Method for producing ceramic and/or metal components

Patent metadata

Field	Value
Publication number	US-2017182554-A1
Application number	US-201515312864-A
Country	US
Kind code	A1
Filing date	May 19, 2015
Priority date	May 20, 2014
Publication date	Jun 29, 2017
Grant date	—

Abstract

The invention relates to a method of manufacturing ceramic and/or metallic components in which a support structure surrounding at least one free space is formed using a polymer and in which at least one free space is filled in at least one predefinable portion with a plastically deformable or liquid mixture of least one metal powder or ceramic powder and at least one organic binder. In this respect, the mixture contacts the wall of the structure at least in part. Subsequently, in a first thermal treatment, the mixture is transformed into a state having a sufficient strength for maintaining its geometrical shape and a temperature is observed in so doing at which the polymer forming the support structure remains stable in shape. Subsequently, in a second thermal treatment, the temperature is increased and in so doing the polymer forming the support structure is completely decomposed and the metal powder and/or ceramic powder is/are sintered.

First claim

1 . A method of manufacturing ceramic and/or metal components in which a support structure surrounding at least one free space is formed by a polymer and in which at least one free space is filled in at least one predefinable portion with a plastically deformable or liquid mixture of at least a metal powder or ceramic powder and with at least one organic binder such that the mixture contacts the wall of the support structure at least in part; and
subsequently, in a first thermal treatment, the mixture is transferred into a state having a sufficient strength for maintaining its geometrical shape and thereby a temperature is observed at which the polymer forming the support structure remains stable in shape; and subsequently, in a second thermal treatment, the temperature is increased and in so doing the polymer forming the support structure is completely decomposed and the metal powder and/or ceramic powder is/are sintered.

2 . A method in accordance with claim 1 , characterize in that the support structure is formed by an areal or selective application of the non-hardened viscous polymer or polymer mixture onto the surface of a carrier and subsequently, on an areal application, a locally defined hardening of the polymer takes place by a locally defined energy input or material input and, subsequently, non-hardened polymer is removed; and
on a selective application, the polymer is only applied in portions in which a support structure is to be formed and will be hardened there.

3 . A method in accordance with claim 1 , characterized in that the support structure is formed by layer-wise application in a plurality of planes arranged above one another.

4 . A method in accordance with claim 3 , characterized in that at least one mixture is filled successively into at least one formed free space successively following the layer-wise formation of the support structure and likewise in a layer-wise manner before the next layer of the support structure is formed.

5 . A method in accordance with claim 1 , characterized in that a support structure is formed which has different geometrical shapes in planes.

6 . A method in accordance with claim 1 , characterized in that an areal application takes place for the formation of a support structure by spreading, rolling, printing or dispensing, preferably in a metered form, and at least the region in which a support structure is to be formed is hardened by locally defined irradiation with electromagnetic radiation or a selectively locally defined application takes place by spraying or by means of a dispenser only in portions in which a support structure is to be formed.

7 . A method in accordance with claim 1 , characterized in that at least two mixtures having mutually different consistencies/compositions are filled into a free space within a support structure.

8 . A method in accordance with claim 7 , characterized in that at least two mixtures are filled in arranged next to one another and/or above one another.

9 . A method in accordance with claim 1 , characterized in that, with a support structure formed successively in a plurality of planes, at least one mixture is filled into free spaces which are newly formed in this process.

10 . A method in accordance with claim 1 , characterized in that a mixture containing ceramic and/or metal particles and an organic binder is used that is plastically deformable or flowable at normal ambient temperature or at the processing temperature.

11 . A method in accordance with claim 1 , characterized in that a polymer or polymer mixture is used for the formation of the support structure in which at least a portion is only decomposed after reaching the maximum temperature in the first thermal treatment.

Assignees

• Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten Forschung E V

Inventors

• Scheithauer Uwe
• Schwarzer Eric
• Poitzsch Claudia
• Richter Hans-Juergen
• Moritz Tassilo
• Stelter Michael

Classifications

• B22F3/1021 Primary

  Removal of binder or filler (removal of binder from ceramics C04B35/638) · CPC title

• C04B2235/3217

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

• C04B35/6261

  Milling · CPC title

• C04B2235/3246

  Stabilised zirconias, e.g. YSZ or cerium stabilised zirconia · CPC title

• C04B35/632

  Organic additives · CPC title