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    • 专利摘要:
    A solid structure member (8) laser or electron beam-wise in an additive manufacturing process of at least one material selected from a group consisting of molybdenum, a molybdenum-based alloy, tungsten, a tungsten-based alloy, and a molybdenum-tungsten-based material Alloy, wherein the component (8) comprises one or more alloying elements, the - in the case of molybdenum and the molybdenum-based alloy for MoO2 and / or MoO3 - in the case of tungsten and the tungsten-based alloy for WO2 and / or WO3 and - in the case of the molybdenum-tungsten-based alloy for at least one oxide of the group MoO2, MoO3, WO2 and WO3 at least in the temperature range ≥ 1500 ° C has a reducing effect, wherein the or at least one of the alloying elements (E) is present both in at least partially unoxidized form as well as in oxidized form.
    公开号:AT16307U2
    申请号:TGM50190/2018U
    申请日:2018-11-19
    公开日:2019-06-15
    发明作者:Leitz Karl-Heinz；Kestler Heinrich；Singer Peter；Leichtfried Gerhard；Braun Jakob；Kaserer Lukas；Stajkovic Janko
    申请人:Plansee Se；
    IPC主号:
    专利说明:

    The invention relates to a component with the features of the preamble of claim 1, an additive manufacturing method for producing a component with the features of the preamble of claim 16 and a use of a powder for an additive manufacturing method.
    Molybdenum (Mo), tungsten (W) and their alloys are due to the high melting point, the low coefficient of thermal expansion and the high thermal conductivity for different high-performance applications, such as for X-ray anodes, heat sinks, high-temperature heating zones, thrusters, extrusion matrices, Parts used for injection molds, hot runner nozzles, resistance welding electrodes or components for ion implantation systems. In addition, these elements have a high density, which ensures good shielding behavior from electromagnetic and particle radiation. Due to the comparatively low ductility at room temperature and the high DBTT (Ductile Brittle Transition Temperature), the processing properties are unfavorable for both cutting and non-cutting processes. In addition, with the exception of molybdenum rhenium and tungsten rhenium, the weldability of these materials is poor. A large-scale process for the production of components from these materials is the powder metallurgical production route, in which the corresponding starting powders are pressed and sintered and are usually subsequently shaped at a high temperature (temperature greater than DBTT).
    The achievable with additive manufacturing methods for geometrical component design far exceed those of conventional methods. In the case of materials such as molybdenum, tungsten and their alloys in particular, the additive manufacturing process is particularly advantageous since, compared to other metallic materials, these materials are much more difficult to machine with conventional manufacturing methods. In the additive manufacturing of metallic materials, mostly powder, less often wires, are used as the starting material. For metallic materials, several processes have been established, such as selective laser sintering (SLS), in which layered powder is sintered locally using a laser beam, selective laser beam melting (SLM) and selective electron beam melting (SEBM), in which layered powder is locally melted, and laser Metal deposition (LMD), in which a powder fed through a nozzle is melted. Additive manufacturing processes do not require any cutting or shaping tools, which enables low-cost production of components. In addition, component geometries can be realized that cannot be manufactured using conventional manufacturing processes, or that can only be produced with very great effort. In addition, high resource efficiency is achieved because powder particles that have not melted or sintered together can be reused. A disadvantage of these processes is currently the very low build-up rate.
    In addition, it must be taken into account in the case of beam-based additive manufacturing processes that other metal-physical mechanisms are effective in comparison to conventional consolidation processes, such as casting or sintering. While surface and grain boundary diffusion determine the compaction during sintering, processes that involve local melting and solidification with a high cooling rate, such as SLM, SEBM and LMD, have different mechanisms of action, which are significantly more complex and not yet fully understood. Wetting behavior, Marangoni convection, recoil effects due to evaporation, segregation, epitaxial grain growth, solidification time, heat flow, heat flow direction and internal stresses as a result of solidification loss should be mentioned. Material concepts that are successful with conventional processes usually do not lead to error-free components in beam-based additive processes.
    The production of pure tungsten via selective laser beam melting is described in a technical article by Dianzheng Wang et al. (Appl. Sci. 2007, 7, 430), the production of Mo
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    AT 16 307 U2 2019-06-15 Austrian patent office lybdenum on selective laser beam melting in a specialist article by D. Faidel et al. (Additive Manufacturing 8 (2015) 88-94). WO2012055398 discloses a selective laser melting process for refractory metals, the composition of the material being able to be changed by reaction with a reactive gas contained in the atmosphere during the construction of the component. In the publication CN 103074532 A and the associated article “Selective Laser Melting Additive Manufacturing of Hard-to-Process TungstenBased Alloy Parts With Novel Crystalline Growth Morphology and Enhanced Performance”, Journal of Manufacturing Science and Engineering, August 2016, Vol. 138, 081003 , by Dongdong Gu et al., describes the laser beam melting of mechanically alloyed tungsten-TiC powder.
