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WO2020014028A1 - Procédé et système d'augmentation de la densité dans un lit de poudre, et article produit à partir de ceux-ci - Google Patents

Procédé et système d'augmentation de la densité dans un lit de poudre, et article produit à partir de ceux-ci Download PDF

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Publication number
WO2020014028A1
WO2020014028A1 PCT/US2019/040135 US2019040135W WO2020014028A1 WO 2020014028 A1 WO2020014028 A1 WO 2020014028A1 US 2019040135 W US2019040135 W US 2019040135W WO 2020014028 A1 WO2020014028 A1 WO 2020014028A1
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WO
WIPO (PCT)
Prior art keywords
powder
roller
layer
particles
deposition module
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2019/040135
Other languages
English (en)
Inventor
Neville Whittle
Deborah Murphy WILHELMY
Justen SCHAEFER
Adam TRAVIS
Nicholas BILLMYER
Eli ALMAN
Jacob RAPLEE
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Howmet Aerospace Inc
Original Assignee
Arconic Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Arconic Inc filed Critical Arconic Inc
Publication of WO2020014028A1 publication Critical patent/WO2020014028A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10—Formation of a green body
    • B22F10/14—Formation of a green body by jetting of binder onto a bed of metal powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/60—Planarisation devices; Compression devices
    • B22F12/63—Rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/60—Planarisation devices; Compression devices
    • B22F12/67—Blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B22F3/03—Press-moulding apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205—Means for applying layers
    • B29C64/214—Doctor blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/34—Process control of powder characteristics, e.g. density, oxidation or flowability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/37—Process control of powder bed aspects, e.g. density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/30—Platforms or substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present disclosure relates to a method and a system for increasing density in a powder bed, and to an article produced using the method and/or system.
  • the method and system are applied in an additive manufacturing process such as, for example, a binder jet additive manufacturing process.
  • Additive manufacturing means a process of joining materials to make objects from three dimensional model data, usually layer upon layer, as opposed to subtractive
  • Non-limiting examples of additive manufacturing processes useful in producing products from metallic feedstock include, for instance, DMLS (direct metal laser sintering), SLM (selective laser melting), SLS (selective laser sintering), and EBM (electron beam melting), among others.
  • Any suitable feedstock may be used, including a powder, a wire, and combinations thereof.
  • the additive manufacturing feedstock is comprised of powder.
  • the present disclosure provides a powder bed additive manufacturing system.
  • the system comprises a powder deposition surface and a powder deposition module.
  • the powder deposition surface is adapted to receive powder.
  • the powder deposition module is adapted to dispose a layer of powder on the powder deposition surface and also is adapted to compact the layer of powder.
  • the powder deposition module is adapted to apply a pressure of at least 1 pound per square inch (“psi”) to a layer of powder disposed by the powder deposition module.
  • the present disclosure provides a powder bed additive manufacturing method.
  • the method comprises depositing a layer of powder on a surface and compacting the layer of powder.
  • compacting the layer of powder comprises applying a pressure of at least 1 psi to the layer of powder.
  • the present disclosure provides a part preform produced by a powder bed additive manufacturing process.
  • the part preform comprises powder and a binder binding the powder in the part preform.
  • a porosity of the part preform is less than 50% by volume such as, for example, less than 40% by volume, less than 35% by volume, or less than 30% by volume.
  • FIG. l is a schematic depiction of a non-limiting embodiment of a powder bed including powder with at least two different sizes according to the present disclosure
  • FIG. 2 is a schematic depiction of a non-limiting embodiment of a powder bed including powder with at least two different general shapes according to the present disclosure
  • FIG. 3 is a schematic depiction of a non-limiting embodiment of an additive manufacturing system including a plate according to the present disclosure
  • FIG. 4 is a schematic depiction of a non-limiting embodiment of a powder layer compaction system including a blade and a roller according to the present disclosure
  • FIG. 5 is a schematic depiction of a non-limiting embodiment of a powder layer compaction system including a blade and a pressing blade according to the present disclosure
  • FIG. 6A is a schematic front view of a non-limiting embodiment of an additive manufacturing system including a powder deposition module in a first position according to the present disclosure
  • FIG. 6B is a schematic front view of a non-limiting embodiment of the additive manufacturing system of FIG. 6 A including the powder deposition module in a second position according to the present disclosure
  • FIG. 6C is a schematic front view of a non-limiting embodiment of the additive manufacturing system of FIG. 6 A including the powder deposition module in a third position according to the present disclosure
  • FIG. 6D is a schematic front view of a non-limiting embodiment of the additive manufacturing system of FIG. 6 A including the powder deposition module in a fourth position according to the present disclosure
  • FIG. 7 is a schematic depiction of a non-limiting embodiment of a powder deposition module including a first roller having a crown shape according to the present disclosure
  • FIG. 8 is a schematic depiction of a non-limiting embodiment of a powder deposition module including a first scraper according to the present disclosure
  • FIG. 9 is a schematic depiction showing aspects of a non-limiting embodiment of an additive manufacturing system including a vibratory unit according to the present disclosure.
