Manufacturing method for green body parts and joining parts

Abstract

SOLUTION: A green body component (360) includes a first green portion (340a), a second green portion (340a), an interface bonding portion (362) between the first green portion (340a) and the second green portion (340a), and a bonding material (350) disposed at the interface bonding portion (362). The bonding material (350) comprises a powder having a particle size distribution of between 1 μm or more and 50 μm or less. A method of manufacturing a bonded part (360) includes applying the bonding material (350) to a surface (352) of the first green portion (340a) and bringing the second green portion (340b) into contact with the bonding material (350) of the surface (352) of the first green portion (340a) to form the bonded green component (360).SELECTED DRAWING: Figure 18

Description

[Technical Field]

[0001] This specification relates to additive manufacturing. More particularly, this specification is directed to additively manufactured joined parts that include joining materials. [Background technology]

[0002] Additive manufacturing, also known as three-dimensional (3D) printing, is a method in which material is built up layer by layer to form an object. Binder jetting is an additive manufacturing technique based on the use of a binder to bond fine particles of powder to form a 3D object. Specifically, the binder is jetted onto successive layers of powder in a build volume, where the layers of powder and binder adhere to each other to form the 3D object.

[0003] Two or more binder jet sections may be joined (e.g., using sinter bonding) to form objects with relatively complex shapes or large dimensions that could not be obtained by printing a single section. However, the binder jet sections may have uneven surfaces, which can cause the joining step to introduce porosity at the bond interface, reducing the bond strength. Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, there is a need for additively manufactured parts with seamless joints. [Means for solving the problem]

[0005] According to a first aspect A1, a green body part can include a first green portion including a first plurality of layers of a first granular material, a second green portion including a second plurality of layers of a second granular material, an interface bond between the first green portion and the second green portion, and a bonding material disposed within the interface bond, the bonding material including a powder having a particle size distribution of 1 μm or more and 50 μm or less.

[0006] A second embodiment A2 includes the green body part according to the first embodiment A1, wherein the powder includes a metal powder, the metal powder including at least one of a nickel alloy, a stainless steel alloy, a cobalt-chromium alloy, an aluminum alloy, an iron alloy, a titanium alloy, a copper alloy, and a copper-nickel alloy.

[0007] A third embodiment A3 includes the green body part according to the first embodiment A1, wherein the powder includes a ceramic powder, the ceramic powder including at least one of alumina, aluminum nitride, zirconia, titania, silica, silicon nitride, silicon carbide, and boron nitride.

[0008] A fourth aspect A4 includes the green body part according to any one of the first to third aspects A1 to A3, and the joining material further includes a binder, which includes a plurality of reactive monomers.

[0009] A fifth aspect A5 includes the green body part according to the first aspect A4, wherein the binder further includes a thickener.

[0010] A sixth embodiment A6 includes the green body part according to the fifth embodiment A5, wherein the thickener comprises at least one of polystyrene, polycarbonate, and polyvinylpyrrolidone.

[0011] A seventh aspect A7 comprises a green body part according to the fifth aspect A5 or the sixth aspect A6, wherein the thickener has a molecular weight of 10,000 g / mol or more and 50,000 g / mol or less.

[0012] An eighth aspect A8 includes the green body part according to any one of the first to seventh aspects A1 to A7, and the weight ratio of the powder to the binder in the joining material is 3:1 to 8:1.

[0013] A ninth aspect A9 includes the green body part according to any one of the first to eighth aspects A1 to A8, wherein the joining material includes 75% by weight or more and 88% by weight or less of a powder and 12% by weight or more and 25% by weight or less of a binder.

[0014] A tenth aspect A18 includes the green body part according to any one of the first to ninth aspects A1 to A9, wherein the joining material has a viscosity of 100 cP or more and 50,000 cP or less.

[0015] An eleventh aspect A11 comprises the green body part according to any one of the first to tenth aspects A1 to A10, wherein the plurality of reactive monomers comprises at least one of an epoxy monomer, an acrylate monomer, and a vinyl ether monomer.

[0016] A twelfth embodiment A12 includes a green body part according to the eleventh embodiment A11, wherein the epoxy monomer includes at least one of 3,4-epoxycyclohexylmethyl 3,4-epoxycyclohexanecarboxylate, diglycidyl 1,2-cyclohexanedicarboxylate, 1,2,7,8-diepoxyoctane, dicyclopentadiene dioxide, 1,2-butanediol diglycidyl ether, and 1,2-epoxydodecane.

[0017] A thirteenth embodiment A13 includes the green body part of eleventh embodiment A11, wherein the acrylate monomer includes at least one of cyanoacrylate, allyl cyanoacrylate, alkyl cyanoacrylate, neopentyl glycol propoxylate (1PH / OH) diacrylate, di(ethylene glycol) diacrylate, 1,6-hexanediol diacrylate, and tri(propylene glycol) diacrylate.

