Metal laminated and shaped object, aluminum-based powder for metal laminating and shaping, and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-10843268-B2
Application number	US-201615545989-A
Country	US
Kind code	B2
Filing date	Dec 26, 2016
Priority date	Dec 26, 2016
Publication date	Nov 24, 2020
Grant date	Nov 24, 2020

Abstract

The present invention provides a robust metal lamination-shaped object containing aluminum and having no defect. A metal powder used for forming this metal lamination-shaped object is an aluminum-based powder having a volume-based 50% particle diameter larger than or equal to 10 μm and smaller than 100 μm when a particle diameter distribution is measured by a laser diffraction-scattering method, a specific surface area smaller than or equal to 0.5 m2/g, and an oxygen amount larger than or equal to 3 mg/m2 and less than or equal to 10 mg/m2 per unit surface area. A relationship between a hydrogen amount (X ml in standard state) per 100 g of the aluminum-based powder and a specific surface area (Y m2/g), and a relationship between the hydrogen amount (X ml in standard state) and an oxygen amount (Z wt %), are respectively in accordance with formulas: X/Y<151 and Z/X>0.0022. A metal lamination-shaped object, that is lamination-shaped by a three-dimensional lamination-shaping apparatus in a powder bed fusion type using the above metal powder, has a hydrogen amount less than or equal to 3 ml in standard state per 100 g, and a relative density more than or equal to 99%.

First claim

The invention claimed is:

1. A metal powder used for lamination-shaping which is an aluminum-based powder having a volume-based 50% particle diameter larger than or equal to 10 μm and smaller than 100 μm when a particle diameter distribution is measured by a laser diffraction-scattering method, a specific surface area smaller than or equal to 0.5 m 2 /g, and an oxygen amount larger than or equal to 3.0 mg/m 2 and less than or equal to 10.0 mg/m 2 per unit surface area,
wherein a relationship between a hydrogen amount (X ml in standard state) per 100 g of the aluminum-based powder and a specific surface area (Y m 2 /g), and a relationship between the hydrogen amount (X ml in standard state) and an oxygen amount (Z wt %), are respectively in accordance with following formulas:
X/Y< 151 and,
Z/X> 0.0022.

2. The metal powder according to claim 1 , wherein the relationship between the hydrogen amount (X ml in standard state) and the specific surface area (Y m 2 /g), and the relationship between the hydrogen amount (X ml in standard state) and the oxygen amount (Z wt %), are respectively in accordance with following formulas:
X/Y≤ 130 and,
Z/X≥ 0.003.

3. A method of manufacturing the metal powder of claim 1 used for lamination-shaping, the method comprising:
manufacturing an aluminum-based alloy powder by gas atomization process or centrifugal atomization process in an inert gas atmosphere in which an oxygen amount is controlled; and
deaerating the aluminum-based alloy powder in an inert gas at 300° C. to 600° C.

4. The method according to claim 3 , wherein, in said deaerating step, the aluminum-based alloy powder is deaerated in an inert gas at 400° C. to 500° C.

5. The method according to claim 3 , wherein, in said deaerating step, the aluminum-based alloy powder is deaerated in an inert gas for 1 to 100 hours.

6. A metal lamination-shaped object that is lamination-shaped by a three-dimensional lamination-shaping apparatus in a powder bed fusion type using the metal powder according to claim 1 ,
wherein a hydrogen amount is less than or equal to 3 ml per 100 g in standard state, and a relative density is more than or equal to 99%, in the metal lamination-shaped object.

7. A metal lamination-shaped object that is lamination-shaped by a three-dimensional lamination-shaping apparatus in a powder bed fusion type using the metal powder according to claim 2 ,
wherein a hydrogen amount is less than or equal to 3 ml per 100 g in standard state, and a relative density is more than or equal to 99%, in the metal lamination-shaped object.

8. The method according to claim 4 , wherein, in said deaerating step, the aluminum-based alloy powder is deaerated in an inert gas for 1 to 100 hours.

9. The method according to claim 5 , where the deaerating step is performed for 10 hours.

10. The method according to claim 8 , where the deaerating step is performed for 10 hours.

Assignees

• Tech Res Association Future Additive Manufacturing

Inventors

• Hashizume Yoshiki
• Murakami Isao
• Muramatsu Kenji
• Ishigami Kenta

Classifications

• B22F3/12 Primary

  Both compacting and sintering (by forging B22F3/17) · CPC title

• B22F12/41

  characterised by the type, e.g. laser or electron beam · CPC title

• B22F10/36

  of energy beam parameters · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• C22C1/026 Primary

  Alloys based on aluminium · CPC title