  • FIG. 10 is a graph illustrating density versus pressure applied by a piston for steel particle samples A-E.
  • any numerical range recited herein includes all sub-ranges subsumed within the recited range.
  • a range of“1 to 10” includes all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10.
  • Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, Applicant reserves the right to amend this specification, including the claims, to expressly recite any sub-range subsumed within the ranges expressly recited. All such ranges are inherently described in this specification.
  • the grammatical articles“a”,“an”, and“the”, as used herein, are intended to include “at least one” or“one or more”, unless otherwise indicated, even if“at least one” or“one or more” is expressly used in certain instances.
  • the foregoing grammatical articles are used herein to refer to one or more than one (i.e., to“at least one”) of the particular identified elements.
  • the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of the usage requires otherwise.
  • “powder” refers to a material comprising a plurality of particles. Powder may be used in a powder bed in an additive manufacturing system or process to produce a tailored alloy product via additive manufacturing.
  • substantially spherical means a shape having a sphericity of at least 0.8, such as, for example, at least 0.85 or at least 0.92.
  • “median particle size” of a powder refers to the diameter at which 50% of the volume of the particles in the powder have a smaller diameter (e.g ., Dso).
  • “Dio” of a powder refers to the diameter at which 10% of the volume of the particles in the powder have a smaller diameter.
  • “D90” of a powder refers to the diameter at which 90% of the volume of the particles in the powder have a smaller diameter.
  • particle size was determined in accordance with ASTM standard B822.
  • a binder jet additive manufacturing system comprises a powder bed, a platform, a powder deposition module, and a binder deposition module.
  • the powder bed can be adapted to receive powder and can comprise the platform and a layer or layers of powder.
  • the powder can be retrieved from a reservoir by the powder deposition module and can be deposited in a layer in the powder bed.
  • the binder deposition module can bind together the powder in one or more selected regions of the layer of powder by depositing binder on one or more regions of the layer.
  • the sequence of depositing a layer of powder and depositing a binder on a selected region or regions of the layer can be repeated as needed to produce a part preform in the powder bed.
  • the part preform can include powder and binder.
  • the powder bed can have a low density and a high porosity, which can affect the density and porosity of a part preform produced therefrom.
  • a porous and low- density part preform can have an undesirable low-tensile strength.
  • the part preform may have to be subjected to additional processing steps to increase the density of the part, such as, for example, infiltration with a secondary material and/or sintering.
  • the powder bed may have defects (e.g., gaps and non-uniform layers), which can become defects in the part preform produced therefrom.
  • the powder bed may have increased uniformity in layer thickness of powder particle layers.
  • the increase in density can increase the strength of a part preform created from the powder bed having increased density. Additionally, the part preform can result in a green part having an increased strength and/or density. Sintering the higher density green part can require less energy input (e.g time in a furnace, temperature) to produce a sintered part having the required minimum density than sintering a less dense green part. Additionally, the higher density green part may shrink and/or distort less during the sintering process than a less dense green part.
  • the higher density green part may comprise geometries that were previously unattainable in an additive manufacturing process due to the increased powder bed density provided by methods and systems according to the present disclosure. Additionally, a sintered part produced from a higher density green part produced by the methods and systems according to the present disclosure may include fewer defects due to reduction or minimization of defects in the powder bed.
  • a method for powder bed additive manufacturing includes depositing a layer of powder on a surface and compacting the layer.
  • compacting the layer comprises at least one of moving a plate into contact with the layer and exerting pressure on the layer with the plate, and moving a press into contact with the layer and applying pressure to the layer with the press.
  • compacting includes applying a pressure of at least 1 psi to the powder layer, such as, for example, at least 1,000 psi.
  • the layer is vibrated.
  • the powder bed 100 can comprise a first powder fraction 102 having a first median particle size and a second powder fraction 104 having a second median particle size.
  • the first and second sizes can differ.
  • the ratio of the first median particle size to the second median particle size can be from 2: 1 to 20: 1, such as, for example, 2: 1 to 10: 1, 5: 1 to 10: 1, 6: 1 to 9: 1, or 7: 1.
  • the first median particle size can be in a range of 50 nm to 325 pm, such as, for example, 1 pm to 325 pm, 20 pm to 325 pm, 20 pm to 300 pm, 20 pm to 250 pm, 20 pm to 200 pm, 30 pm to 150 pm, or 30 pm to 90 pm.
  • the second median particle size can be in a range of 50 nm to 65 pm, such as, for example, 1 nm to 65 pm, 5 pm to 50 pm, 2.5 pm to 32.5 pm, 5 pm to 40 pm, or 5 pm to 30 pm. Providing at least two different median particle sizes of the powder in the powder bed 100 can facilitate a higher density packing of the powder bed with powder.
  • the particle size can affect the layer thickness of the powder.
  • the layer thickness can be from 1 time to 10 times the median particle size of the powder, such as, for example, 2 to 8 times the median particle size, 2 to 4 times the median particle size, or 3 times the median particle size.
  • the layer thickness can be from 5 pm to 3,250 pm, such as, for example, 10 pm to 2,000 pm, 10 pm to 1,000 pm, 50 pm to 300 pm, or 1,000 pm.
