Method of producing ceramic manufactured object

Patent metadata

Field	Value
Publication number	US-12042952-B2
Application number	US-202016855922-A
Country	US
Kind code	B2
Filing date	Apr 22, 2020
Priority date	Oct 27, 2017
Publication date	Jul 23, 2024
Grant date	Jul 23, 2024

Abstract

A method of producing a ceramic manufactured object including (i) a step of leveling a ceramic powder to form a powder layer, (ii) a step of irradiating the powder layer with a laser beam based on three-dimensional data to crystallize an irradiated site, and (iii) performing the steps (i) and (ii) in repetition, wherein in the step (ii), a surface of the powder layer is irradiated with the laser beam in an unfocused state.

First claim

What is claimed is:

1. A method of producing a ceramic manufactured object, comprising repeatedly performing:
(i) a step of leveling a ceramic powder to form a powder layer; and
(ii) a step of irradiating the powder layer with a scanned laser beam being scanned based on three-dimensional data to melt an irradiated site of the powder layer and then solidifying the irradiated site to form a solidified portion;
wherein a focal position of the scanned laser beam formed by a laser focusing optical system is shifted from a surface of the powder layer, and the solidified portion includes a crystalline region and an amorphous region smaller than the crystalline region,
wherein the crystalline region and the amorphous region contains at least one oxide in common,
wherein in the step (ii), the surface of the powder layer is irradiated with the laser beam so that a ratio D/L falls within a range of 0.2≤D/L≤0.7, thereby suppressing formation of an amorphous substance, and
wherein (L) represents the width of fusion and (D) represents the depth of the fusion at the solidified portion formed by one-line scan irradiation of the power layer with the scanned laser beam.

2. The method of producing a ceramic manufactured object according to claim 1 , wherein in the step (ii), preliminary heating is not performed.

3. The method of producing a ceramic manufactured object according to claim 1 , wherein in the step (ii), the scanned laser beam has an energy of fusing the powder layer at the irradiated site.

4. The method of producing a ceramic manufactured object according to claim 1 , wherein the ceramic powder includes a metal oxide.

5. The method of producing a ceramic manufactured object according to claim 1 , wherein the ceramic powder includes aluminum oxide.

6. The method of producing a ceramic manufactured object according to claim 1 , wherein a weight loss caused by heating of the ceramic powder to 800° C. is 2% or less.

7. The method of producing a ceramic manufactured object according to claim 1 , wherein the scanned laser is a Yb fiber laser, and a laser power of the scanned laser beam is less than 50 W.

8. The method of producing a ceramic manufactured object according to claim 1 , wherein the ceramic powder layer has a layer thickness of 5 μm or more to 100 μm or less.

9. The method of producing a ceramic manufactured object according to claim 5 , wherein the ceramic powder includes at least one selected from the group consisting of gadolinium oxide, terbium oxide, and praseodymium oxide.

10. The method of producing a ceramic manufactured object according to claim 1 , wherein the solidified portion has a relative density of 90% or more, the relative density being defined by (100×(density of the solidified portion)/(density when the solidified portion is completely crystalline)).

11. The method of producing a ceramic manufactured object according to claim 1 , wherein the focal position is out of the powder layer.

12. The method of producing a ceramic manufactured object according to claim 1 , wherein a distance between the focal position and the surface of the powder layer is 1.5 mm or more.

13. The method of producing a ceramic manufactured object according to claim 12 , wherein a distance between the focal position and the surface of the powder layer is 5.5 mm or less.

14. The method of producing a ceramic manufactured object according to claim 1 , wherein the scanned laser beam is formed to have a beam diameter of 65 μm.

15. The method of producing a ceramic manufactured object according to claim 1 , wherein the laser is a Nd:YAG laser.

Assignees

• Canon Kk

Inventors

• Yasui Nobuhiro
• Oshima Kanako
• Yabuta Hisato

Classifications

• C04B2235/665

  Local sintering, e.g. laser sintering · CPC title

• C04B2235/6026

  Computer aided shaping, e.g. rapid prototyping · CPC title

• C04B2235/3224

  Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide · CPC title

• C04B2235/3217

  Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina · CPC title

• C04B35/64

  Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F}) · CPC title