Method for manufacturing a component containing an iron alloy material

Patent metadata

Field	Value
Publication number	US-2016201155-A1
Application number	US-201514877532-A
Country	US
Kind code	A1
Filing date	Oct 7, 2015
Priority date	Aug 27, 2014
Publication date	Jul 14, 2016
Grant date	—

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, 0.0.01 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

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
0.0.01 to 30% Mn
≦6% 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% of at least one of Ag, Au, Pd and Pt, applying the powder mixture onto a carrier by means of a powder application device, and selectively irradiating electromagnetic or particle radiation onto the powder mixture applied onto the carrier by means of 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 further comprises 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%.

3 . The method according to claim 1 ,
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 ≦15%, in particular ≦10% and more particular ≦5% of at least one of Ag, Au, Pd and Pt.

4 . The method according to claim 1 ,
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 ≦0.5%, in particular ≦1% and more particular ≦2% of at least one of Ag, Au, Pd and Pt.

5 . The method according to claim 1 ,
wherein the 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.

6 . 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.

7 . An iron alloy material, comprising in wt. %:
0.01 to 1% C 0.01 to 30% Mn ≦6% Al, 0.05 to 6.0% Si, and 0.1 to 20% Ag, the remainder being Fe and usual contaminants.

8 . The iron alloy material according to claim 7 ,
further comprising 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%.

9 . The iron alloy material according to claim 7 ,
wherein the Ag content of the iron alloy material is ≦15%, in particular ≦10% and more particular ≦5%.

10 . The iron alloy material according to claim 7 ,
wherein the Ag content of the iron alloy material is ≧0.5%, in particular ≧1% and more particular ≧2%.

11 . The iron alloy material according to claim 7 ,
wherein, in the microstructure of the iron alloy material, Ag is present in the form of Ag particles dispersed in an iron alloy matrix.

12 . The iron alloy material according to claim 7 ,
wherein, in the microstructure of the iron alloy material, an iron alloy matrix is present which, upon plastic deformation of the iron alloy material, shows twinning induced plasticity and/or transformation induced plasticity.

13 . Component, in particular implant component, containing an iron alloy material according to claim 7 .

Assignees

• SLM Solutions Group AG

Inventors

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

Classifications

• A61L27/08

  Carbon {; Graphite} · CPC title

• C22C38/14

  containing titanium or zirconium · CPC title

• C22C33/0207

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

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title

• A61L27/042

  Iron or iron alloys · CPC title