  • the powder bed 100 can comprise powder of a single median particle size.
  • the median particle size of the powder in the powder bed 100 can be in a range of 50 nm to 325 pm, such as, for example, 1 pm to 325 pm, 5 pm to 325 pm, 10 pm to 100 pm, 105 pm to 180 pm, 20 pm to 50 pm, 60 pm to 90 pm, 50 pm to 100 pm, 10 pm to 150 pm, 15 pm to 45 pm, 20 pm to 65 pm, 25 pm to 45 pm, 50 pm to 150 pm, 65 pm to 90 pm, 10 pm to 200 pm, 5 pm to 30 pm, 30 pm to 90 pm, or 5 pm to 50 pm.
  • the median particle size of the powder in the powder bed 100 can be less than 325 pm such as, for example, less than 300 pm, less than 275 pm, less than 250 pm, less than 225 pm, less than 200 pm, less than 175 pm, less than 150 pm, less than 125 pm, less than 100 pm, less than 90 pm, less than 70 pm, less than 10 pm, or less than 1 pm,.
  • the powder bed 100 can comprise powder having a span of at least 0.1.
  • the powder in the powder bed 100 can have a span in a range of 1 to 5 such as, for example, 1.5 to 5, 1.6 to 5, 1.7 to 5, 1.8 to 5, 1.9 to 5, 2 to 5, 2.1 to 5, 2.2 to 5, 2.3 to 5, 2.4 to 5, 2.5 to 5, 2.6 to 5, 2.7 to 5, 2.8 to 5, 2.9 to 5, 3 to 5, 4 to 5, 1 to 4, 1.5 to 4, 1 to 3, 1.5 to 3, 2 to 4, or 2 to 3.
  • a powder with a span in the ranges described herein can increase the density of the powder in the powder bed 100 by at least 2% such as, for example, at least 5%, at least 10%, or at least 20%.
  • the span is based on the median particle size (Dso), Dio, and D90 as shown in equation 1.
  • the D lo of the powder can be in a range of 0.1 pm to 200 pm such as, for example, 1 pm to 50 pm, 5 pm to 45 pm, 10 pm to 20 pm, 10 pm to 50 pm, 1 pm to 125 pm, 10 pm to 30 pm, 1 pm to 45 pm, 1 pm to 30 pm, 30 pm to 90 pm, or 45 pm to 65 pm.
  • the D90 of the powder can be in a range of 10 pm to 500 pm such as, for example, 20 pm to 400 pm, 50 pm to 200 pm, 100 pm to 200 pm, 75 pm to 150 pm, 30 pm to 200 pm, 30 pm to 60 pm, 45 pm to 90 pm, 55 pm to 75 pm, 75 pm to 175 pm, or 80 pm to 105 pm.
  • the Dio of the powder in the powder bed 100 can be in a range of 1 pm to 125 pm such as, for example, 10 pm to 30 pm
  • the median particle size of the powder in the powder bed 100 can be in a range of 10 pm to 150 pm such as, for example, 15 pm to 45 pm
  • the D90 of the powder in the powder bed 100 can be in a range of 30 pm to 200 pm such as, for example, 30 pm to 60 pm.
  • the Dio of the powder in the powder bed 100 can be in a range of 1 pm to 45 pm such as, for example, 1 pm to 30 pm
  • the median particle size of the powder in the powder bed 100 can be in a range of 20 pm to 65 pm such as, for example, 25 pm to 45 pm
  • the D90 of the powder in the powder bed 100 can be in a range of 45 pm to 90 pm such as, for example, 55 pm to 75 pm.
  • the Dio of the powder in the powder bed 100 can be in a range of 30 pm to 90 pm such as, for example, 45 pm to 65 pm
  • the median particle size of the powder in the powder bed 100 can be in a range of 50 pm to 150 pm such as, for example, 65 pm to 90 pm
  • the D90 of the powder in the powder bed 100 can be in a range of 75 pm to 175 pm such as, for example, 80 pm to 105 pm.
  • the powder can be produced with a desired span.
  • two or more powders can be blended together to achieve the desired span before providing the powder to the powder bed 100.
  • the powder can be manually mixed prior to adding the powder to an additive manufacturing system or dynamically mixed by an additive manufacturing system to achieve the desired span.
  • an additive manufacturing system can have two or more hoppers which have powders that have differing particle sizes. The two more or more hoppers can feed into a reservoir a desired amount of powder from each hopper to achieve the desired span and/or size ratio. The two or more powders can be blended together utilizing a mixer until the powder is suitable for additive manufacturing ( e.g substantially homogeneous).
  • the first and second powder 102, 104 can be substantially spherical in shape.
  • a powder bed 200 can have a first powder fraction 206 having a first general particle shape and a second powder fraction 208 having a second general particle shape.
  • the first and second particle shapes can differ.
  • the first general particle shape can be irregular.
  • the irregularly shaped powder of the first powder fraction 206 may include at least one sharp edge having an acute exterior angle.
  • the second general particle shape can be
  • substantially spherical Utilizing certain combinations of powder fractions with different general shapes can enhance packing density of the powder in the powder bed 200.
