder, ρ

(kg/m³) represents a true density of the powder, and S (m²/kg) represents a specific surface area of the powder.

2. The powder according to claim 1, wherein the balance other than the three kinds that are Ni, Fe, and Co comprises:

at least one of C, Si, Cr, Mo, Al, Ti, V, W, Nb, Zn, Ta, B, Ag, Cu, and Sn; and

an unavoidable impurity.

3. The powder according to claim 2, wherein a ratio of a cumulative 60 vol % particle size D60 to the particle size D10 (D60/D10) is 1.0 or more and less than 10.0.

4. The powder according to claim 3, wherein a ratio of the particle size D50 to a mode diameter Dm (D50/Dm) is 0.80 to 1.20.

5. The powder according to claim 4, wherein the ratio P2 is 80% or more.

6. The powder according to claim 3, wherein the ratio P2 is 80% or more.

7. The powder according to claim 2, wherein a ratio of the particle size D50 to a mode diameter Dm (D50/Dm) is 0.80 to 1.20.

8. The powder according to claim 7, wherein the ratio P2 is 80% or more.

9. The powder according to claim 2, wherein the ratio P2 is 80% or more.

10. The powder according to claim 1, wherein a ratio of a cumulative 60 vol % particle size D60 to the particle size D10 (D60/D10) is 1.0 or more and less than 10.0.

11. The powder according to claim 10, wherein a ratio of the particle size D50 to a mode diameter Dm (D50/Dm) is 0.80 to 1.20.

12. The powder according to claim 11, wherein the ratio P2 is 80% or more.

13. The powder according to claim 10, wherein the ratio P2 is 80% or more.

14. The powder according to claim 1, wherein a ratio of the particle size D50 to a mode diameter Dm (D50/Dm) is 0.80 to 1.20.

15. The powder according to claim 14, wherein the ratio P2 is 80% or more.

16. The powder according to claim 1, wherein the ratio P2 is 80% or more.

17. The powder according to claim 1, having an oxygen concentration of less than 1000 ppm.

18. The powder according to claim 1, wherein a flow rate is less than 35.0 s/50 g.

19. The powder according to claim 1, wherein a cumulative 60 vol % particle size D60 is 50.0 μ

m or more.