NOBLE-METAL POWDER AND THE USE THEREOF FOR PRODUCING COMPONENTS

• US 20170252854A1
• Filed: 03/03/2017
• Published: 09/07/2017
• Est. Priority Date: 03/07/2016
• Status: Active Grant

• Current Assignee: Haraeus Deutschland GmbH & Co. KG
• Original Assignee: Haraeus Deutschland GmbH & Co. KG
• Inventors: Maier, Dirk, Humm, Stephen
• Granted Patent: US 10,744,590 B2
• 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 1/065 Spherical particles
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/34 of powder characteristics, e.g. density, oxidation or flowability
• CPC Class Codes: B22F 10/64 by thermal means control of energy beam parameters for post heating B22F10/364
• CPC Class Codes: B23K 15/0086 welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C22C 1/0466 Alloys based on noble metals
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The present invention relates to a powder composed of spherical noble-metal particles having a particle size distribution with a d₁₀ value of ≧10.0 μm and a d₉₀ value of ≦80.0 μm.

Claims

1. Powder composed of spherical noble-metal particles having a particle size distribution with a d₁₀ value of ≧

10.0 μ

m and a d₉₀ value of ≦

80.0 μ

m.

2. Powder according to claim 1, wherein the noble metal is a platinum-group metal, gold or silver or an alloy composed of at least two of the aforementioned noble metals.

3. Powder according to claim 2, wherein the platinum-group metal is platinum, iridium, palladium, ruthenium, rhodium or osmium or an alloy composed of at least two of the aforementioned platinum-group metals.

4. Powder according to claim 1, wherein the noble-metal particles contain elements which are not noble metals in a proportion of not more than 0.1% by weight.

5. Powder according to claim 1, wherein the d₉₀ value and the d₁₀ value differ by at least 15 μ

m.

6. Powder according to claim 1, wherein the d₁₀ value is within the range from 10.0 to 35.0 μ

m, and/or the d₉₀ value is within the range from 40.0 to 80.0 μ

m.

7. Powder according to claim 1, wherein the noble metal is iridium, the d₁₀ value is within the range from 20.0 to 30.0 μ

m, the d₉₀ value is within the range from 40.0 to 80.0 μ

m, and the difference between the d₉₀ value and the d₁₀ value is at least 20 μ

m.

8. Powder according to claim 1, wherein the powder satisfies the following condition:

F/ρ

_TH≦

0.30 s/(50 cm³)

where F is the flowability of the powder in s/(50 g), determined in accordance with DIN EN ISO 4490;

2014-11, and

ρ

_TH is the theoretical density in g/cm³ of the noble metal forming the noble-metal particles.

9. Powder according to claim 1, wherein, based on the number of noble-metal particles, at least 80% of the noble-metal particles satisfy the following condition:

0.8≦

d_min/d_max≦

1.0;

where d_min and d_max are the minimum diameter and the maximum diameter, respectively, of a noble-metal particle.

10. Powder according to claim 1, wherein the noble-metal particles have a mean crystallite size ≧

200 nm.

11. Powder according to claim 1, obtainable via an atomization of liquid noble metal, preferably a gas atomization, a plasma atomization, a centrifugal atomization or a crucible-free atomization, and optionally a classification carried out after the atomization.

13. Component which is obtainable from the powder according to claim 1, via an additive manufacturing process and which has a porosity of less than 10%.

14. Additive manufacturing process for producing a component, comprising the following steps:

(a) applying the powder according to claim 1, in the form of a first layer to a substrate in a construction space,

(b) at least partially melting the powder of the first layer using high-energy radiation and allowing solidification of the melted powder,

(c) applying a further layer of the powder to the first layer,

(d) at least partially melting the powder of the further layer using high-energy radiation and allowing solidification of the melted powder, and

(e) repeating steps (c) and (d).

12. (canceled)