  • including two or more powder fractions having differing general shapes in the powder bed 200 can result in green parts requiring less energy during sintering to achieve a desired minimum density than green parts produced from powder beds that do not include multiple powder fractions with different general shapes.
  • the shapes of the powder in the powder fractions in the powder bed 200 can be chosen to increase the packing density of the powder bed 200.
  • including powder fractions with different powder particle shapes in the powder bed 200 can increase the efficiency of sintering a part preform produced from the powder bed 200.
  • including irregularly shaped powder in the powder bed 200 can enhance sintering of a part preform produced from the powder bed 200 due to the sharp angle present at the edges of the irregularly shaped powder and higher surface area, which can allow the particles to heat more efficiently.
  • the sharp angles present at the edges of higher surface area powder can be less stable than sphere shaped powder. The instability at the edges can promote increased mass diffusion which can lower the surface area of the powder.
  • the powder in the powder bed comprises at least one of metallic particles, plastic particles, and ceramic particles.
  • the powder can comprise, for example, at least one of titanium particles, titanium alloy particles, aluminum particles, aluminum alloy particles, nickel particles, nickel alloy particles, iron particles, iron alloy particles, cobalt particles, cobalt alloy particles, copper particles, copper alloy particles, molybdenum particles, molybdenum alloy particles, tantalum particles, tantalum alloy particles, tungsten particles, and tungsten alloy particles.
  • the powder can comprise at least one of titanium particles and titanium alloy particles.
  • ceramic particles can comprise, for example, at least one of non-oxide ceramic particles and oxide ceramic particles.
  • the ceramic particles can comprise at least one of an oxide, a carbide, a nitride, and a boride.
  • FIG. 3 a schematic depiction of a front view of a non-limiting embodiment of an additive manufacturing system 300 including a plate 322 is provided.
  • the additive manufacturing system 300 can comprise a powder bed 310, a platform 312, a powder deposition module 314, and a binding module 316.
  • the powder bed 310 can be adapted to receive powder.
  • the powder bed 310 can comprise the platform 312 and a layer or layers of powder.
  • the powder deposition module 314 can deposit the powder in the powder bed 310.
  • the powder deposition module 314 can obtain powder from a powder reservoir 318.
  • the powder deposition module 314 can move the obtained powder to the powder bed 310 and deposit a layer of the powder in the powder bed 310.
  • the powder deposition module 314 can source powder from a powder hopper (not shown) and deposit the powder as a layer in the powder bed 310.
  • the powder deposition module 314 can source powder from two or more powder hoppers (not shown), mix the powder from the powder hoppers, and deposit them as a layer in the powder bed 310.
  • the reservoir 318 can include at least two compartments (not shown) to hold different fractions of powder.
  • the reservoir 318 can receive powder from two or more powder hoppers (not shown) and blend the powders together such that the resulting blended powder is suitable for additive manufacturing ( e.g substantially homogeneous).
  • the binding module 316 can be a binder deposition module adapted to deposit a binder in one or more predetermined regions of powder layers deposited in the powder bed 310.
  • the binder can be a liquid binder.
  • the binding module 316 can comprise an energy source adapted to selectively sinter and/or melt powder in one or more predetermined regions of powder layers deposited in the powder bed 310.
  • the energy source can comprise at least one of a laser and an electron beam gun.
  • the bound particles can form all or a portion of a part preform, wherein the part preform includes powder bound together.
  • the part preform can include powder and binder holding the powder together. The sequence of depositing a layer of powder and binding a selected region or regions of the layer can be repeated as needed to produce the part preform.
  • the additive manufacturing system 300 can comprise the plate 322, which can be adapted to contact a surface 3 lOa of the powder bed 310.
  • the plate 322 can be configured to apply pressure to the powder bed 310 and compact the powder bed 310.
  • the pressure exerted by the plate 322 can increase the density of all or a portion of the powder bed 310, such as in a layer of powder deposited in the powder bed 310.
  • the plate 322 can compact all or a portion of the powder deposited in the powder bed 310 after the powder deposition module 314 deposits the powder in the powder bed 310.
  • the plate 322 can apply a compaction force to the powder bed 310 generally orthogonal to the depositing direction of the powder by the powder deposition module 314.
  • the size and shape of the plate 322 can vary among various embodiments of system 300.
  • the plate 322 can have a contact area that is similar to the exposed surface area of the surface 3 lOa of the powder bed 310.
  • the plate 322 can have a contact area that is less than the exposed surface area of the surface 3 lOa of the powder bed 310.
  • the plate 322 can compact a first region of the powder bed 310 and can be adapted to move and compact a second region of the powder bed 310, different than the first region.
  • the plate 322 can be adapted to apply a variable pressure to the powder bed 310.
  • the plate 322 can apply a first pressure to the first region of the powder bed 310, and apply a second pressure to a second region of the powder bed 310. Varying the applied pressure among different regions of the powder bed 310 can be used to create a uniform layer of powder and, in certain embodiments, create a denser area of the layer of powder for printing.
  • the plate 322 can compact the layer of powder until a selected density or a selected thickness of the layer is achieved in the region to which the pressure is applied.
