Dip-coat binder solutions comprising a dip-coat metallic precursor for use in additive manufacturing

Patent metadata

Field	Value
Publication number	US-2022143699-A1
Application number	US-202117500390-A
Country	US
Kind code	A1
Filing date	Oct 13, 2021
Priority date	Nov 9, 2020
Publication date	May 12, 2022
Grant date	—

Abstract

A dip-coat binder solution comprises a dip-coat metallic precursor and a dip-coat binder. The dip-coat binder solution has a viscosity greater than or equal to 1 cP and less than or equal to 150 cP. A method of forming a part includes providing a green body part comprising a plurality of layers of print powder and a print binder, dipping the green body part in a dip-coat binder solution, and heating the dip-coated green body part. The dip-coated green body part is heated to form a coated green body part having a metallic precursor coating on an outer surface of the coated green body part. The coated green body part has a strength greater than or equal to 10 MPa.

First claim

What is claimed is:

1 . A dip-coat binder solution comprising:
greater than or equal to 10 wt % to less than or equal to 49 wt % of a dip-coat metallic precursor, based on a total weight of the dip-coat binder solution; and a dip-coat binder, wherein the dip-coat binder solution has a viscosity greater than or equal to 1 cP and less than or equal to 150 cP.

2 . The dip-coat binder solution of claim 1 , wherein the dip-coat binder solution comprises greater than or equal to 20 wt % and less than or equal to 47 wt % of the dip-coat metallic precursor, based on a total weight of the dip-coat binder solution.

3 . The dip-coat binder solution of claim 1 , wherein the dip-coat metallic precursor is selected from the group consisting of an alkaline earth metal, a transition metal, a post-transition metal, a metalloid, a rare earth metal, and combinations thereof.

4 . The dip-coat binder solution of claim 1 , wherein the dip-coat metallic precursor comprises an organometallic compound, the organometallic compound comprising ferrocene, cobaltocene, iron pentacarbonyl, metal acetylacetonate, a cyclopentadienyl complex, a metal alkyl, a metal aryl, or a combination thereof.

5 . The dip-coat binder solution of claim 1 , wherein the dip-coat metallic precursor comprises a salt, the salt comprising a compound selected from the group consisting of carboxylates, nitrates, sulfates, carbonates, formates, chlorides, halides, a derivative thereof, and combinations thereof.

6 . The dip-coat binder solution of claim 5 , wherein the salt comprises nickel chloride, nickel carbonate, nickel formate, nickel nitrate, iron chloride, copper chloride, copper nitrate, silver nitrate, aluminium nitrate, magnesium chloride, barium nitrate, barium chloride, titanium nitrate, or a combination thereof.

7 . The dip-coat binder solution of claim 1 , wherein the dip-coat metallic precursor comprises metallic nanoparticles, the metallic nanoparticles comprising nickel, silver, chromium, aluminum, cobalt, iron, copper, gold or a combination thereof.

8 . The dip-coat binder solution of claim 1 , wherein the dip-coat metallic precursor has an incipient melting temperature greater than or equal to 300° C. and less than or equal to 600° C.

9 . The dip-coat binder solution of claim 1 , wherein the dip-coat binder solution has a viscosity greater than or equal to 10 cP to less than or equal to 100 cP.

10 . The dip-coat binder solution of claim 1 , wherein the dip-coat binder comprises a thermoplastic polymer having a first polymer strand, wherein the first polymer strand has an average molecular weight greater than or equal to 7,000 g/mol and less than or equal to 50,000 g/mol.

11 . The dip-coat binder solution of claim 10 , wherein the first polymer strand is selected from the group consisting of polystyrene (PS), polyvinyl pyrrolidone (PVP), polycarbonate, derivatives thereof, and combinations thereof.

12 . A coated green body part comprising:
a plurality of layers of print powder; and a metallic precursor coating on an outer surface of the plurality of layers of print powder, the metallic precursor coating comprising:
greater than or equal to 10 wt % and less than or equal to 49 wt % of a dip-coat metallic precursor, based on a total weight of the metallic precursor coating; and
a dip-coat binder,
wherein the coated green body part comprises a strength greater than or equal to 10 MPa.

13 . The coated green body part of claim 12 , wherein the dip-coat metallic precursor comprises an organometallic compound, the organometallic compound comprising ferrocene, cobaltocene, iron pentacarbonyl, metal acetylacetonate, a cyclopentadienyl complex, a metal alkyl, a metal aryl, or a combination thereof.

14 . The coated green body part of claim 12 , wherein the dip-coat metallic precursor comprises a salt selected from the group consisting of carboxylates, nitrates, sulfates, carbonates, formats, chlorides, halides, derivatives thereof, and combinations thereof.

15 . The coated green body part of claim 12 , wherein the dip-coat metallic precursor comprises metallic nanoparticles, the metallic nanoparticles comprising nickel, silver, chromium, aluminum, cobalt, iron, copper, gold or a combination thereof.

16 . A method of forming a part, the method comprising:
providing a green body part comprising a plurality of layers of print powder and a print binder; dipping the green body part in a dip-coat binder solution, the dip-coat binder solution comprising:
greater than or equal to 10 wt % and less than or equal to 49 wt % of a dip-coat metallic precursor, based on a total weight of the dip-coat binder solution; and
a dip-coat binder; and
heating the dip-coated green body part.

17 . The method of claim 16 , wherein heating the dip-coated green body part comprises heating the dip-coated green body part above a first temperature greater than or equal to 50° C. and less than or equal to 200° C. to form a coated green body part having a metallic precursor coating on an outer surface of the coated green body part.

18 . The method of claim 17 , wherein the coated green body part has a strength greater than or equal to 10 MPa.

19 . The method of claim 17 , wherein the method further comprises heating the coated green body part above a second temperature greater than or equal to 100° C. and less than or equal to 600° C. to remove at least a portion of the print binder and at least a portion the dip-coat binder to form a coated brown body part having the metallic precursor coating on an outer surface of the coated body part.

20 . The method of claim 19 , wherein the method further comprises heating the coated brown body part above a third temperature greater than or equal to 1000° C. and less than or equal to 1400° C. to sinter the dip-coat metallic precursor and the print powder to form a consolidated part with a metallic outer surface.

Assignees

• Gen Electric

Inventors

• Natarajan Arunkumar
• Bonilla Carlos H

Classifications

• Y02P10/25

  Process efficiency · CPC title

• B33Y40/20

  Post-treatment, e.g. curing, coating or polishing · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B29C64/165

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title