Powder material for use in additive layer manufacturing, additive layer manufacturing method using same, and molded article

Patent metadata

Field	Value
Publication number	US-12447533-B2
Application number	US-201917292795-A
Country	US
Kind code	B2
Filing date	Oct 23, 2019
Priority date	Nov 12, 2018
Publication date	Oct 21, 2025
Grant date	Oct 21, 2025

Abstract

There is provided a powder material that is for manufacturing a molded article having low porosity and having uniformly present micropores by an additive layer manufacturing method. A powder material for use in additive layer manufacturing contains ceramics and metals, in which a tapped filling rate defined by (tapped density/theoretical density)×100% is 30% or more and less than 40%.

First claim

The invention claimed is:

1. A powder material for use in additive layer manufacturing comprising:
tungsten carbide (WC); and
cobalt,
wherein:
the powder material comprises a main powder and an additional powder;
a porosity of the main powder is larger than a porosity of the additional powder;
the porosity of the main powder is 10% or more; and
a tapped filling rate defined by (tapped density/theoretical density)×100% is 30% or more and less than 40%.

2. The powder material according to claim 1 , wherein
when a particle diameter at an integrated value of 50% (Dv50) in a volume-based particle size distribution of the main powder is defined as A and a particle diameter at an integrated value of 50% (Dv50) in a volume-based particle size distribution of the additional powder is defined as B, A/B is 25 or less.

3. The powder material according to claim 2 , wherein
the main powder has a particle size range of 5 to 150 μm and the additional powder has a particle size range of 0.1 to 15 μm.

4. The powder material according to claim 2 , wherein the powder material is used for manufacturing a ceramic filter or a catalyst carrier material by the additive layer manufacturing.

5. A molded article obtained by applying additive layer manufacturing to the powder material according to claim 2 .

6. The powder material according to claim 1 , wherein
the main powder has a particle size range of 5 to 150 μm and the additional powder has a particle size range of 0.1 to 15 μm.

7. The powder material according to claim 6 , wherein the powder material is used for manufacturing a ceramic filter or a catalyst carrier material by the additive layer manufacturing.

8. A molded article obtained by applying additive layer manufacturing to the powder material according to claim 6 .

9. The powder material according to claim 1 , wherein the powder material is used for manufacturing a ceramic filter or a catalyst carrier material by the additive layer manufacturing.

10. A molded article obtained by applying additive layer manufacturing to the powder material according to claim 9 .

11. A molded article obtained by applying additive layer manufacturing to the powder material according to claim 1 .

12. The molded article according to claim 11 , wherein the molded article is a ceramic filter or a catalyst carrier material.

13. A method of additive layer manufacturing comprising supplying the powder material according to claim 1 .

14. The method according to claim 13 comprising additive layer manufacturing a cemented carbide.

15. The powder material according to claim 1 , wherein the porosity of the main powder is 17.8% or more and 31.5% or less.

Assignees

• Fujimi Inc

Inventors

• Yamada Junya
• Ibe Hiroyuki
• Kato Nobuaki
• Kato Yuta
• Sugiyama Yoshikazu

Classifications

• B22F1/12

  Metallic powder containing non-metallic particles (containing lubricating or binding agents or organic material B22F1/10) · CPC title

• B22F1/052

  characterised by a mixture of particles of different sizes or by the particle size distribution · CPC title

• B22F1/148

  Agglomerating · CPC title

• B22F1/10

  Metallic powder containing lubricating or binding agents; Metallic powder containing organic material · CPC title

• B22F2304/10

  Micron size particles, i.e. above 1 micrometer up to 500 micrometer · CPC title