    The most widely used additive manufacturing process is the selective laser beam melting process (SLM). Here, a powder layer is applied to a substrate using a doctor blade. A laser beam is then passed over this layer of powder. This melts the powder particles locally, as a result of which the individual powder particles melt together and with the previously applied layer. A layer of the component to be manufactured is thus created by successive local melting of powder particles and subsequent solidification. Another layer of powder is then applied to the already processed layer of powder and the process begins again. The component is thus built up with each new powder layer, the direction of construction being arranged normal to the respective levels of the powder layers. Since the additive manufacturing process forms a characteristic microstructure, it is possible for the person skilled in the art to recognize whether a component is produced by a conventional or an additive process.
    Molybdenum and tungsten have a high melting point, high thermal conductivity in the solid phase and high surface tension and viscosity in the liquid phase. These materials are among the most difficult to process using an additive manufacturing process. The short time in the molten phase due to the high thermal conductivity, combined with the high surface tension and the high viscosity, favor the balling effect, which in turn leads to pores and thus to crack-causing defects and a low density. The balling effect also has a negative effect on the surface quality, especially on the surface roughness. Since molybdenum and tungsten have a very low fracture toughness, local defects, combined with the inherent, thermally induced stresses inherent in the process, lead to cracks.
    Components made of molybdenum and tungsten produced by selective laser or electron beam melting show a stem-crystalline structure, with the average grain aspect ratio (Grain Aspect Ratio - GAR value; ratio grain length to grain width) in the direction of construction typically being greater than 8. In the plane normal to the direction of construction, an intercrystalline crack network is formed, which depicts the melting trace of the laser or electron beam. The cracks are predominantly intergranular hot and cold cracks. These are partially connected to each other, which means that components often have open porosity and are not sealed against gases and liquids. If the component is subjected to stress, there is generally no plastic deformation and intercrystalline fracture behavior is predominantly observed. An intergranular fracture behavior is a fracture that is mainly caused by cracks along the grain boundaries. Due to this fracture behavior, components manufactured in this way have low fracture strength, low fracture toughness and low ductility.
    The object of the invention is to provide a generic component in which the problems discussed above are avoided, a generic additive manufacturing process for the reliable production of a component with the aforementioned properties and a powder which is optimized for use in an additive manufacturing process Behavior shows. In particular, it is the object of the invention to provide a component which has the following properties:
    [0010] - reduced frequency of errors, in particular cracks
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    AT 16 307 U2 2019-06-15 Austrian Patent Office [0011] - improved fracture toughness [0012] - improved ductility [0013] - improved density [0014] - closed porosity [0015] This object is achieved by a component with the features of claim 1 , an additive manufacturing method with the features of claim 16 and a use of a powder with the features of claim 18 solved. Advantageous embodiments of the invention are defined in the dependent claims.
    Typically, components made of molybdenum, tungsten, molybdenum and tungsten-based alloys produced by means of beam-based additive manufacturing processes have an oxygen content of between 0.25 and 0.6 at%. When using mechanically alloyed powders, significantly higher oxygen contents of 2 at% and above can occur. The oxygen content is not reduced by the additive manufacturing process, such as selective laser or electron beam melting. When using high-resolution examination methods such as scanning or transmission electron microscopy, it can be seen that in the case of components according to the prior art, the oxygen is mainly excreted at the grain boundaries in the form of molybdenum or tungsten oxide. These precipitates are arranged across the grain boundaries and are responsible for the intergranular fracture behavior with consequently low fracture strength and toughness of additively manufactured components made of molybdenum, tungsten and their alloys. The high oxygen content can cause both hot and cold cracks. Hot cracks occur during production due to a reduced grain boundary strength. In the given case, in the heat-affected zone of the melting trace, the grain boundary strength is adversely affected by the melting of the oxides deposited on the grain boundaries. Cold cracks are due to thermally induced stresses in connection with defects (pores, micro cracks), which act as crack nuclei. If the grain boundary strength is clearly lower than the strength inside the grain, as is the case with the prior art, an intercrystalline crack pattern occurs.
    [0017] In addition, a high oxygen content also increases the balling effect. The oxygen is enriched in the edge area of the melting zone and reduces the surface tension there. Marangoni convection thus favors a material flow from the edge area into the center of the melting zone, which significantly increases the balling triggered by the Plateau-Rayleigh instability.
    A component according to the invention is therefore characterized in that the component has an alloy element or a plurality of alloy elements, which 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 of the group MoO 2 , MoO 3 , WO 2 and WO 3 has a reducing effect at least in the temperature range> 1500 ° C. , wherein the or at least one of the alloy element (s) is both in at least partially non-oxidized form and in oxidized form.
    The term alloy element in the singular also includes several alloy elements in the following text which have a reducing effect on molybdenum and / or tungsten.