[0018] A fourteenth embodiment A14 comprises the green body part according to the eleventh embodiment A11, wherein the vinyl ether monomer comprises at least one of cyclohexyl vinyl ether and diethylene glycol divinyl ether.

[0019] A fifteenth aspect A15 includes the green body portion of any one of the fourth through fourteenth aspects A4-A14, wherein the joining material further includes 0.01% to 2% by weight of a thermal initiator, the thermal initiator including at least one of a blocked ammonium antimony hexafluoride catalyst, 1,1'-azobis(cyclohexanecarbonitrile), 2,2'-azobis(2-methylpropionitrile), (4-hydroxyphenyl)methyl(2-methylbenzyl)sulfonium hexafluoroantimonate, and benzyl(4-hydroxyphenyl)methylsulfonium hexafluoroantimonate.

[0020] A sixteenth aspect A16 includes a green body part according to any one of the first to fifteenth aspects A1 to A15, in which the interface bonded portion has at least one curved portion.

[0021] A seventeenth aspect A17 includes the green body part according to any one of the first to sixteenth aspects A1 to A16, wherein the powder includes the same elements as at least one of the first granular material and the second granular material.

[0022] An eighteenth aspect A18 includes the green body part according to any one of the first to seventeenth aspects A1 to A17, wherein at least one of the first particulate material and the second particulate material includes a metal particulate material, and the metal particulate material includes at least one of a nickel alloy, a cobalt alloy, a cobalt chromium alloy, a titanium alloy, an aluminum-based alloy, a tungsten alloy, a stainless steel alloy, a low-carbon steel, and copper.

[0023] A nineteenth aspect A19 includes the green body part according to any one of the first to seventeenth aspects A1 to A17, wherein at least one of the first particulate material and the second particulate material includes at least one of ceramic materials, and the ceramic material includes alumina, aluminum nitride, zirconia, titania, silica, silicon nitride, silicon carbide, and boron nitride.

[0024] According to twentieth aspect A20, a method of manufacturing a joined component may include providing a first green part including a first plurality of layers of a first particulate material and a second green part including a second plurality of layers of a second particulate material; applying a joining material onto a surface of the first green part, the joining material including a powder having a particle size distribution of 1 μm or more and 50 μm or less; and contacting the second green part with the joining material on the surface of the first green part to form a joined green part having an interfacial bond between the first green part and the second green part.

[0025] A twenty-first aspect A21 includes the green body part of the twentieth aspect A20, wherein the powder includes a metal powder, the metal powder including at least one of a nickel alloy, a stainless steel alloy, a cobalt-chromium alloy, an aluminum alloy, an iron alloy, a titanium alloy, a copper alloy, and a copper-nickel alloy.

[0026] A twenty-second embodiment A22 includes a green body part according to the twentieth embodiment A20 or the twenty-first embodiment A21, wherein the joining material further includes a binder, the binder including a plurality of reactive monomers.

[0027] A twenty-third aspect A23 includes the green body component according to any one of the twentieth to twenty-second aspects A20 to A22, and the method further includes heating the joined green body components at a temperature of 65°C or higher and 140°C or lower to cure the joining material.

[0028] A twenty-fourth embodiment, A24, includes a green body part according to any of the twentieth to twenty-third embodiments, A20 to A23, the method including heating the joined green body parts above a first temperature to remove at least a portion of the binder and sintering at least a portion of the powder such that the sintered powder forms a neck region between the first and second particulate materials, thereby forming the joined green body part; and sintering the first and second particulate materials to thereby form a joined consolidated portion. [Effects of the Invention]

[0029] Various embodiments of the green body parts disclosed herein meet these needs by including a joining material having a powder with a particle size distribution of 1 μm or more and 50 μm or less, which fills the uneven surfaces of the joined green parts to create a seamless joint, thereby improving the strength of the joined parts. [Brief explanation of the drawings]