  • the additive manufacturing system 300 can include at least two plates (not shown).
  • the system may include a plurality of plates arranged in a checkerboard pattern.
  • the plates can be controlled individually or collectively.
  • the plates can be stationary or adapted to move relative to the powder bed 310. Regardless of the plate 322 configuration, the individual plates can apply a pressure to all or a region of the powder layer to compact the powder layer.
  • the powder deposition module 314 or additive manufacturing system can comprise a compaction system 400, 500 that includes a press.
  • the press can comprise at least one of a roller 426 (FIG. 4) and a pressing blade 530 (FIG. 5).
  • FIG. 4 a schematic front view of a non-limiting embodiment of a compaction system 400 including a blade 424 and a roller 426 is provided.
  • the roller 426 can be operatively coupled to the blade 424 by connector 428.
  • the connector 428 can facilitate communication between the blade 424 and the roller 426.
  • the blade 424 can be configured to obtain powder from a reservoir, such as, for example, reservoir 318, and can deposit the retrieved particles in the powder bed 310.
  • the blade 424 can push powder into the powder bed 310.
  • the blade 424 can be disposed at a depositing depth into the powder bed 310, at a distance above the existing surface of the powder bed 310, and can move across the powder bed 310 in a direction 446 to deposit the obtained powder across the powder bed 310 to produce a layer of powder having a first density.
  • the blade 424 can provide a level and/or smooth surface 3 lOd on the powder bed 310.
  • the roller 426 can be configured to follow the blade 424 and apply pressure to the powder deposited on the powder bed 310, which can compact the powder bed 310.
  • the roller 426 can thereby increase a density of the powder bed 310.
  • a pre-compaction section 310b of the powder bed 310 can have a first density
  • a post-compaction section 3 lOc of the powder bed 310 can have a second density.
  • the first and second densities can differ.
  • the roller 426 can apply a compaction force to the powder bed 310 generally orthogonal to the direction 446 of movement of the blade 424 to deposit the powder in the powder bed 310.
  • the roller 426 can compact the powder bed 310 after the blade 424 deposits the powder in the powder bed 310.
  • the blade 424 can compact the powder bed 310 and can increase a density of the powder bed 310.
  • FIG. 5 a schematic front view of a non-limiting embodiment of a compaction system 500 including the blade 424 and the pressing blade 530 is provided.
  • the pressing blade 530 can be operatively coupled to the blade 424.
  • the pressing blade 530 can be configured to apply a pressure to the powder bed 310 and compact the powder bed 310.
  • the pressing blade 530 can increase the density of the powder bed 310.
  • a pre- compaction section 310b of the powder bed 310 can have the first density
  • a post- compaction section 3 lOc of the powder bed 310 can have the second density.
  • the first and second densities can differ.
  • the pressing blade 530 can apply a compaction force to the powder bed 310 generally orthogonal to the direction 446 of movement of the blade 424 to deposit the powder in the powder bed 310.
  • the pressing blade 530 can compact the powder bed 310 after the blade 424 deposits the powder in the powder bed 310.
  • FIG. 6A a schematic depiction of a non-limiting embodiment of an additive manufacturing system 600 including a powder deposition module 614 in a first position is provided.
  • the additive manufacturing system 600 comprises the powder bed 310, the platform 312, the powder deposition module 614, the powder reservoir 318, and a vertically movable reservoir platform 620.
  • the additive manufacturing system 600 can also comprise a binding module (not shown).
  • the powder deposition module 614 can comprise a first roller 6l4a and a second roller 6l4b (e.g., backup roller).
  • the first roller 6l4a can have a first diameter
  • the second roller 6l4b can have a second diameter that is larger than the first diameter.
  • Decreasing a diameter of the first roller 614a can decrease the portion of the first roller 6l4a that is in contact with the powder bed 310, which can increase the pressure applied by the first roller 6l4a to the powder bed 310.
  • the first roller 6l4a has a relatively small diameter and/or is applying large pressures, the first roller 6l4a can deflect along its length, and the pressure applied to the powder bed 310 may not be uniform.
  • the resulting variation in applied pressure along the length of the first roller 614a may produce a part preform with varying densities and inaccurate features due to variations in layer thickness and/or defects in the layer.
  • FIG. 6 A shows the powder deposition module 614 in a first position.
  • the powder reservoir platform 620 is shown in a position that has raised the level of powder in the reservoir 318 above the elevation of the existing powder bed 310.
  • the powder deposition module 614 can contact the exposed powder and facilitate movement of the powder to the powder bed 310.
  • the powder deposition module 614 can move laterally from the first position illustrated in FIG. 6A to a second position illustrated in FIG. 6B so that the first roller 6l4a pushes powder 632 laterally out of the reservoir 318 and toward the powder bed 310.
  • the powder deposition module 614 can move laterally from the second position illustrated in FIG. 6B to a third position illustrated in FIG. 6C.
  • the lateral movement of the powder deposition module 614 can deposit the powder 632 pushed from the reservoir 318 along the top surface of the powder bed 310.
  • the powder deposition module 614 can apply pressure to the powder 632 distributed along the powder bed 310 to compact the powder 632 into a layer 644 having an increased density.
