Method for manufacturing a component containing an iron alloy material

Patent metadata

Field	Value
Publication number	US-10513748-B2
Application number	US-201514877532-A
Country	US
Kind code	B2
Filing date	Oct 7, 2015
Priority date	Aug 27, 2014
Publication date	Dec 24, 2019
Grant date	Dec 24, 2019

Abstract

In a method for manufacturing a component containing an iron alloy material, a pulverulent pre-alloy is provided. The pre-alloy comprises, in wt. %, 0.01 to 1% C, .0.01 to 30% Mn, ≤6% Al, and 0.05 to 6.0% Si, the remainder being Fe and usual contaminants. The pulverulent pre-alloy is mixed with at least one of elementary Ag powder, elementary Au powder, elementary Pd powder and elementary Pt powder so as to produce a powder mixture containing 0.1 to 20% of at least one of Ag, Au, Pd and Pt. The powder mixture is applied onto a carrier (16) by means of a powder application device (14). Electromagnetic or particle radiation is selectively irradiated onto the powder mixture applied onto the carrier (16) by means of an Irradiation device (18) so as to generate a component from the powder mixture by an additive layer construction method.

First claim

The invention claimed is:

1. A method for manufacturing a component containing an iron alloy material, the method comprising the steps:
providing a pulverulent pre-alloy, the pre-alloy comprising in wt. %:
0.01 to 1% C,
0.01 to 30% Mn,
≤6% Al,
0.05 to 6.0% Si, and
at least one of Cr at a content of ≤2%, Cu at a content of ≤2%, Ti at a content of ≤2%, Co at a content of ≤2%, Zr at a content of ≤2%, V at a content of ≤2°/s, Nb at a content of ≤2%, Ta at a content of ≤2% and B at a content of ≤0.2%, the remainder being Fe and usual contaminants,
mixing the pulverulent pre-alloy with elementary Ag powder, so as to produce a powder mixture containing 0.5 to 20 wt. % Ag,
applying the powder mixture onto a carrier by a powder application device, and selectively irradiating electromagnetic or particle radiation onto the powder mixture applied onto the carrier by an irradiation device so as to generate a component from the powder mixture by an additive layer construction method.

2. The method according to claim 1 , wherein the pulverulent pre-alloy is mixed with elementary Ag powder, so as to produce a powder mixture containing ≤5 wt. % Ag.

3. The method according to claim 1 , wherein the pulverulent pre-alloy is mixed with elementary Ag powder, so as to produce a powder mixture containing ≥2 wt. % Ag.

4. The method according to claim 1 , wherein an operation of the powder application device and the irradiation device is controlled in such a manner that local melt pools are formed in the powder mixture upon being irradiated with electromagnetic or particle radiation, and that the melt in the local melt pools solidifies at a solidification rate of approximately 7×10 6 K/s.

5. The method according to claim 1 , wherein the generated component is heat-treated in an inert atmosphere for 1 minute to 24 hours at a temperature between 200° C. and 1100° C.

6. A method for manufacturing a component containing an iron alloy material, the method comprising the steps:
providing a pulverulent pre-alloy, the pre-alloy comprising in wt. %:
0.04 to 1% C,
9.0 to 24.0% Mn,
0.05 to 4% Al, and
0.05 to 6.0% Si, the remainder being Fe and usual contaminants,
mixing the pulverulent pre-alloy with at least one of elementary Ag powder, elementary Au powder, elementary Pd powder, and elementary Pt powder so as to produce a powder mixture containing 0.1 to 20 wt. % of at least one of Ag, Au, Pd and Pt,
applying the powder mixture onto a carrier by a powder application device, and
selectively irradiating electromagnetic or particle radiation onto the powder mixture applied onto the carrier by an irradiation device so as to generate a component from the powder mixture by an additive layer construction method.

7. The method of claim 6 , wherein the pulverulent pre-alloy is mixed with at least one of elementary Ag powder, elementary Au powder, elementary Pd powder, and elementary Pt powder so as to produce a powder mixture containing ≤5 wt. % of at least one of Ag, Au, Pd and Pt.

8. The method of claim 7 , wherein the pulverulent pre-alloy is mixed with elemental Ag powder so as to produce a powder mixture containing 0.1 wt. % to ≤5 wt. % Ag.

