NEW POWDER METAL PROCESS FOR PRODUCTION OF COMPONENTS FOR HIGH TEMPERATURE USEAGE

• US 20170120339A1
• Filed: 05/13/2015
• Published: 05/04/2017
• Est. Priority Date: 05/13/2014
• Status: Abandoned Application

• Current Assignee: Metalvalue SAS
• Original Assignee: Metalvalue SAS
• Inventors: ASLUND, Christer
• Application Number:
  US15/310,825
• Publication Number:
  US 20170120339A1
• Time in Patent Office: Days
• CPC Class Codes: B22F 1/00 Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
• CPC Class Codes: B22F 1/065 Spherical particles
• CPC Class Codes: B22F 1/10 Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
• CPC Class Codes: B22F 1/148 Agglomerating
• CPC Class Codes: B22F 2301/35 Iron
• CPC Class Codes: B22F 2302/253 Aluminum oxide (Al2O3)
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/04 by applying fluid pressure , e.g. by cold isostatic pressing [CIP]
• CPC Class Codes: B22F 3/087 using high energy impulses, e.g. magnetic field impulses
• CPC Class Codes: B22F 3/1021 Removal of binder or filler removal of binder from ceramics C04B35/638
• CPC Class Codes: B22F 3/15 Hot isostatic pressing
• CPC Class Codes: B22F 3/16 in successive or repeated steps
• CPC Class Codes: B22F 7/008 characterised by the composition
• CPC Class Codes: B22F 9/04 starting from solid material, e.g. by crushing, grinding or milling C22C1/1084 takes precedence; crushing, grinding or milling, in general, see the relevant subclasses, e.g. B02C
• CPC Class Codes: C01F 7/02 Aluminium oxide; Aluminium hydroxide; Aluminates
• CPC Class Codes: C01G 25/02 Oxides
• CPC Class Codes: C01P 2002/60 Compounds characterised by their crystallite size
• CPC Class Codes: C01P 2006/34 Melting temperatures
• CPC Class Codes: C22C 1/05 Mixtures of metal powder with non-metallic powder C22C1/08 takes precedence
• CPC Class Codes: C22C 32/0026 Matrix based on Ni, Co, Cr or alloys thereof

Abstract

There is provided a method for the manufacture of a metal part from powder comprising the steps: a) providing a spherical metal powder, b) mixing the powder with a hydrocolloid in water to obtain an agglomerated metal powder, c) compacting the agglomerated metal powder to obtain a part of compacted agglomerated metal powder, wherein the structure of the part is open, d) debinding the part to remove the hydrocolloid, e) compacting the part using high velocity compaction (HVC) preferably to a density of more than 95% of the full theoretical density, f) further compacting the part using hot isostatic pressing (HIP) preferably to more than 99% of the full theoretical density to obtain a finished metal part, wherein at least one oxide is added to the metal powder before step c), which oxide has a melting point higher than the melting point of the metal powder.

Claims

1. A method for the manufacture of a metal part from spherical metal powder comprising the steps:

a. providing a spherical metal powder,

b. mixing the spherical powder with a hydrocolloid in water to obtain an agglomerated spherical metal powder,

c. compacting the agglomerated spherical metal to obtain a part of compacted agglomerated metal powder, wherein the structure of the part is open,

d. debinding the part to remove the hydrocolloid,

e. compacting the part using high velocity compaction (HVC) preferably to a density of more than 95% of the full theoretical density,

f. further compacting the part using HIP, preferably to more than 99% of the full theoretical density, to obtain a finished metal part,

wherein at least one oxide is added to the metal powder before step c), which oxide has a melting point higher than the melting point of the metal powder.

2. The method according to claim 1, wherein the oxide has a melting point at least 100°

C. higher than the metal powder, wherein the oxide is stable at the melting point of the metal powder, and wherein the oxide does not react with the metal powder at the melting point of the metal powder.

3. The method according to claim 1, wherein the metal is steel.

4. The method according to claim 1, wherein the metal is stainless steel.

5. The method according to claim 1, wherein the oxide is a metal oxide.

6. The method according to claim 1, wherein the oxide is at least one selected from the group consisting of aluminium oxide and zirconium oxide.

7. The method according to claim 1, wherein the oxide is the form of a powder with an average grain size smaller than 1 μ

m.

8. The method according to claim 1, wherein the oxide is mixed together with the powder and the hydrocolloid in water in step b) to obtain the agglomerated metal powder.

9. The method according to claim 1, wherein the part is treated in at least one additional step between steps e) and f).

10. The method according to claim 1, wherein the grain size in the spherical metal powder provided in step a) is selected in order to control the grain size in the finished product.

11. A metal part comprising an oxide and which is manufactured according to claim 1.