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Functionalized non-spherical powder raw material and preparation method thereof

A technology of functionalized, non-spherical particles, applied in the direction of additive manufacturing, improving energy efficiency, metal processing equipment, etc., can solve the problems of expensive spherical powders, limiting the practicality and implementation of metal additive manufacturing

Pending Publication Date: 2022-07-08
HRL LAB
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0011] However, melt atomization of fine (less than 65 μm) and monodisperse (15–60 μm) spherical powders from bulk ingots is known to be very expensive compared to conventional subtractive manufacturing processes
As an example, the cost of aluminum alloys is typically $2-5 / kg depending on the composition, while atomized aluminum powder is only commercially available at a high cost of $45-300 / kg
Significant price differences between raw materials and atomized powders have so far limited the practicality and implementation of metal AM and relegated it to prototypes or high-margin components where manufacturing cost is not a significant design driver (e.g., satellite or spaceflight). device structure)

Method used

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  • Functionalized non-spherical powder raw material and preparation method thereof
  • Functionalized non-spherical powder raw material and preparation method thereof
  • Functionalized non-spherical powder raw material and preparation method thereof

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0194] Example 1: Mechanical milling of aluminum alloys.

[0195] Unmodified extruded Al-7075 aluminum alloy rods were obtained as bulk starting materials. The Al-7075 rods were mechanically milled under ambient conditions using a laboratory-scale planetary mill. The temperature of mechanical milling was kept below the melting point of Al-7075 (477°C).

[0196] The first experiment was performed with a single milling / grinding step. image 3 is an SEM image (scale bar = 1 mm) showing a single Al-7075 particle produced by mechanical milling of the extruded rod bulk starting material. The Al-7075 particles have a characteristic size of less than 600 microns. Mechanically milled particles are non-spherical.

[0197] A second experiment was performed in which the grinding intensity was varied by adjusting the parameters of the planetary mill, including the number and spacing of grinding teeth, shear rate, screen size and number of passes. Figure 4 The particle size distributi...

example 2

[0199]Example 2: Low temperature mechanical milling of aluminum alloys.

[0200] Unmodified extruded Al-7075 aluminum alloy rods were obtained as bulk starting materials.

[0201] The bulk starting material was processed by cryogenic milling (cryomilling) using a laboratory scale cryogenic mill (Retsch GmbH, Haan, Germany). The temperature of cryogenic milling is about -195°C, which is much lower than the melting point of Al-7075 (477°C).

[0202] Figure 5 is shown produced by cryogenic milling of extruded rod body starting material compared to single particles of Al-7075 produced by mechanical milling of extruded rod body starting material at ambient temperature (right hand image; see Example 1) Photograph of a single Al-7075 particle (left-hand image). The cryogenically milled particles are non-spherical. Particles milled at low temperature have smaller feature sizes than particles milled at ambient temperature due to reduced ductility.

example 3

[0203] Example 3: Chemical pretreatment before mechanical milling of aluminum alloys.

[0204] A bulk starting material consisting of fragments of extruded Al-7075 aluminum alloy rods was obtained.

[0205] To embrittle the metal to reduce ductility, the bulk starting material was exposed to a forming gas (Ar / H 2 , 96% / 4% by volume) to reduce the ductility of aluminum alloys by hydrogen embrittlement. The pretreatment temperature is lower than the liquidus temperature (635°C) of the Al-7075 aluminum alloy.

[0206] After hydrogen pretreatment, the bulk material was then mechanically milled at ambient temperature using a laboratory-scale planetary mill.

[0207] Figure 6A is an SEM image (scale bar = 200 microns) showing a single non-spherical particle of Al-7075 produced by exposure to synthesis gas followed by mechanical stirring at ambient temperature. Figure 6B is an SEM image showing a single Al-7075 aspheric particle with embrittled regions (scale bar = 50 microns)....

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Abstract

The present disclosure provides improvements to the prior art by teaching low cost methods for producing raw material powders from industrially related forged alloys without undergoing phase changes, which alloys can be widely obtained at low cost. The surfaces of the non-spherical particles are functionalized with particulates having a different size and composition than those particles to control the solidification response of the feedstock. Some variations provide a metal-containing functionalized material comprising: a plurality of non-spherical particles comprising a metal or metal alloy; and a plurality of metal or ceramic-containing particles assembled on the surface of the non-spherical particles wherein the particles are compositionally different from the non-spherical particles. Methods of making and using metal-containing functionalized materials are described. Compared with a traditional gas atomization or water atomization metal powder raw material, the method has the advantage that economic advantages are provided for powder-based metal additive manufacturing or other powder metallurgy processes.

Description

[0001] priority data [0002] This International Patent Application claims priority to US Provisional Patent Application No. 62 / 936,713, filed November 18, 2019, and US Patent Application No. 17 / 026,218, filed September 19, 2020, each of which is hereby incorporated by reference Incorporated herein by reference. [0003] Field of Invention [0004] The present invention generally relates to powder-based additive manufacturing processes and other powder-based metallurgical processes, and metal-containing functionalized materials that can be used in these processes. [0005] Background of the Invention [0006] Metal-based additive manufacturing, or three-dimensional (3D) printing, has applications in many industries, including the aerospace and automotive industries. Building metal parts layer by layer increases design freedom and manufacturing flexibility, enabling complex geometries while eliminating traditional economies of scale constraints. In metal-based additive manufa...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B22F1/06B22F1/05B22F1/054B22F1/062B22F1/068B22F1/145B22F1/17
CPCC22C1/05B22F2009/043B22F2999/00B33Y70/10B22F10/28Y02P10/25B22F1/062B22F1/05B22F1/068B22F1/054B22F1/145B22F1/17B22F1/06B22F9/04B22F2998/10B22F2304/10B22F2304/15B22F2304/05B22F2009/045B22F1/16
Inventor 雅各布·亨德利布伦南·亚哈塔约翰·马丁托拜厄斯·舍德勒
Owner HRL LAB