POWDER MATERIAL FOR POWDER ADDITIVE MANUFACTURING AND POWDER ADDITIVE MANUFACTURING METHOD USING SAME

• US 20170189960A1
• Filed: 06/22/2015
• Published: 07/06/2017
• Est. Priority Date: 06/20/2014
• Status: Abandoned Application

• Current Assignee: Fujimi Incorporated
• Original Assignee: Fujimi Incorporated
• Inventors: IBE, Hiroyuki
• Application Number:
  US15/320,034
• Publication Number:
  US 20170189960A1
• Time in Patent Office: Days
• CPC Class Codes: B22F 1/052 characterised by a mixture of particles of different sizes or by the particle size distribution
• CPC Class Codes: B22F 1/054 Nanosized particles
• CPC Class Codes: B22F 1/056 Submicron particles having a size above 100 nm up to 300 nm
• CPC Class Codes: B22F 1/065 Spherical particles
• CPC Class Codes: B22F 1/148 Agglomerating
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/36 of energy beam parameters
• CPC Class Codes: B22F 12/41 characterised by the type, e.g. laser or electron beam
• CPC Class Codes: B22F 9/026 Spray drying of solutions or suspensions
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B28B 1/30 by applying the material on to a core or other moulding surface to form a layer thereon to form a permanent layer B28B19/00
• CPC Class Codes: B29B 2009/125 Micropellets, microgranules, microparticles
• CPC Class Codes: B29B 9/12 characterised by structure or composition
• CPC Class Codes: B29B 9/16 Auxiliary treatment of granules
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 67/00 Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/10 Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
• CPC Class Codes: B33Y 80/00 : Products made by additive manufacturing
• CPC Class Codes: C04B 2235/528 : Spheres
• CPC Class Codes: C04B 2235/5296 : with a defined aspect ratio, e.g. indicating sphericity spherical constituents C04B2235/528
• CPC Class Codes: C04B 2235/5409 : expressed by specific surface values
• CPC Class Codes: C04B 2235/5436 : micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/5454 : nanometer sized, i.e. below 100 nm
• CPC Class Codes: C04B 2235/549 : the particle size being expressed by crystallite size or primary particle size
• CPC Class Codes: C04B 2235/6026 : Computer aided shaping, e.g. rapid prototyping
• CPC Class Codes: C04B 2235/77 : Density
• CPC Class Codes: C04B 2235/96 : Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
• CPC Class Codes: C04B 2235/963 : Surface properties, e.g. surface roughness
• CPC Class Codes: C04B 35/111 : Fine ceramics
• CPC Class Codes: C04B 35/622 : Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
• CPC Class Codes: C04B 35/62802 : Powder coating materials
• CPC Class Codes: C04B 35/63488 : Polyethers, e.g. alkylphenol polyglycolether, polyethylene glycol [PEG], polyethylene oxide [PEO]
• CPC Class Codes: C22C 29/08 : based on tungsten carbide
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

[Problem] To provide a powder material that has good fluidity and is used for powder additive manufacturing.

[Solution] The powder material of this invention is used in powder additive manufacturing. The powder material is formed of particles having a form of secondary particles that are formed with primary particles bound three-dimensionally with interspaces. The secondary particles forming the powder material preferably have an average particle diameter of 1 μm or larger, but 100 μm or smaller. The secondary particles forming the powder material are preferably granulated particles. The powder additive manufacturing method of this invention is carried out, using the powder material.

Claims

1. A powder material for powder additive manufacturing comprising:

particles having a form of secondary particles, the secondary particles formed with primary particle bound three-dimensionally with interspaces.

2. The powder material according to claim 1, wherein the secondary particles have an average particle diameter of 1 μ

m or larger and 100 μ

m or smaller.

3. The powder material according to claim 1, wherein the secondary particles are granulated particles obtainable by spherical granulation of the primary particles.

4. The powder material according to claim 1, wherein the secondary particles are granulated sintered particles obtainable by spherical granulation and sintering of the primary particles.

5. The powder material according to claim 1, wherein the primary particles have an average particle diameter of 1 nm or larger, but 10 nm or smaller.

6. The powder material according to claim 1, wherein

the secondary particles are formed of core particles being the first primary particles and microparticles being the second primary particles, with the core particles bearing the microparticles on their surfaces,

the core particles have an average particle diameter of 1 μ

m or larger, but 100 μ

m or smaller, and

the microparticles have an average particle diameter of 1 nm or larger, but smaller than 1000 nm.

7. The powder material according to claim 6, comprising the microparticles at 100 ppm or greater, but 5000 ppm or less by mass.

8. The powder material according to claim 1 formed of at least one species of material selected from the group consisting of metal materials, ceramic materials and cermets.

9. A three-dimensional object obtained by powder additive manufacturing using the powder material according to claim 1.

10. A powder additive manufacturing method using the powder material according to claim 1.

11. A method for producing a three-dimensional object, using the powder additive manufacturing method according to claim 10.