    The alloy element can be either elementary or as a component of a compound. It should be clarified that gases such as hydrogen are usually not referred to as alloying elements and also in the sense of this invention. The invention also requires that the alloy element be present both in at least partially non-oxidized form and in oxidized form. This means that the oxidized form of the alloy element in the component is in the solid state.
    The basic idea of the invention is the formation of molybdenum or tungsten
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    AT 16 307 U2 2019-06-15 Austrian patent office
    To reduce oxides, in particular at the grain boundaries, by offering oxygen in the form of the reducing, at least one alloying element, a more attractive reaction partner. The oxygen content of the component is therefore not reduced, but the oxygen is at least partially, preferably largely, in an oxide form which is solid (at room temperature) and is formed with the alloy element (s). The oxygen bound in this way can no longer have an adverse effect on the grain boundary strength.
    Suitable alloying elements with a reducing effect can be found in a simple manner by the person skilled in the art in tables. With the help of Gibb's energy (free enthalpy) or with the help of the Richardson-Ellingham diagram, the elements reducing the effect of molybdenum or tungsten oxide can be found on the basis of the differences between their free standard enthalpies of formation. This makes it possible in a simple manner to find elements which are suitable as reducing agents for molybdenum or tungsten oxide. The alloying element preferably has a reducing effect for all molybdenum oxides (eg MoO 2 , MoO 3 ) or for all tungsten oxides (eg WO 2 , WO 3 ), regardless of their stoichiometry. So that the alloy element can reliably bind the oxygen in the form of an oxide, the alloy element must have a reducing effect for molybdenum or tungsten oxide, at least in the temperature range> 1500 ° C. At temperatures <1500 ° C the reaction kinetics are too low, so that a sufficient reduction of molybdenum or tungsten oxide no longer occurs. The alloying element preferably has a reducing effect in the temperature range from room temperature to liquidus temperature of the molybdenum or tungsten alloy for molybdenum or tungsten oxide.
    The proof that the alloy element is present in the component in at least partially non-oxidized and in oxidized form can be done by conventional methods, such as XRD, micro-probe, ICP-OES, ICP-MS, RFA, REM / EDX, TEM / EDX and carrier gas hot extraction. The quantitative determination of the alloying element content takes place, for example, via ICP-OES or ICP-MS, the quantitative determination of the oxygen content by hot gas extraction or XRF. Whether the alloying element is present both in oxidized form and in non-oxidized form can be determined by XRD and, in the case of low contents, by spatially resolving methods, such as, for example, microsonde, REM / EDX or TEM / EDX.
    An additive manufacturing process according to the invention is characterized in that the starting powder provided has at least one element which, 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 of the group MoO 2 , MoO 3 , WO 2 and WO 3 , has a reducing effect at least in the temperature range> 1500 ° C. and in the starting powder provided in at least partially non-oxidized form and that in the component produced the or at least one of the alloy element (s) is at least partially present as an oxide. The at least one alloy element can be either elementary or as a component of a compound.
    The material used, from which the component is made, is preferably a powder. All of the jet-based additive manufacturing processes known according to the prior art, in particular those in which a large number of individual powder particles are melted together to form a solid structure by an energy-rich jet, can be used in the invention.
    [0026] The step of providing the starting powder can comprise spheroidizing the particles in the melting phase. When spheroidizing in the melting phase, a high cooling rate is achieved due to the small particle volume even without additional measures. This leads to a very uniform distribution of the alloy element, for example in that the alloy element is present in the Mo or W crystal lattice in a forcibly dissolved manner or is precipitated in the form of very small particles. The reducing alloying element is thus homogeneously distributed in the powder particles. The homogeneous distribution ensures that the alloying element is present at every point of the component and can bind the oxygen in the form of an oxide. In addition, spheroidized powders show over the melting phase
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    AT 16 307 U2 2019-06-15 Austrian patent office very good powder lift behavior. It is thus possible to achieve powder layers with a uniform surface coverage.
    The step of providing the starting powder can also comprise granulating a raw powder to which the at least one reducing element (which is then present in the finished component as at least one alloy element) is added. Granulation is the aggregation and binding together of finely dispersed primary particles to form larger powder particles. Starting from a homogeneous raw powder mixture which contains molybdenum and / or tungsten and the alloying element, a homogeneous granulate can be produced. Compared to a ground powder, granulated powder particles have a good flow behavior, which makes it possible to apply a uniform layer of powder. In addition, a high oxygen content and other impurities in the powder, which can be attributed to abrasion from the grinding unit, are avoided.
    In an additive manufacturing method according to the invention, it can preferably be provided that fine carbides, nitrides or borides smaller than 1 micrometer are formed during the melting process, which have a grain-refining effect and thus increase the toughness of the processed material. At the same time, they lead to an increase in strength.
