Additively-manufactured refractory metal component, additive manufacturing process, and powder

Patent metadata

Field	Value
Publication number	US-2022016699-A1
Application number	US-201917294845-A
Country	US
Kind code	A1
Filing date	Oct 3, 2019
Priority date	Nov 19, 2018
Publication date	Jan 20, 2022
Grant date	—

Abstract

A component has a matrix phase composed of at least one material selected from the group molybdenum, a molybdenum-based alloy, tungsten, a tungsten-based alloy and a molybdenum-tungsten-based alloy. The component is manufactured using a laser or electron beam in an additive manufacturing process. The molybdenum content, the tungsten content or the total content of molybdenum and tungsten is more than 85 at %, and the component contains particulates having a melting point above the melting point of the matrix phase.

First claim

1 - 20 (canceled)

21 . A component, comprising:
a matrix phase composed of at least one material selected from the group consisting of molybdenum, a molybdenum-based alloy, tungsten, a tungsten-based alloy, and a molybdenum-tungsten-based alloy, the component having the characteristics of having been manufactured using a laser or electron beam in an additive manufacturing process; a molybdenum content, a tungsten content, or a total content of molybdenum and tungsten being greater than 85 at %; and particulates contained in the component having a melting point above a melting point of the matrix phase.

22 . The component according to claim 21 , wherein a content of the particulates in the component is sufficiently high to define an average grain area in the matrix phase of less than 10,000 μm 2 (micrometers squared).

23 . The component according to claim 22 , wherein the average grain surface area in the matrix phase is less than 2500 μm 2 .

24 . The component according to claim 21 , wherein an average particulate size of the particulates is less than 5 μm.

25 . The component according to claim 21 , wherein a volume content of the particulates in the component is between 0.05 vol % and 10 vol %.

26 . The component according to claim 21 , wherein at least in one fracture plane the component exhibits a fracture behavior having a transcrystalline proportion of more than 50% of a fracture area.

27 . The component according to claim 21 , having the characteristics of having been manufactured in a build direction in an additive manufacturing process, and wherein an average grain extent in a plane parallel to the build direction is less than 5.

28 . The component according to claim 21 , wherein the particulates are individually or in combination selected from the group consisting of:
oxides, being ZrO 2 , HfO 2 ; carbides, being ZrC, NbC, MoC, TiC, TaC, HfC; nitrides, being YN, TaN, HfN; and borides, being TaB 2 , HfB 2

29 . The component according to claim 21 , which comprises one or more alloying elements which, at least in a temperature range ≥1500° C., have a reducing effect for the following:
in the case of molybdenum and the molybdenum-based alloy, for MoO 2 and/or MoO 3 ;
in the case of tungsten and the tungsten-based alloy, for WO 2 and/or WO 3 ; and
in the case of the molybdenum-tungsten-based alloy, for at least one oxide selected from the group consisting of MoO 2 , MoO 3 , WO 2 and WO 3 ; and
wherein at least one of the alloying elements is present both in at least partially unoxidized form and in oxidized form.

30 . An additive manufacturing process for producing a component, the method comprising:
providing a starting powder with particles composed of at least one material selected from the group consisting of molybdenum, a molybdenum-based alloy, tungsten, a tungsten-based alloy, and a molybdenum-tungsten-based alloy; providing the starting powder with at least one of the following:
particulates having a melting point above a melting point of a matrix phase of the component;
at least one precursor substance for particulates, wherein the melting point of the particulates lies above the melting point of the matrix phase and the particulates composed of the at least one precursor substance are formed during layer-wise fusing of the particles of the starting powder using a laser or electron beam;
at least one component which in reaction with at least one component of a process gas atmosphere during layer-wise fusing of the particles of the starting powder using a laser or electron beam forms particulates having a melting point above the melting point of the matrix phase;
layer-wise fusing the particles of the starting powder with a laser or electron beam to form the component with a matrix phase having a molybdenum content, a tungsten content or a total content of molybdenum and tungsten greater than 85 at %.

31 . The manufacturing process according to claim 30 , wherein the step of providing the starting powder comprises spheroidizing the particles in the melt phase and/or pelletizing a raw powder.

32 . The manufacturing process according to claim 30 , wherein an average size of the particulates is less than 5 μm.

33 . The manufacturing process according to claim 30 , which comprises forming the component with a volume content of the particulates in the component between 0.05 vol % and 10 vol %.

34 . The manufacturing process according to claim 30 , wherein the starting powder comprises at least one reducing element which, at least in a temperature range ≥1500° C., has a reducing effect, in the case of molybdenum and the molybdenum-based alloy for MoO 2 and/or MoO 3 , in the case of tungsten and the tungsten-based alloy for WO 2 and/or WO 3 , and in the case of the molybdenum-tungsten-based alloy for at least one oxide from the group of MoO 2 , MoO 3 , WO 2 and WO 3 and the reducing element is present in the starting powder in at least partially unoxidized form and the component is produced to have at least one of the reducing elements at least partially in the form of oxide.

35 . A powder, comprising:
particles composed of at least one material selected from the group consisting of molybdenum, a molybdenum-based alloy, tungsten, a tungsten-based alloy, and a molybdenum-tungsten-based alloy, wherein the particles comprise a matrix phase and wherein the molybdenum content, the tungsten content or the total content of molybdenum and tungsten in the matrix phase is more than 85 at %; particulates having a melting point above a melting point of the matrix phase of the particles; and/or at least one precursor substance for particulates, wherein the melting point of the particulates lies above the melting point of the matrix phase of the particles and the particulates composed of the at least one precursor substance are formed during a layer-wise fusing of the particles of the starting powder using a laser or electron beam; and the powder is configured for an additive manufacturing process to form a component with layer-by-layer fusing with a laser or electron beam.

36 . The powder according to claim 35 , wherein the particles of the powder comprise the particulates in the form of fine precipitations.

37 . The powder according to claim 35 , wherein the powder is a mixture containing particles containing molybdenum, a molybdenum-based alloy, tungsten, a tungsten-based alloy or a molybdenum-tungsten-based alloy and particulates having a melting point above a melting point of the matrix phase.

38 . The powder according to claim 35 , wherein the at least one precursor substance for the particulates having a melting point above a melting point of the matrix phase is at least partially in the form of a layer on particles of the powder.

39 . The powder according to claim 35 , wherein an average particle size of the particulates having a melting point above the melting point of the matrix phase of the particles is less than 5 μm.

40 . The powder according to claim 35 , wherein a volume content of the particulates having a melting point above the melting point of the matrix phase of the particles in the powder is between 0.05 vol % and 10 vol %.

41 . The powder according to claim 35 , further comprising one or more elements which, at least in a temperature range ≥1500° C., have a reducing effect for the following: in the case of molybdenum and the molybdenum-based alloy, for MoO 2 and/or MoO 3 ; in the case of tungsten and the

Assignees

• Plansee Se

Inventors

• Leitz Karl-Heinz
• Kestler Heinrich
• Singer Peter
• Leichtfried Gerhard
• Braun Jakob
• Kaserer Lukas
• Stajkovic Janko

Classifications

• B23K15/0086 Primary

  welding for purposes other than joining, e.g. build-up welding · CPC title

• B22F10/34

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

• C22C32/0047

  with carbides, nitrides, borides or silicides as the main non-metallic constituents · CPC title

• C22C32/0031

  Matrix based on refractory metals, W, Mo, Nb, Hf, Ta, Zr, Ti, V or alloys thereof · CPC title

• B22F1/12

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