Method for producing metal or ceramic components and components

Patent metadata

Field	Value
Publication number	US-10486385-B2
Application number	US-201716084230-A
Country	US
Kind code	B2
Filing date	Mar 24, 2017
Priority date	Apr 13, 2016
Publication date	Nov 26, 2019
Grant date	Nov 26, 2019

Abstract

Disclosed is a method for producing a metal or ceramic component having regions of differing porosities. The method includes subjecting powder or a presintered precursor to a pressure-assisted pressing and sintering step, using at least one punch for the pressing step. The at least one punch has a contact surface that is intended for making contact with the powder or the presintered precursor and that has a flat outer region and an inner region having a concave recess. After the sintering step, a component is obtained that has a flat outer compacted region having a first porosity and an inner porous region having a second porosity. The component has, on at least one side, a defined transition region between the outer region and the inner region.

First claim

The invention claimed is:

1. A method for producing a metal or ceramic component having regions of differing porosities,
subjecting powder or a presintered precursor to a pressure-assisted pressing and sintering step,
wherein at least one punch is used for the pressure-assisted pressing and sintering step, the at least one punch having a contact surface that is intended for making contact with the powder or the presintered precursor and that has a flat outer region and an inner region having a concave recess that, proceeding from the flat outer contact surface, includes at least one flank at an angle of 0<α≤90°,
wherein the pressure-assisted pressing and sintering step is assisted by an electric field, and,
wherein after the pressure-assisted pressing and sintering step, a component is obtained that has a flat outer compacted region having a porosity of less than 5 vol. % and an inner porous region having a porosity of between 10 and 60 vol. %, the component having on at least one side, a defined transition region between the outer region and the inner region.

2. The method according to claim 1 , wherein the at least one punch has a circular, oval, square, rectangular or polygonal contact surface.

3. The method according to claim 1 , wherein the at least one punch has at least one circular, oval, square, rectangular or polygonal inner region having a concave recess.

4. The method according to claim 3 , wherein the at least one punch has at least one inner region having a concave recess including at least one flank having an angle α of between 15° and 75°.

5. The method according to claim 1 , wherein the at least one punch includes a circular inner region in a center thereof, which has a concave recess having a flank having a constant angle α.

6. The method according to claim 1 , wherein the at least one punch includes at least one inner region having a concave recess having a flat inner region in portions, which is oriented in particular in parallel with the contact surface of the flat outer region.

7. The method according to claim 1 , wherein two punches having a contact surface are used, each of which comprises a flat outer region and an inner region having a concave recess, which, proceeding from the flat outer contact surface, comprises at least one flank at an angle of 0<α≤90°.

8. The method according to claim 1 , wherein the contact surface defines multiple separate concave recesses arranged to produce multiple separate regions of greater porosity in a plane of the component such that each of the multiple separate regions of greater porosity is separated from the other one or more regions of greater porosity by one or more regions of lesser porosity;
wherein the inner porous region serves as one of the regions of greater porosity and the flat outer compacted region serves as at least a portion of the one or more regions of lesser porosity.

9. A metal or ceramic component, which has a prismatic or cylindrical shape and different porosities, comprising:
a flat outer compacted region having a higher density and an inner porous region comprising at least one convex raised portion and having a lower density; and
on at least one side, a defined transition region between the flat outer region and the inner region,
wherein the flat outer compacted region has a porosity of less than 5 vol. % and the inner porous region has a porosity of between 10 and 60 vol. %.

10. The component according to claim 9 , further comprising a circular inner region.

11. The component according to claim 9 , which has a cylindrical shape, wherein the flat outer region is in the form of a ring.

12. The component according to claim 9 , which has a prismatic shape.

13. The component according to claim 10 , wherein the circular inner region includes a flank having a constant angle α.

14. The component according to claim 10 , wherein the circular inner region includes a flank having an angle α of between greater than 0° and 90°.

15. The component according to claim 9 which includes, on two opposite sides, a flat outer region and at least one inner region having a convex raised portion.

16. The component according to claim 15 , wherein the at least one inner region having a convex raised portion comprises a flat inner region.

17. The component according to claim 9 , wherein the flat outer compacted region has a porosity of less than 2 vol. %.

18. The component according to claim 9 , wherein the inner porous region has a porosity of between 20 and 55 vol. %.

19. The method according to claim 1 , wherein the flat outer region of the contact surface is configured to be movable relative to the inner region of the contact surface, and
wherein the pressure-assisted pressing and sintering step comprises moving the inner region of the contact surface with respect to the flat outer region of the contact surface so as to apply a pressure by the inner region of the contact surface against the powder or presintered precursor that is different a pressure applied by the flat outer region of the contact surface, both regions of the contact surface simultaneously contacting the powder or presintered precursor during the pressure-assisted pressing and sintering step.

20. The method according to claim 1 , wherein the punch is hollow to define a cavity in which a measurement probe is disposed.

Assignees

• Forschungszentrum Juelich Gmbh

Inventors

• Bram Martin
• Vassen Robert
• Gonzalez Jesus
• Marcano Diana

Classifications

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• C04B2235/775

  Products showing a density-gradient · CPC title

• B22F3/105

  by using electric current {other than for infrared radiant energy}, laser radiation or plasma (B22F3/11 takes precedence){; by ultrasonic bonding (B22F3/115 takes precedence)} · CPC title

• C04B2235/666

  Applying a current during sintering, e.g. plasma sintering [SPS], electrical resistance heating or pulse electric current sintering [PECS] · CPC title

• B30B15/065 Primary

  Press rams · CPC title