    A powder for use according to the invention in an additive manufacturing process, in particular an additive manufacturing process according to the invention, is characterized in that the powder has one or more elements, which 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 MoO 2 , MoO 3 , WO 2 and WO 3 , at least in Temperature range> 1500 ° C has a reducing effect, and that the or at least one of the reducing element (s) (which is or are present in the component as an alloy element (s)) in at least partially non-oxidized form is present. The at least one reducing element can be either elementary or as a component of a compound.
    It is preferably provided that the or at least one of the reducing elements in the powder is partially dissolved in a phase rich in molybdenum or tungsten, preferably to more than 50 at%.
    [0031] Molybdenum-based alloy is understood to mean an alloy which contains at least 50 at% molybdenum. In particular, a molybdenum-based alloy has at least 80, 90, 95 or 99 at% molybdenum. A tungsten-based alloy contains at least 50 at% tungsten. In particular, a tungsten-based alloy has at least 80, 90, 95 or 99 at% tungsten. A molybdenum-tungsten alloy is understood to mean an alloy which has at least 50 at% molybdenum and tungsten in total, in particular at least 80, 90, 95 or 99 at% molybdenum and tungsten in total. Molybdenum-tungsten alloys are a preferred embodiment in all concentration ranges.
    The individual powder particles are preferably melted using an additive manufacturing process, SLM (selective laser beam melting) or SEBM (selective electron beam melting) advantageously being used.
    [0033] The component is preferably built up in layers. For example, a powder layer is applied to a base plate using a doctor blade. The powder layer usually has a height of 10 to 150 micrometers.
    In the SEBM, the powder particles are first sintered to one another in a conductive manner using a defocused electron beam. Then the powder is melted locally by energy input (using an electron beam). With the SLM, the local melting of the powder can be started immediately by energy input (using a laser beam).
    The beam creates a cellular melt trace pattern with a line width of typically 30 microns to 200 microns. The laser or electron beam is over
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    AT 16 307 U2 2019-06-15 Austrian patent office managed the powder layer. The entire powder layer or only part of the powder layer can be melted and subsequently solidified by suitable beam guidance. The melted and solidified areas of the powder layer are part of the finished component. The unmelted powder is not part of the manufactured component. Another layer of powder is then applied using a doctor blade and the laser or electron beam is again guided over this layer of powder. This creates a layered structure and a characteristic component structure. By guiding the electron or laser beam, a so-called scan structure is formed in each powder layer. Furthermore, a typical layer structure also forms in the direction of construction, which is determined by the application of a new powder layer. Both the scan structure and the individual layers can be recognized on the finished component.
    The structure of powder particles melted together selectively to form a solid structure by means of an additive manufacturing process using a high-energy beam (preferably by means of a laser or electron beam) differs significantly from a structure produced by other processes, for example thermal spraying. In thermal spraying, individual spray particles are accelerated in a gas stream and hurled onto the surface of the component to be coated. The spray particles can be in molten or melted (plasma spraying) or solid (cold gas spraying) form. A layer formation takes place because the individual spray particles flatten out when they hit the component surface, stick primarily through mechanical clamping and build up the spray layer in layers. A plate-like layer structure is formed. Layers produced in this way show a grain stretching perpendicular to the building direction in a plane parallel to the building direction with an average grain stretching ratio (Grain Aspect Ratio - GAR value; ratio of grain length to grain width) well above 2 and thus differ significantly from layers produced by selective laser or electron beam melting / Components that also have an average grain stretching ratio significantly above 2 in a plane parallel to the building direction, but with a grain stretching parallel to the building direction.
    In one embodiment of the component according to the invention it is provided that at least one of the alloy elements in the component is partially dissolved, preferably more than 50 at% dissolved, in a phase rich in molybdenum or tungsten. Thus, in the assembly process, the at least one alloy element is present in every area of the component in sufficient quantity to be able to bind the oxygen in the form of an oxide. While the oxygen in the form of a molybdenum and / or tungsten oxide covers the grain boundaries over a large area and, as described, greatly reduces the grain boundary strength, the oxygen in the component according to the invention is present as an oxide which is locally bound by the at least one alloy element and does not cover the grain boundaries.
    In one embodiment of the component according to the invention it is provided that at least one of the alloy elements is a metallic alloy element. This alloy element is preferably at least partially soluble in molybdenum and / or tungsten.
    In one embodiment of the component according to the invention it is provided that at least one of the alloy elements is an element of group 2, 3 or 4 of the periodic table, preferably titanium, zirconium or hafnium. These alloying elements are characterized by a strong affinity for oxygen.
    In one embodiment of the component according to the invention it is provided that the component contains an oxide which has a melting point> 1800 ° C, in particular> 2600 ° C. Preferred oxides are TiO 2 (melting point: 1843 ° C), ZrO 2 (melting point: 2715 ° C) or HfO 2 (melting point: 2758 ° C). These oxides have a low tendency to coarsen. In addition to the grain-refining, toughness-increasing effect, this also results in a strength-increasing effect in the component, especially at high operating temperatures. Mixed oxides that contain TiO 2 , ZrO 2 or HfO 2 also have the aforementioned positive effects.