  • the powder deposition module 614 can move further laterally from the third position illustrated in FIG. 6C to a fourth position illustrated in FIG. 6D.
  • the lateral movement of the powder deposition module 614 to the fourth position can complete deposition and
  • a portion of the powder 632 pushed from the reservoir 318 by the lateral movement of the powder deposition module 614 shown in FIGs. 6A-6D may not be deposited in the layer 644 and can be removed from the print bed 310 and returned to the reservoir 318 or otherwise disposed of.
  • FIG. 7 a schematic depiction from a side of aspects of a non-limiting embodiment of a powder deposition module 700 including a first roller 7l4a having a crown shape is provided.
  • the powder deposition module comprises the first roller 714a and a second roller 714b.
  • the second roller 714b can be configured so that its circumferential surface is in contact with the circumferential surface of the first roller 7l4a.
  • the second roller 714b can limit the deflection of the first roller 714a and facilitate the application of pressure by the first roller 7l4a to the powder bed 310.
  • the first roller 7l4a can have a crown shape, which can limit the deflection of the first roller 714a and can facilitate uniform application of pressure by the first roller 7l4a to the powder bed 310.
  • the crown shape can control a contact stress of the first roller 714a induced by application of pressure to the powder bed 310.
  • the first roller 714a can have at least one of a generally cylindrical shape, a crown shape, a double crown shape, a variable crown shape, and a stepped shape.
  • the second roller 7l4b can have a variable shape.
  • the second roller 714b can have a variable crown shape complimentary to a variable crown shape of the first roller 7l4a.
  • the complimentary variable crown shapes can adjust the pressure applied to the powder bed 310 dynamically. For example, if the position of the second roller 7l4b changes with resect to the position of the first roller 714a, the pressure applied by the first roller 714a to the powder bed 310 can change.
  • FIG. 8 a schematic side view depiction of certain aspects of a non limiting embodiment of a powder deposition module 800 including a first scraper 834 is provided.
  • the powder deposition module 800 comprises a first roller 8l4a and a second roller 814b in contact with the first roller 814a.
  • powder may adhere to a surface 8l4ai of the first roller 8l4a.
  • the adhered powder may limit the ability of the powder deposition module 800 to deposit a uniform layer of powder.
  • a first scraper 834 can be configured to remove powder from the surface 8l4ai of the first roller 8l4a as the first roller, for example, rotates about its axis of rotation.
  • the first scraper 834 can be disposed proximal to the first roller 8l4a such that the first scraper 834 contacts powder on the surface 8l4ai of the first roller 8l4a.
  • a second scraper 836 can be configured to remove powder from a surface 8l4bi of the second roller 8l4b.
  • the second scraper 836 can be disposed proximal to the second roller 8l4b such that the second scraper 836 contacts powder on the surface 8l4bi of the second roller 8l4b and removes the powder.
  • the first roller 8l4a and/or second roller 8l4b can comprise a coating on an outer surface.
  • the coating may provide resistance to powder particle pickup and/or to scratches from the first scraper 834 and/or second scraper 836.
  • the coating may be any suitable protective and/or non-stick coating as known by one of ordinary skill in the art.
  • the first roller 8l4a and second roller 8l4b can be configured to rotate.
  • the first roller 814a can rotate in direction 838a or direction 838b.
  • the second roller 814b can rotate in direction 840a or direction 840b.
  • the first roller 8l4a rotates in direction 838a
  • the second roller 814b rotates in direction 840a.
  • first roller 814a rotates in direction 838b
  • second roller 814b rotates in direction 840b
  • the second roller 8l4b can contact the first roller 8l4a, and when the second roller 8l4b rotates, the first roller 8l4a rotates due to friction caused by the contact.
  • the first roller 8l4a and the second roller 8l4b can be connected by a gearbox (not shown).
  • the direction of rotation of the first roller 8l4a can be in a direction opposite a direction of linear movement of the powder deposition module 800 relative to a surface of a powder bed.
  • the first roller 814a can rotate in direction 838a.
  • the first roller 8l4a can rotate in direction 838b.
  • the direction of rotation of the first roller 8l4a can be in the same direction as a direction of linear movement of the powder deposition module 800 relative to a surface of a powder bed.
  • the first roller 814a can rotate in direction 838a.
  • the first roller 8l4a can rotate in direction 838b.
  • the pressure applied by the plate 322, the roller 426, the pressing blade 530, the first roller 6l4a, the first roller 7l4a, and/or the first roller 8l4a to the powder bed 310 can be at least 1 psi, such as, for example, at least 10 psi, at least 100 psi, at least 1,000 psi, at least 3,000 psi, at least 5,000 psi, or at least 10,000 psi.
  • the pressure applied by the plate 322, the roller 426, the pressing blade 530, the first roller 6l4a, the first roller 7l4a, and/or the first roller 8l4a to the powder bed 310 can be in a range from 1 psi to 10,000 psi such as, for example, from 1 to 10 psi, from 10 to 100 psi, from 100 to 1,000 psi, from 1,000 psi to 10,000 psi, or from 5,000 psi to 10,000 psi.