[0030] [Figure 1] FIG. 2 is a schematic diagram of a first green portion and a second green portion according to one or more embodiments shown and described herein. [Figure 2] 2 is an enlarged view of the first green portion and the second green portion of FIG. 1. [Figure 3] FIG. 1 is a schematic diagram of bonded green body components bonded via a sinter bonding process. [Figure 4] FIG. 1 is a schematic illustration of a joined green body part according to one or more embodiments shown and described herein. [Figure 5] 1 is a flow diagram of an embodiment of a method for manufacturing a part using a joining material according to one or more embodiments shown and described herein. [Figure 6] FIG. 1 is a block diagram of an additive manufacturing apparatus according to one or more embodiments shown and described herein. [Figure 7] 1 is a schematic illustration of a layer of particulate material from which a green part is made according to one or more embodiments shown and described herein. [Figure 8] FIG. 2 is a schematic diagram of a green portion according to one or more embodiments shown and described herein. [Figure 9] FIG. 1 is a schematic illustration of a green part having a joining material applied thereto, according to one or more embodiments shown and described herein. [Figure 10] FIG. 1 is a schematic illustration of a joined green body part according to one or more embodiments shown and described herein. [Figure 11] FIG. 2 is a schematic diagram of another embodiment of a joined green body part according to one or more embodiments shown and described herein. [Figure 12] FIG. 2 is a schematic diagram of another embodiment of a joined green body part according to one or more embodiments shown and described herein. [Figure 13] FIG. 2 is a schematic diagram of another embodiment of a joined green body part according to one or more embodiments shown and described herein. [Figure 14] FIG. 2 is a schematic diagram of another embodiment of a joined green body part according to one or more embodiments shown and described herein. [Figure 15] FIG. 2 is a schematic diagram of another embodiment of a joined green body part according to one or more embodiments shown and described herein. [Figure 16] FIG. 2 is a schematic diagram of another embodiment of a joined green body part according to one or more embodiments shown and described herein. [Figure 17] FIG. 2 is a schematic diagram of another embodiment of a joined green body part according to one or more embodiments shown and described herein. [Figure 18] FIG. 1 is a schematic illustration of a joined green body part according to one or more embodiments shown and described herein. [Figure 19] FIG. 1 is a schematic diagram of joined brown body parts according to one or more embodiments shown and described herein. [Figure 20] FIG. 1 is a schematic diagram of a joined integrated component according to one or more embodiments shown and described herein. [Figure 21] 1 is a photograph of a first green section according to one or more embodiments shown and described herein. [Figure 22] 1 is a photograph of a control green body part having a first green portion disposed over a second green portion. [Figure 23] 10 is a microscopic image of a control junction. [Figure 24] 1 is a microscopic image of an exemplary interface according to one or more embodiments shown and described herein. [Figure 25]25 is a magnified microscope image of the exemplary interface of FIG. 24. [Figure 26] 1 is a microscopic image of an exemplary interface according to one or more embodiments shown and described herein. [Figure 27] 27 is a magnified microscope image of the exemplary interface of FIG. 26. [Figure 28] 10 is a magnified microscope image of a control junction. [Figure 29] 1 is a magnified microscope image of an exemplary interface according to one or more embodiments shown and described herein. [Figure 30] 10 is a magnified microscope image of another exemplary interface according to one or more embodiments shown and described herein. [Figure 31] 1 is a schematic diagram of a control interface component according to one or more embodiments of the present disclosure as shown and described herein; FIG. [Figure 32] This is a photograph of the control joint after a three-point beam bending experiment. [Figure 33] 1 is a schematic diagram of an exemplary interface component according to one or more embodiments shown and described herein. [Figure 34] 1 is a photograph of an exemplary bonded portion after being subjected to a three-point beam bending experiment according to one or more embodiments shown and described herein. DETAILED DESCRIPTION OF THE INVENTION

[0031] Additional features and advantages of the embodiments disclosed herein will be set forth in the detailed description which follows, and in part will become readily apparent to those skilled in the art from that description, or may be learned by practicing the disclosed embodiments as described herein, including the following detailed description, the claims, and the accompanying drawings.

[0032] It is to be understood that both the foregoing general description and the following detailed description are intended to describe various aspects and provide an overview or framework for understanding the nature and characteristics of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various aspects, and are incorporated into and constitute a part of this specification. The drawings illustrate various aspects described herein and, together with the description, serve to explain the principles and operation of the claimed subject matter.

[0033] Reference is now made in detail to various embodiments of joining materials including additively manufactured parts. In particular, various embodiments of green body parts include a first green part including a first plurality of layers of a first particulate material, a second green part including a second plurality of layers of a second particulate material, an interface or interfacial bond between the first and second green parts, and joining material disposed within the interfacial bond, the joining material including a powder having a particle size distribution of 1 μm or greater and 50 μm or less. Reference is made herein to various embodiments of green body parts with specific reference to the accompanying drawings.

[0034] Ranges can be expressed herein as from "about" one particular value or to "about" another particular value. When such a range is expressed, another embodiment includes from one particular value or to the other particular value. Also, when a numerical value is preceded by a term such as "about" or "approximately," it is intended to be understood as excluding that term. The starting point and the end point of a range each have a significant meaning in relation to the other point (the end point and the starting point), and each have a meaning independent of the other point.

[0035] Directional terms used herein—e.g., up, down, right, left, front, back, superior, inferior—refer only to the depicted figures and are not intended to imply absolute orientations.