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    AT 16 307 U2 2019-06-15 Austrian Patent Office [0041] In one embodiment of the component according to the invention it is provided that the content of the at least one alloy element in the component in non-oxidized and oxidized form is in a range from 0.05 at% to 20 at%, preferably from 0.1 at% to 10 at%. The effect according to the invention does not occur to a sufficient extent below 0.05 at%. Above 20 at%, the strength-increasing effect of the at least one alloy element is strongly pronounced, as a result of which stresses in the build-up process are reduced to a lesser extent.
    In one embodiment of the component according to the invention it is provided that a carbon content in the component is in a range from 0.05 at% to 20 at%. In the case of molybdenum, the carbon is preferably in excreted form as Mo 2 C, in the case of tungsten preferably in excreted form as W 2 C. Both Mo 2 C and W 2 C have a solubility for oxygen at temperatures that occur in the component to be manufactured during the additive manufacturing process. This also makes it possible to avoid covering grain boundaries with molybdenum oxide or tungsten oxide and their resulting weakening. In addition, carbon in both molybdenum and tungsten and their alloys causes grain refinement through constitutional hypothermia during the solidification of the material melted by the energy beam. However, below 0.05 at% the effect is only weakly pronounced, above 20 at% there is strong solidification, which affects the reduction of thermally induced stresses.
    In one embodiment of the component according to the invention it is provided that the molybdenum content, the tungsten content or the total content of molybdenum and tungsten is greater than 60 at%, preferably greater than 80 at%, particularly preferably greater than 90 at% or 95 at% ,
    In one embodiment of the component according to the invention it is provided that the component has a fracture behavior at least in a fracture plane with a transcrystalline fraction of more than 50%, preferably more than 80%, particularly preferably more than 90%, of the fracture surface. Transcrystalline fracture behavior means that if the component breaks due to overloading, the crack does not run along the grain boundaries, but mainly through the grains. The transcrystalline fraction is evaluated by scanning electron microscopy of a fracture surface generated at room temperature. The area with transcrystalline and the area with intercrystalline fracture behavior is measured at a representative point on the fracture surface and the transcrystalline fraction is determined from the ratio of the transcrystalline surface to the total surface examined.
    In one embodiment of the component according to the invention it is provided that the component is manufactured in layers in one direction of construction and preferably has an average grain extension in a plane parallel to the direction of construction less than 5, preferably less than 3. A high grain stretch ratio parallel to the direction of the structure favors an intercrystalline fracture course along the grain boundaries, which essentially extend in the direction of the structure, when the loads are perpendicular to the direction of the structure, since the fracture path is short and therefore the fracture surface generated (due to the directional course of the grain boundaries) is small. A small grain stretch ratio, on the other hand, ensures that there is sufficient fracture toughness even under such loads perpendicular to the direction of construction. This ensures an isotropy of the mechanical properties that is sufficient for the customarily required performance properties.
    In one embodiment of the component according to the invention it is provided that the component has a fine-grained structure with an average grain area smaller than 10,000, in particular smaller than 1,000 square micrometers. As a result, the component has high strength and toughness combined with high ductility. The grain area is determined by quantitative microscopy (stereology) using planimetry.
    In one embodiment of the component according to the invention it is provided that the component is fine carbide, nitride or boride particles, preferably with a medium size
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    AT 16 307 U2 2019-06-15 Austrian patent office smaller than 1 micrometer, contains. On the one hand, these particles increase the strength and, on the other hand, they can also have a grain-fine effect, which increases the fracture toughness. The fine particles are preferably carbides, nitrides or borides of the reducing alloying element.
    In one embodiment of the component according to the invention it is provided that the oxidized form of the at least one alloy element in the component is in the form of fine oxide precipitates with an average size of less than 5 micrometers, preferably <1 micrometer. The oxides are preferably formed by reaction of the at least one alloy element with the oxygen in the material during the additive manufacturing process. These oxides can have a nucleating effect, as a result of which the component has an advantageously fine structure with high strength and toughness.
    In one embodiment of the component according to the invention, the additive manufacturing method according to the invention and the use according to the invention it is provided that in the starting powder the sum of all reducing alloying elements in at% (based on the composition of the starting powder) is at least 50% higher, preferably at least 100% is higher than the oxygen content of the starting powder in at% (based on the composition of the starting powder).
    In a further exemplary embodiment of the component according to the invention, the additive manufacturing method according to the invention and the use according to the invention it is provided that the sum of all metallic alloy elements or reducing elements in at% is at least 50% higher, preferably at least 100% higher, as an oxygen content of the component in at%.