  • the plate 322, the roller 426, the pressing blade 530, the first roller 6l4a, the first roller 7l4a, and/or the first roller 8l4a can be configured to apply pressure by, for example, at least one of a spring and an actuator.
  • the actuator may comprise at least one of an electric actuator, a hydraulic actuator, and a pneumatic actuator.
  • the pressure can be applied to the powder bed 310 by the plate 322, the roller 426, the pressing blade 530, the first roller 6l4a, the first roller 7l4a, and/or the first roller 8l4a after the binding module 316 deposits a binder in the powder bed 310.
  • the binder can act as a lubricant to facilitate packing of the powder bed 310.
  • at least two layers of powder can be deposited and compacted in the powder bed 310 prior to an application of a binder by the binding module 316. In other
  • a single layer of powder can be deposited and compacted in the powder bed prior to an application of a binder by the binding module.
  • the plate 322, the roller 426, the pressing blade 530, the first roller 6l4a, the first roller 7l4a, and/or the first roller 8l4a substantially compact the layer of powder deposited by the powder deposition module 314, 614, 700, 800.
  • the plate 322, the roller 426, the pressing blade 530, the first roller 6l4a, the first roller 7l4a, and/or the first roller 8l4a substantially compact a portion of the powder bed 310 or the entire powder bed 310.
  • the system 900 can comprise a plurality of vibratory units 942a-g.
  • the vibratory units 942a-c can be operatively coupled to the platform 312.
  • the vibratory units 942d-g can be operatively coupled to an enclosure 944 disposed adjacent to the powder bed 310.
  • the vibratory units 942a-g can be configured to vibrate and/or oscillate the powder bed 310. The vibrations can cause powder to shift into voids present in the powder bed 310, which can increase the packing density of powder in the powder bed 310.
  • the vibratory units 942a-g can comprise at least one of an ultrasonic transducer, a non-ultrasonic transducer, and a vibration motor.
  • the vibratory units 942a-g can be configured to operate individually or collectively.
  • vibratory units 942d, 942g can be configured to vibrate a first region 3 lOe of the powder bed 310 while minimizing vibrations in a second region 31 Of of the powder bed 310.
  • the first and second regions 3 lOe, 3 lOf can be different regions of a layer of powder, one or more layers of powder, or combinations thereof.
  • the selective vibrations can increase the density of the selected region of the powder bed 310 while maintaining the integrity of non-selected regions of the powder bed 310, such that any regions of the part preform already formed will not be damaged.
  • a porosity of the part preform produced according to the present disclosure is less than 50% by volume such as, for example, less than 40% by volume, less than 35% by volume, or less than 30% by volume. In various examples, the porosity of the part preform is in a range of 45% to 50% by volume.
  • Layers including various sizes of powder comprising maraging steel particles suitable for additive manufacturing feedstock were tested for density improvements as a result of applied pressure.
  • the steel particles were substantially spherical.
  • Steel particle sample A included a particle size distribution of 12 pm to 23 pm and a median particle size of 17 pm.
  • Steel particle sample B included a particle size distribution of 20 pm to 36 pm and a median particle size of 27 pm.
  • Steel particle sample C included a particle size distribution of 40 pm to 71 pm and a median particle size of 52 pm.
  • Steel particle sample D included a bimodal particle size distribution of powder.
  • Steel particle sample D comprised a first powder fraction including steel particle sample A and a second powder fraction including steel particle sample C.
  • Steel particle sample E included a particle size distribution of 19 pm to 48 pm and a median particle size of 29 pm.
  • graph 1000 depicts the density as calculated in grams per cubic centimeter versus the pressure applied by the piston for the particular powder sample as measured in psi.
  • the x-axis (pressure applied) is in logarithmic scale.
  • Steel particle sample A corresponds to curve 1002; steel particle sample B corresponds to curve 1004; steel particle sample C corresponds to curve 1006; steel particle sample D corresponds to curve 1008; and steel particle sample E corresponds to curve 1010.
  • the density of each sample increased as increased pressure was applied, and the density increased more significantly after an applied pressure of at least 100 psi and at least 1,000 psi. It is believe that the compression trends in this example should apply to various other materials.
  • an increased powder bed density may yield an increased green part density, which in turn may yield an increased sintered part density.
  • an increased powder bed density decreases the porosity of a part produced therefrom and can reduce entrapped gas porosity in the part.
  • the increased density in a powder bed of an additive manufacturing process can reduce the occurrence of and/or eliminate aberrations in the final part ( e.g ., density lower than specifications, pores, and/or cavitation).
  • the products produced by these methods have commercial end- uses in industrial applications, consumer applications (e.g. consumer electronics and/or appliances) or other areas.
  • consumer applications e.g. consumer electronics and/or appliances
  • the components or resulting products can be utilized in the aerospace field, automotive field, transportation field, building and construction field, in a variety of forms: fasteners, sheet, plate, castings, forgings, extrusions, post processed additive manufacturing forms, among others, including various applications (e.g., structural applications) and components like beams, frames, rails, brackets, bulkheads, spars, ribs, among others.
