Dip-coat binder solutions comprising a dip-coat metallic precursor for use in additive manufacturing

Patent metadata

Field	Value
Publication number	US-12064810-B2
Application number	US-202117500390-A
Country	US
Kind code	B2
Filing date	Oct 13, 2021
Priority date	Nov 9, 2020
Publication date	Aug 20, 2024
Grant date	Aug 20, 2024

Abstract

A dip-coat binder solution comprises a dip-coat metallic precursor and a dip-coat binder. The dip-coat binder solution has a viscosity greater than or equal to 1 cP and less than or equal to 150 cP. A method of forming a part includes providing a green body part comprising a plurality of layers of print powder and a print binder, dipping the green body part in a dip-coat binder solution, and heating the dip-coated green body part. The dip-coated green body part is heated to form a coated green body part having a metallic precursor coating on an outer surface of the coated green body part. The coated green body part has a strength greater than or equal to 10 MPa.

First claim

What is claimed is:

1. A dip-coat binder solution comprising, based on a total weight of the dip-coat binder solution:
greater than or equal to 10 wt % to less than or equal to 49 wt % of a dip-coat metallic precursor;
greater than 50 wt % of a thermoplastic polymer, the thermoplastic polymer comprising one or more thermoplastic polymer strands; and
optionally, greater than or equal to 1 wt. % of a solvent; and
wherein the dip-coat binder solution has a viscosity greater than or equal to 1 cP and less than or equal to 150 cP, wherein the viscosity is measured using a rheometer in accordance with ASTM E3116.

2. The dip-coat binder solution of claim 1 , wherein the dip-coat binder solution comprises greater than or equal to 20 wt % and less than or equal to 47 wt % of the dip-coat metallic precursor, based on a total weight of the dip-coat binder solution.

3. The dip-coat binder solution of claim 1 , wherein the dip-coat metallic precursor is selected from the group consisting of an alkaline earth metal, a transition metal, a post-transition metal, a metalloid, a rare earth metal, and combinations thereof.

4. The dip-coat binder solution of claim 1 , wherein the dip-coat metallic precursor comprises an organometallic compound, the organometallic compound comprising ferrocene, cobaltocene, iron pentacarbonyl, metal acetylacetonate, a cyclopentadienyl complex, a metal alkyl, a metal aryl, or a combination thereof.

5. The dip-coat binder solution of claim 1 , wherein the dip-coat metallic precursor comprises a salt, the salt comprising a compound selected from the group consisting of carboxylates, nitrates, sulfates, carbonates, formates, chlorides, halides, a derivative thereof, and combinations thereof.

6. The dip-coat binder solution of claim 1 , wherein the dip-coat metallic precursor comprises metallic nanoparticles, the metallic nanoparticles comprising nickel, silver, chromium, aluminum, cobalt, iron, copper, gold or a combination thereof.

7. The dip-coat binder solution of claim 1 , wherein the dip-coat metallic precursor has an incipient melting temperature greater than or equal to 300° C. and less than or equal to 600° C.

8. The dip-coat binder solution of claim 1 , wherein the dip-coat binder solution has a viscosity greater than or equal to 10 cP to less than or equal to 100 cP, wherein the viscosity is measured using a rheometer in accordance with ASTM E3116.

9. The dip-coat binder solution of claim 1 , wherein the thermoplastic polymer has a first polymer strand, wherein the first polymer strand has an average molecular weight greater than or equal to 7,000 g/mol and less than or equal to 50,000 g/mol.

10. The dip-coat binder solution of claim 9 , wherein the first polymer strand is selected from the group consisting of polystyrene (PS), polyvinyl pyrrolidone (PVP), polycarbonate, derivatives thereof, and combinations thereof.

11. A coated green body part comprising:
a plurality of layers of print powder; and
a metallic precursor coating on an outer surface of the plurality of layers of print powder, the metallic precursor coating comprising, based on a total weight of the metallic precursor coating:
greater than or equal to 10 wt % and less than or equal to 49 wt % of a dip-coat metallic precursor; and
greater than 50 wt % of a thermoplastic polymer, the thermoplastic polymer comprising one or more thermoplastic polymer strands,

wherein the coated green body part comprises a strength greater than or equal to 10 MPa, wherein the strength is measured using a three-point flexural strength test in accordance with ASTM B312-14.

12. The coated green body part of claim 11 , wherein the dip-coat metallic precursor comprises an organometallic compound, the organometallic compound comprising ferrocene, cobaltocene, iron pentacarbonyl, metal acetylacetonate, a cyclopentadienyl complex, a metal alkyl, a metal aryl, or a combination thereof.

13. The coated green body part of claim 11 , wherein the dip-coat metallic precursor comprises a salt selected from the group consisting of carboxylates, nitrates, sulfates, carbonates, formats, chlorides, halides, derivatives thereof, and combinations thereof.

14. The coated green body part of claim 11 , wherein the dip-coat metallic precursor comprises metallic nanoparticles, the metallic nanoparticles comprising nickel, silver, chromium, aluminum, cobalt, iron, copper, gold or a combination thereof.

15. The dip-coat binder solution of claim 1 , wherein the dip-coat binder solution comprises greater than or equal to 1 wt % of the solvent.

Assignees

• Gen Electric

Inventors

• Natarajan Arunkumar
• Bonilla Carlos H

Classifications

• B22F1/105

  containing inorganic lubricating or binding agents, e.g. metal salts · CPC title

• B22F1/103

  containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent · CPC title

• B22F10/62

  by chemical means · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title