    The above-mentioned conditions ensure that the content of the at least one alloy element at every point of the component in the additive manufacturing process is sufficiently high to prevent the unfavorable occupancy of the grain boundaries by molybdenum or tungsten oxide.
    Exemplary embodiments of the invention are discussed with reference to the figures. Show it:
    Figure 1: Schematic representation of the SLM process Figure 2: Optical microscope image of a Mo sample produced by SLM according to the prior art (sample number 1) with a section plane perpendicular to the direction of assembly (Figure 2a) and parallel to the direction of assembly (Figure 2b) [0055] FIG. 3: scanning electron microscope image of a fracture surface according to the prior art (sample number 1) [0056] FIG. 4: light microscope image of a sample according to the invention produced using SLM (sample number 4) with ground plane perpendicular to the direction of construction [0057] sample according to the prior art Technique (sample number 1):
    For a sample not according to the invention, spheroidal Mo powder of the sieve fraction <40 micrometers was used.
    The chemical and physical powder properties are shown in Table 1. With typical parameters for the volume build-up of molybdenum, this powder was used in a commercial SLM system to produce samples for the structure characterization and determination of the density with the dimensions 10 mm x 10 mm x 10 mm as well as for bending samples with the dimensions 35 mm x 8 mm x 8 mm processed.
    The SLM process is shown schematically in FIG. 1. A control system controls u. a. the laser 1, the laser mirror 2, the doctor blade 3, the powder feed 4 from a powder storage container 6 and the position of the base plate 5 in the installation space 7. The installation has an installation space heater. For the experiments, the Mo base plate was heated to 500 ° C. A powder layer was applied using the doctor blade 3. The laser guided with the help of the laser mirror 2
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    AT 16 307 U2 2019-06-15 Austrian patent office beam scanned over the powder layer and melted the particles and partly the underlying, already melted and solidified layer where there is material according to the component design (component 8). Subsequently, the base plate 5 was lowered by 30 micrometers and the doctor blade 3 applied another layer of powder and the process started again.
    The samples were separated from the base plate 5 by wire erosion and the sample density of the 10 mm × 10 mm × 10 mm samples was determined by the buoyancy method (hydrostatic weighing), open pores having previously been closed by immersion in molten paraffin. The samples were examined metallographically. The 35 mm x 8 mm x 8 mm samples (3 parallel samples) were subjected to a 3-point bending test. The fracture surface of the bending samples was examined by scanning electron microscopy and the proportion of intercrystalline or transcrystalline fracture surface was determined.
    2 shows the structure of the Mo sample according to the prior art (sample number 1). The ground plane is perpendicular in FIG. 2a and parallel to the direction of construction in FIG. 2b. The sample has many pores and tiled intercrystalline cracks, which depict the scan structure of the process. The structure is formed like a stem crystal parallel to the direction of construction. The grain stretching ratio was determined by image analysis by determining the mean grain length and the mean grain width and subsequently dividing the mean grain length by the mean grain width. A grain stretch ratio of 8 was calculated. The flexural strength of the sample is shown in Table 2. The low value is due to the low grain boundary strength. The proportion of intergranular fracture is 95%. The scanning electron microscope examination of the fracture surface shows that the grain boundaries are covered with Mo oxide precipitates (FIG. 3).
    [0063] Samples According to the Invention:
    For the samples according to the invention, spheroidized powders (sample numbers 2, 3 and 4) of the sieve fraction <40 μm were used over the melting phase. The chemical and physical powder properties are shown in Table 1. These powders were processed with typical parameters for the volume build-up of molybdenum at an installation temperature of 800 ° C. The samples for the structure characterization and the determination of the density had dimensions of 10 mm x 10 mm x 10 mm. The bending samples had a size of 35 mm x 8 mm x 8 mm.
    [0065] The SLM process and the characterization of the samples were carried out under the same conditions as described for the samples according to the prior art.
    The metallographic examination of the sample with sample number 2 (Mo-0.55 at% Hf), the sample with sample number 3 (Mo - 1.1 at% Zr) and the sample with sample number 4 (Mo - 0.9 at % Ti - 0.09 at% Zr - 0.10 at% C) shows that all samples according to the invention are free of cracks, as is documented in FIG. 4 as an example for the sample with sample number 4 by means of a light microscope image (ground plane perpendicular to the direction of assembly) , The structure in one plane parallel to the direction of construction has an average grain stretch ratio of 3.8 (sample with sample number 2), 3.9 (sample with sample number 3) and 2.9 (sample with sample number 4).
    The results of the chemical analysis, the bending test and the evaluation of the fracture surface are shown in Table 2.
