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

Patent metadata

Field	Value
Publication number	US-2021394263-A1
Application number	US-201917292795-A
Country	US
Kind code	A1
Filing date	Oct 23, 2019
Priority date	Nov 12, 2018
Publication date	Dec 23, 2021
Grant date	—

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

1 . A powder material for use in additive layer manufacturing comprising:
ceramics; and metals, wherein 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
the powder material contains a main powder and an additional powder, and a porosity of the main powder is larger than a porosity of the additional powder.

3 . 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.

4 . 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.

5 . 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.

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

7 . The molded article according to claim 6 , wherein the molded article is a ceramic filter or a catalyst carrier material.

8 . An additive layer manufacturing method using the powder material according to claim 1 .

9 . A method for manufacturing a cemented carbide, using the additive layer manufacturing method according to claim 8 .

10 . The powder material according to claim 2 , 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.

11 . 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.

12 . The powder material according to claim 3 , 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.

13 . 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.

14 . The powder material according to claim 3 , wherein the powder material is used for manufacturing a ceramic filter or a catalyst carrier material by the additive layer manufacturing.

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

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

17 . A molded article obtained by applying additive layer manufacturing to the powder material according to claim 3 .

18 . A molded article obtained by applying additive layer manufacturing to the powder material according to claim 4 .

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

20 . An additive layer manufacturing method using the powder material according to claim 2 .

Assignees

• Fujimi Inc

Inventors

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

Classifications

• B22F1/148

  Agglomerating · CPC title

• B22F1/10

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

• B22F1/052

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

• B22F1/05

  Metallic powder characterised by the size or surface area of the particles · CPC title

• Y02P10/25

  Process efficiency · CPC title