9. The method of claim 6 , wherein the pulverulent pre-alloy is mixed with at least one of elementary Ag powder, elementary Au powder, elementary Pd powder and elementary Pt powder so as to produce a powder mixture containing ≥2 wt. % of at least one of Ag, Au, Pd and Pt.

10. The method of claim 9 , wherein the pulverulent pre-alloy is mixed with elemental Ag powder so as to produce a powder mixture containing ≥2 wt. % to 20 wt. % Ag.

11. The method of claim 6 , wherein an operation of the powder application device and the irradiation device is controlled in such a manner that local melt pools are formed in the powder mixture upon being irradiated with electromagnetic or particle radiation, and that the melt in the local melt pools solidifies at a solidification rate of approximately 7×10 6 K/s.

12. The method of claim 6 , wherein the generated component is heat-treated in an inert atmosphere for 1 minute to 24 hours at a temperature between 200° C. and 1100° C.

13. The method of claim 6 , wherein the pulverulent pre-alloy further comprises Cr at a content of ≤2 wt. %.

14. The method of claim 6 , wherein the pulverulent pre-alloy further comprises, in wt. %, at least one of Cr at a content of ≤2%, Cu at a content of ≤2%, Ti at a content of ≤2%, Co at a content of ≤2%, Zr at a content of ≤2%, V at a content of ≤2%, Nb at a content of ≤2%, Ta at a content of ≤2% and B at a content of ≤0.2%.

15. A method for manufacturing a component containing an iron alloy material, the method comprising the steps:
providing a pulverulent pre-alloy, the pre-alloy comprising in wt. %:
0.01 to 1% C,
0.01 to 30% Mn,
≤6% Al, and
0.05 to 6.0% Si, the remainder being Fe and usual contaminants,
mixing the pulvenilent pre-alloy with elementary Ag powder so as to produce a powder mixture containing 0.1 to 20 wt. % Ag,
applying the powder mixture onto a carrier by a powder application device, and
selectively irradiating electromagnetic or particle radiation onto the powder mixture applied onto the carrier by an irradiation device so as to generate a component from the powder mixture by an additive layer construction method.

16. The method of claim 15 , wherein the pulverulent pre-alloy is mixed with elemental Ag powder so as to produce a powder mixture containing 0.1 wt. % to ≤5 wt. % Ag.

17. The method of claim 15 , wherein the pulverulent pre-alloy is mixed with elemental Ag powder so as to produce a powder mixture containing ≥2 wt. % to 20 wt. % Ag.

18. The method of claim 16 , wherein the pulverulent pre-alloy further comprises, in wt. %, at least one of Cr at a content of ≤2%, Cu at a content of ≤2%, Ti at a content of ≤2%, Co at a content of ≤2%, Zr at a content of ≤2%, V at a content of ≤2%, Nb at a content of ≤2%, Ta at a content of ≤2% and B at a content of ≤0.2%.

19. The method of claim 17 , wherein the pulverulent pre-alloy further comprises, in wt. %, at least one of Cr at a content of ≤2%, Cu at a content of ≤2%, Ti at a content of ≤2%, Co at a content of ≤2%, Zr at a content of ≤2%, V at a content of ≤2%, Nb at a content of ≤2%, Ta at a content of ≤2% and B at a content of ≤0.2%.

20. The method of claim 15 , wherein an operation of the powder application device and the irradiation device is controlled in such a manner that local melt pools are formed in the powder mixture upon being irradiated with electromagnetic or particle radiation, and that the melt in the local melt pools solidifies at a solidification rate of approximately 7×10 6 K/s.

Assignees

• SLM Solutions Group AG

Inventors

• Niendorf Thomas
• Maier Hans Juergen
• Brenne Florian
• Schaper Mirko
• Grundmeier Guido
• Schwarze Dieter

Classifications

• C22C33/0207

  Using a mixture of pre-alloyed powders or a master alloy · CPC title

• A61L27/08

  Carbon {; Graphite} · CPC title

• C22C38/14

  containing titanium or zirconium · CPC title

• A61L27/042

  Iron or iron alloys · CPC title

• C22C38/10

  containing cobalt · CPC title