    The bending strength in the samples according to the invention is about a factor of 10 higher than in the sample according to the prior art. The dominant fracture mechanism in all samples is a transcrystalline fracture. A small proportion (3%) of intercrystalline fracture surface could be detected in the samples with sample numbers 2 and 3, the grain boundaries being aligned in the plane of the transcrystalline fracture path in this area. No Mo oxide could be detected in these areas by energy-dispersive X-ray spectroscopy (EDX). The sample with sample number 4 shows only transcrystalline breakage. XRD studies
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    AT 16 307 U2 2019-06-15 Austrian Patent Office point for the sample with sample number 2, the phases of Mo and HfO 2, for the sample with sample number 3, the phase Mo and ZrO 2, and for the sample having sample number 4, the phases of Mo and TiO 2 out. SEM / EDX investigations revealed 2 HfO 2 particles in the sample with sample number 2, 3 ZrO 2 particles in the sample with sample number and 4 TiO 2 particles in the sample with sample number. The larger volume fraction of the respective oxides was however so fine that the particle size was below the detection limit of the SEM. In the first TEM investigations on the sample with sample number 4, particles were found whose average size was in the range of 30 nm.
    sample number 1 2 3 4 Chemical composition of the starting powder O: 0.28 at% remainder Mo and other contaminants Hf: 0.55 at% 0: 0.29 at% balance Mo and other contaminants Zr: 1.1 at% 0: 0.28 at% remainder Mo and other contaminants Ti: 0.98 at% Zr: 0.09 at% C: 0.18 at% 0: 0.21 at% balance Mo and other contaminants Particle size distribution (d10 / d50 / d90) 14.5 μm25.9 µm45.7 µm 13.2 µm24.9 µm44.1 µm 12.5 μm24.1 µm42.8 µm 12.8 µm24.5 μm43.6 μm Bulk density / tap density 5.5 g / cm 3 6 g / cm 3 5.6 g / cm 3 6.1 g / cm 5.2 g / cm 3 5.9 g / cm 5.7 g / cm 3 6.2 g / cm 3
    Table 1
    sample number 1 2 3 4 Chemical composition 0: 0.27 at% remainder Mo and other impurities Hf 0.55 at% 0: 0.28 at% remainder Mo and other contaminants Zr: 1.1 at% 0: 0.29 at% remainder Mo and other contaminants Ti: 0.9 at%Zr: 0.09 at%C: 0.10 at% 0: 0.12 at% remainder Mo and other contaminants sample density 9.79 g / cm 3 10.04 g / cm 3 9.90 g / cm 3 10.12 g / cm 3 3-point bending strength (test force parallel to the direction of installation) 88 N / mm 2 880 N / mm 2 850 N / mm 2 907 N / mm 2 Proportion of transcrystallineFracture (fracture surface parallel to the direction of assembly) 5 97 97 100
    Table 2
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    AT 16 307 U2 2019-06-15 Austrian patent office
    LIST OF REFERENCE NUMBERS:
    laser
    laser mirror
    doctor
    powder feed
    baseplate
    Powder reservoir
    space
    component
    权利要求:
    Claims (17)
    [1]
    1. Component (8) with a solid structure, which is made by laser or electron beam in an additive manufacturing process from at least one material selected from a group comprising molybdenum, a molybdenum-based alloy, tungsten, a tungsten-based alloy and a molybdenum-tungsten - Based alloy, was manufactured, characterized in that the component (8) has one or more alloy elements, the or
    - 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 MoO 2 , MoO 3 , WO 2 and WO 3 has or has a reducing effect at least in the temperature range> 1500 ° C., the or at least one of the alloying elements (e) is present both in at least partially non-oxidized form and in oxidized form, the or at least one of the alloying elements being an element of group 2, 3 or 4 of the periodic table, preferably titanium, zirconium or hafnium.
    [2]
    2. Component according to claim 1, wherein the or at least one of the alloy element (s) in the component (8) is partially dissolved, preferably more than 50 at% dissolved, is present in a phase rich in molybdenum or tungsten.
    [3]
    3. Component according to at least one of the preceding claims, wherein the or at least one of the alloy element (s) is a metallic element.
    [4]
    4. Component according to at least one of the preceding claims, wherein the component (8) contains TiO 2 , ZrO 2 or HfO 2 .
    [5]
    5. Component according to at least one of the preceding claims, wherein the content of the at least one alloy element in the component (8) in non-oxidized and in oxidized form in a range from 0.05 at% to 20 at%, preferably from 0.1 at% to 10 at%.
    [6]
    6. Component according to at least one of the preceding claims, wherein a content of carbon in the component (8) is in a range from 0.05 at% to 20 at%.
    [7]
    7. Component according to the preceding claim, wherein the carbon in the component (8) is at least partially in the form of carbide.
    [8]
    8. Component according to at least one of the preceding claims, wherein the molybdenum content, the tungsten content or the total content of molybdenum and tungsten is greater than 60 at%.
    [9]
    9. The component according to at least one of the preceding claims, wherein the component (8) has at least in a fracture plane a fracture behavior with a transcrystalline fraction of more than 50% of the fracture surface.