  • a powder bed additive manufacturing system comprising:
  • the powder deposition module further comprises a plate moveable relative to the surface and adapted to compact a layer of the powder disposed by the powder deposition module.
  • the powder deposition module further comprises a blade moveable relative to the powder deposition surface and adapted to deposit and compact a layer of the powder disposed by the powder deposition module.
  • the powder deposition module further comprises a press moveable relative to the powder deposition surface and adapted to compact a layer of the powder disposed by the powder deposition module.
  • the powder deposition module further comprises a plate moveable relative to the surface and adapted to compact the layer of the powder.
  • the press is operatively connected to a blade that is moveable relative to the powder deposition surface and adapted to deposit and compact a layer of the powder disposed by the powder deposition module.
  • the press comprises a pressing blade.
  • the press comprises a first roller.
  • the first roller comprises at least one of a crown shape, a double crown shape, a variable crown shape, and a stepped shape.
  • the system of clauses 8-9 further comprising a second roller in contact with the first roller, the second roller comprising a diameter larger than a diameter of the first roller, the second roller limiting deflection of the first roller.
  • the system of clauses 8-10 wherein the first roller is adapted to rotate in a direction opposite a direction of linear movement of the first roller relative to the powder deposition surface.
  • the system of clauses 8-11 wherein the first roller is adapted to rotate in the same direction as a direction of linear movement of the first roller relative to the powder deposition surface.
  • the system of clauses 8-12 further comprising a scraper adapted to remove powder from the first roller as the first roller rotates.
  • the system of clauses 1-13 wherein the powder deposition module is adapted to apply a pressure of at least 1 psi to a layer of the powder deposited by the powder deposition module.
  • the system of clauses 1-14 wherein the powder deposition module is adapted to apply a pressure of at least 1,000 psi to a layer of the powder deposited by the powder deposition module.
  • the system of clauses 1-15 further comprising a print head adapted to dispense a liquid binder on at least one predetermined region of a layer of the powder disposed by the powder deposition module.
  • the system of clauses 1-16 further comprising an energy source adapted to at least one of sinter and melt at least one predetermined region of a layer of the powder deposited by the powder deposition module.
  • a first vibratory unit operatively in communication with the enclosure and adapted to selectively vibrate the layer of powder.
  • the system of clause 20, comprising a plurality of vibratory units including the first vibratory unit, the plurality of vibratory units operatively in communication with the enclosure and adapted to selectively vibrate the layer.
  • the additive manufacturing method is a powder bed additive
  • compacting the layer of powder comprises moving a plate into contact with the layer and exerting pressure on the layer of powder with the plate.
  • depositing the layer of powder comprises moving a blade in contact with the layer of powder relative to the surface to deposit the layer of powder.
  • compacting the layer of powder comprises moving a press into contact with the layer of powder and applying pressure to the layer of powder with the press.
  • the press comprises a pressing blade.
  • the press comprises a first roller and wherein moving the press into contact with the layer of powder comprises rolling the first roller across the layer of powder.
  • the first roller comprises at least one of a crown shape, a variable crown shape, and a stepped shape.
  • the press further comprises a second roller in contact with the first roller, the second roller having a diameter larger than a diameter of the first roller, the second roller limiting deflection of the first roller.
  • compacting the layer of powder further comprises rotating the first roller in a direction opposite a direction of linear movement of the first roller relative to the surface.
  • compacting the layer of powder further comprises rotating the first roller in the direction of linear movement of the first roller relative to the surface.
  • the method of clauses 27-31 further comprising removing powder from the first roller utilizing a scraper as the first roller rolls along the layer of powder.
  • the method of clauses 22-32, wherein compacting the layer of powder comprises applying a pressure of at least 1 psi to the layer of powder.
  • the method of clauses 22-33, wherein compacting the layer of powder comprises applying a pressure of at least 1,000 psi to the layer of powder.
  • the method of clauses 22-34 further comprising vibrating the layer of powder.
  • the method of clauses 22-35 wherein the powder comprises at least one of metallic particles, plastic particles, and ceramic particles.
  • the ceramic particles comprise at least one of an oxide, a carbide, a nitride, and a boride.
  • the powder comprises at least one of titanium particles, titanium alloy particles, aluminum particles, aluminum alloy particles, nickel particles, nickel alloy particles, iron particles, iron alloy particles, cobalt particles, cobalt alloy particles, copper particles, copper alloy particles, molybdenum particles, molybdenum alloy particles, tantalum particles, tantalum alloy particles, tungsten particles, and tungsten alloy particles.

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  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne un procédé et un système permettant d'améliorer la densité dans un lit de poudre, et un article produit à partir de ceux-ci. Le système comprend une surface de dépôt de poudre et un module de dépôt de poudre. La surface de dépôt de poudre est conçue pour recevoir de la poudre. Le module de dépôt de poudre est conçu pour disposer une couche de poudre sur la surface et est conçu pour compacter la couche.
PCT/US2019/040135 2018-07-10 2019-07-01 Procédé et système d'augmentation de la densité dans un lit de poudre, et article produit à partir de ceux-ci Ceased WO2020014028A1 (fr)

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