Method for manufacturing an aluminium alloy part by additive manufacturing from a mixture of powders containing yttria-stabilized zirconia

Patent metadata

Field	Value
Publication number	US-2020360993-A1
Application number	US-202016872469-A
Country	US
Kind code	A1
Filing date	May 12, 2020
Priority date	May 13, 2019
Publication date	Nov 19, 2020
Grant date	—

Abstract

Method for manufacturing an aluminium alloy part by additive manufacturing comprising a step during which a layer of a mixture of powders is locally melted and then solidified, characterised in that the mixture of powders comprises:
first particles comprising at least 80% by mass of aluminium and up to 20% by mass of one or more additional elements, and second yttria-stabilized zirconia particles, the mixture of powders comprising at least 1.5% by volume of second particles.

First claim

1 . A method for manufacturing an aluminium alloy part by additive manufacturing, the method comprising locally melting a layer of a mixture of powders and then solidifying, wherein the mixture of powders comprises:
first particles comprising at least 80% by mass of aluminium and up to 20% by mass of one or more additional elements; and second particles comprising yttria-stabilized zirconia, the mixture of powders comprising at least 1.5% by volume of second particles.

2 . The method according to claim 1 , wherein the second particles have a larger dimension ranging from 5 nm to 600 nm.

3 . The method according to claim 1 , wherein the second particles have a larger dimension ranging from 100 nm to 400 nm.

4 . The method according to claim 1 , wherein the second particles have a larger dimension ranging from 200 nm to 300 nm.

5 . The method according to claim 1 , wherein a volume percentage of second particles in the mixture of powders ranges from 1.5% to 2.5%.

6 . The method according to claim 1 , wherein the first particles have a larger dimension ranging from 10 μm to 100 μm.

7 . The method according to claim 1 , wherein the first particles have a larger dimension ranging from 20 μm to 65 μm.

8 . The method according to claim 1 , wherein the one or more additional elements are selected from the group consisting of Cu, Si, Zn, Mg, Fe, Ti, Mn, Zr, Va, Ni, Pb, Bi and Cr.

9 . The method according to claim 1 , wherein the aluminium alloy is the alloy 7075, the alloy 2024, the alloy 2219 or the alloy 6061.

10 . The method according to claim 1 , wherein the method for manufacturing an aluminium alloy part is a selective laser melting method or a selective electron beam melting method.

11 . The method according to claim 1 , wherein the method comprises a step in which the mixture of powders is obtained in a 3D dynamic mixer or by mechano-synthesis.

12 . The method according to the preceding claim 11 , wherein a specific surface of the mixture of powders obtained in the 3D dynamic mixer is greater than 0.3 m 2 /g.

13 . The method according to claim 1 , wherein the mixture of powders further comprises a reducing element.

14 . The method according to claim 13 , wherein the reducing element is magnesium.

15 . The method according to claim 13 , wherein the mixture of powders comprises at least 0.5% by mass of the reducing element.

16 . The method according to claim 13 , wherein the mixture of powders comprises between 0.5% and 10% by mass of the reducing element.

17 . The method according to claim 13 , wherein the reducing element is present in the first particles.

18 . An aluminium alloy part obtained according to the method according to claim 1 , wherein the part comprises zirconia and yttrium.

19 . The part according to claim 18 , wherein the part is a heat exchanger.

Assignees

• Commissariat Energie Atomique

Inventors

• Opprecht Mathieu
• Garandet Jean-Paul
• Roux Guilhem
• Soulier Mathieu

Classifications

• B22F10/32

  of the atmosphere, e.g. composition or pressure in a building chamber · CPC title

• B22F10/366

  Scanning parameters, e.g. hatch distance or scanning strategy · CPC title

• B22F10/36

  of energy beam parameters · CPC title

• B22F10/34

  of powder characteristics, e.g. density, oxidation or flowability · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title