    [10]
    10. Component according to at least one of the preceding claims, wherein the component (8) is made in layers in one direction of construction and preferably has an average grain extension in a plane parallel to the direction of construction less than 5.
    [11]
    11. The component according to at least one of the preceding claims, wherein the component (8) contains fine carbide, nitride or boride particles, preferably with an average size of less than 1 micrometer.
    [12]
    12. The component according to at least one of the preceding claims, wherein the oxidized form of the at least one alloy element in the component (8) is in the form of fine oxide precipitates with an average size of less than 5 micrometers.
    [13]
    13. Additive manufacturing method for producing a component (8), in particular a component (8) according to at least one of the preceding claims, comprising the following steps:
    12/16
    AT 16 307 U2 2019-06-15 Austrian patent office
    - Providing a starting powder, from at least one material selected from a group comprising molybdenum, a molybdenum-based alloy, tungsten, a tungsten-based alloy and a molybdenum-tungsten-based alloy
    - Layerwise melting together of the particles of the starting powder by means of a laser or electron beam, characterized in that the starting powder provided has at least one element which, 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 MoO 2 , MoO 3 , WO 2 and WO 3 , has a reducing effect at least in the temperature range> 1500 ° C. and in the starting powder provided is present in at least partially non-oxidized form and that in the component (8) produced, the or at least one of the alloy element (s) is at least partially present as an oxide.
    [14]
    14. The method according to the preceding claim, wherein in the starting powder the sum of all metallic reducing elements in at% is at least 50% higher than an oxygen content of the starting powder in at%.
    [15]
    15. Use of a powder which comprises particles of at least one material selected from a group comprising molybdenum, a molybdenum-based alloy, tungsten, a tungsten-based alloy and a molybdenum-tungsten-based alloy, the particles being granulated and / or the melting phase are produced, characterized in that the powder further comprises one or more elements, which 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 MoO 2 , MoO 3 , WO 2 and WO 3 , has a reducing effect at least in the temperature range> 1500 ° C. act, and that the or at least one of the reducing element (s) is in at least partially non-oxidized form for an additive manufacturing process, in particular for an additive Manufacturing method according to claim 13 or 14.
    [16]
    16. Use according to the preceding claim, wherein the or at least one of the reducing element (s) in the powder is partially dissolved in a phase rich in molybdenum or tungsten, preferably to more than 50 at%.
    [17]
    17. Use according to one of the two preceding claims, wherein the sum of all metallic reducing elements in at% is at least 50% higher, preferably at least 100% higher, than an oxygen content of the powder in at%.
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    同族专利:
    公开号 | 公开日
    KR20210087968A|2021-07-13|
    US20220017999A1|2022-01-20|
    CN113039029A|2021-06-25|
    WO2020102832A1|2020-05-28|
    AT16307U3|2019-12-15|
    EP3883711A1|2021-09-29|
    JP2022513611A|2022-02-09|
    TW202020177A|2020-06-01|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    EP3892404A1|2020-04-08|2021-10-13|Heraeus Deutschland GmbH & Co KG|Additive fabrication of refractory metals with reduced degree of contamination|EP0190378B1|1985-02-05|1990-05-23|Nippon Steel Corporation|Method for surface-alloying metal with a high-density energy beam and an alloy steel|
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    DE102015209583A1|2015-05-26|2016-12-01|Siemens Aktiengesellschaft|Molybdenum-silicon-boron alloy and process for the production and component|
    WO2017077137A2|2015-11-06|2017-05-11|Innomaq 21, S.L.|Method for the economic manufacturing of metallic parts|
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    ATGM50190/2018U|AT16307U3|2018-11-19|2018-11-19|Additively manufactured refractory metal component, additive manufacturing process and powder|ATGM50190/2018U| AT16307U3|2018-11-19|2018-11-19|Additively manufactured refractory metal component, additive manufacturing process and powder|
    EP19787132.0A| EP3883711A1|2018-11-19|2019-10-03|Additively-manufactured refractory metal component, additive manufacturing process, and powder|
    JP2021527248A| JP2022513611A|2018-11-19|2019-10-03|Additional refractory metal parts, additional manufacturing methods and powders|
    US17/294,843| US20220017999A1|2018-11-19|2019-10-03|Additively manufactured refractory metal component, additive manufacturing process and powder|
    PCT/AT2019/060323| WO2020102832A1|2018-11-19|2019-10-03|Additively-manufactured refractory metal component, additive manufacturing process, and powder|
    KR1020217016507A| KR20210087968A|2018-11-19|2019-10-03|Additive Manufacturing Refractory Metal Components, Additive Manufacturing Methods and Powders|
    CN201980076147.XA| CN113039029A|2018-11-19|2019-10-03|Refractory metal component produced by additive method, additive method and powder|
    TW108137055A| TW202020177A|2018-11-19|2019-10-15|additively fabricated fire-proof metal part, process for additively producing, and powder|
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