Refractory metal component

Patent metadata

Field	Value
Publication number	US-2025003035-A1
Application number	US-202218707663-A
Country	US
Kind code	A1
Filing date	Nov 3, 2022
Priority date	Nov 4, 2021
Publication date	Jan 2, 2025
Grant date	—

Abstract

A component having a solid structure of an alloy which, as a main component, contains a refractory metal (RM) from the group of molybdenum and tungsten and, as a further component, boron (B) and optionally carbon (C). The solid structure is manufactured additively by laser beam or electron beam, and the solid structure has regions made of the RM or a mixed crystal of the RM and the regions are at least partially delimited by (RM)2B, where B in (RM)2B can be partially replaced by C.

First claim

1 - 13 . (canceled)

14 . A component, comprising:
a solid structure consisting of an alloy which comprises, as a main component, a refractory metal (RM) selected from the group consisting of molybdenum and tungsten and, as a further component, boron (B) and optionally carbon (C); said solid structure having the characteristics of having been manufactured additively via laser beam or electron beam; and said solid structure having regions composed of the RM or of a solid solution of the RM and said regions being at least partially bounded by (RM) 2 B, where B in the (RM) 2 B may be replaced in part by C.

15 . The component according to claim 14 , wherein said alloy contains a rare earth metal, with a rare earth metal content of 0.01 to 3 at %.

16 . The component according to claim 15 , wherein said rare earth metal is lanthanum.

17 . The component according to claim 14 , further containing oxygen, which is at least partially in solution in the (RM) 2 B.

18 . The component according to claim 14 , wherein a content of B lies in a range from 0.08 at % to eutectic composition.

19 . The component according to claim 18 , wherein the content of B lies in a range from 2 at % to 3.5 at %.

20 . The component according to claim 14 , wherein a collective content of the alloy elements, not including the contents of RM and B, is less than 10 at %.

21 . The component according to claim 20 , wherein the collective content of the alloy elements is less than 1 at %.

22 . The component according to claim 14 , wherein a collective content of elements selected from the group consisting of aluminum, silicon, and germanium in the alloy is less than 0.5 at %.

23 . The component according to claim 15 , wherein the rare earth metal is in metallic form.

24 . The component according to claim 14 , wherein the regions composed of the RM or of the solid solution of the RM and at least partially bounded by (RM) 2 B are part of a predominantly cellular microstructure.

25 . The component according to claim 24 , wherein a mean cell size of the cellular microstructure is less than 2 micrometers and more than 0.01 micrometer.

26 . The component according to claim 24 , wherein the cellular microstructure has cell walls that are formed at least partially of (RM) 2 B.

27 . The component according to claim 14 , wherein the component has an average grain aspect ratio (GAR; ratio grain length/grain width) in a build direction of less than 8.

28 . The component according to claim 27 , wherein the average grain aspect ratio in the build direction is less than 5.

29 . The component according to claim 14 , wherein the component has a fine-grained microstructure with an average grain size of 8 μm.

30 . An additive manufacturing process for producing a component having a solid structure, the method comprising:
providing a starting powder composed of a material that contains, as a main component, a refractory metal (RM) selected from the group consisting of molybdenum and tungsten and, as a further component boron (B) and optionally carbon (C); producing the solid structure by layer-wise fusing of the particles of the starting powder via laser beam or electron beam, with an energy to form the solid structure with regions composed of the RM or of a solid solution of the RM and the regions being at least partially bounded by (RM) 2 B, where B in the (RM) 2 B may be replaced in part by C.

31 . A powder, comprising:
a main material component of a refractory metal (RM) selected from the group consisting of molybdenum and tungsten; and a further material component being boron (B) and optionally carbon (C), with a content of further alloy elements being less than 10 at %.

32 . The powder according to claim 31 , wherein the content of the further alloy elements is less than 1 at %.

33 . The method according to claim 30 , which comprises producing the component according to claim 14 by an additive manufacturing process with a starting the starting powder having:
a main material component of a refractory metal (RM) selected from the group consisting of molybdenum and tungsten; and
a further material component being boron (B) and optionally carbon (C), with a content of further alloy elements being less than 10 at %.

Assignees

• Plansee Se

Inventors

• Leichtfried Gerhard
• Kaserer Lukas
• Braun Jakob
• Kestler Heinrich

Classifications

• B22F10/28

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

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• Y02P10/25

  Process efficiency · CPC title