[0036] Unless otherwise expressly stated, it is never intended that any method described herein be construed as requiring its steps to be performed in a particular order or as requiring a particular orientation of any device. Thus, if a method claim does not actually recite an order to follow its steps, or if any apparatus claim does not actually recite an order or orientation for individual components, or if it is specifically stated otherwise in the claim or description that the steps are to be limited to a particular order or no particular order or orientation for the apparatus components is recited, then no order or orientation is intended to be inferred in any respect. This applies to any possible implicit basis for interpretation, including matters of logic regarding the arrangement of steps, operational flow, component order, or component orientation, plain meaning derived from grammatical organization or punctuation, and the number or type of aspects described herein.

[0037] As used herein, the singular forms "a," "an," and the like include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "one" element includes aspects having two or more such elements unless the context clearly dictates otherwise.

[0038] The term "particle size distribution" as used herein refers to the particle size distribution D50 or the median diameter of the particle size distribution.

[0039] As used herein, the phrases "green part" and "bonded green body part" refer to a part or component before it is subjected to a heat treatment to remove the print binder.

[0040] As used herein, the phrase "bonded brown body part" refers to a part that has undergone a debinding heat treatment to remove at least a portion of the printed binder.

[0041] As used herein, the term "debinding" refers to heating a bonded green body part to remove at least a portion of the printed binder to form a bonded brown body part.

[0042] The phrase "thermoplastic polymer," as used herein, refers to a polymer having one or more polymer strands with functional groups capable of interacting with one another through weak non-covalent forces (e.g., interactions, bonds) that link or otherwise bind the respective thermoplastic polymer strands to one another.

[0043] As used herein, the phrase "thermoset polymer" refers to a crosslinked polymer network.

[0044] The phrase "weak non-covalent forces" as used herein refers to hydrogen bonds, ionic bonds, van der Waals forces, etc., having a bond force or strength of 1 kcal / mol or more and 7 kcal / mol or less.

[0045] As used herein, the phrase "thermal initiator" refers to a compound that generates reactive species (ie, free radicals, cations, or anions) upon exposure to heat.

[0046] Microscopic images include non-limiting exemplary embodiments of the present disclosure and were collected at 100x magnification using a Zeiss optical microscope.

[0047] Binder jet printing can be limited by the complex configuration of the part being printed or the size of the printer. To create parts with relatively complex shapes or large sizes, additive manufacturers can binder jet print two or more parts and utilize a joining step, such as sinter bonding.

[0048] 1 and 2, the first green part 102 and the second green part 104 obtained by conventional binder jetting have uneven surfaces including peaks 106 and valleys 108. Thus, as shown in FIG. 3, when the green parts 102, 104 are joined via a sinter bonding step, voids 110 exist at the interface bond 112. This porosity at the interface bond 112 reduces the bond strength and overall strength of the parts and can result in mechanical or bond failure.

[0049] As described with reference to FIG. 4 , the green body part 200 described herein includes a first green part 202, a second green part 204, an interfacial bond 212 between the first green part 202 and the second green part 204, and a joining material 214 disposed within the interfacial bond 212. The joining material 214 includes powder having a relatively small particle size distribution compared to the particulate material of the first and second green parts 202, 204, such that peaks and valleys at the interfacial bond 212 fill and form a seamless bond, thereby improving the bond strength and overall strength of the part. As used herein, the term “relatively small particle size distribution” refers to a particle size distribution of 50 μm or less.

[0050] In some embodiments, the powder of the joining material can have a particle size distribution of 1 μm or more and 50 μm or less, such that the powder fills the uneven surfaces of the green part to produce a part with a seamless joint (i.e., limited or void-free). In embodiments, the powder can have a particle size distribution of 1 μm or more, 5 μm or more, 10 μm or more, or even 15 μm or more. In embodiments, the powder can have a particle size distribution of 50 μm or less, 25 μm or less, or even 20 μm or less. In embodiments, the powder can have a particle size distribution of from 1 μm to 50 μm, from 1 μm to 25 μm, from 1 μm to 20 μm, from 5 μm to 50 μm, from 5 μm to 25 μm, from 5 μm to 20 μm, from 10 μm to 50 μm, from 10 μm to 25 μm, from 10 μm to 20 μm, from 15 μm to 50 μm, from 15 μm to 25 μm, or from 15 μm to 20 μm, or any and all subranges formed from any of these endpoints.

[0051] In some embodiments, the joining material powder can include a metal powder. In embodiments, the metal powder can include at least one of a nickel alloy (e.g., Inconel 625, Rene' 108, Rene' 80), a stainless steel alloy (e.g., 316L, 17-4PH), a cobalt-chromium alloy, an aluminum alloy (e.g., Al6061), an iron alloy, a titanium alloy (e.g., Ti64), a copper alloy, and a copper-nickel alloy (e.g., C18000). In other embodiments, the joining material powder can include a ceramic powder. In some embodiments, the ceramic powder can include at least one of alumina, aluminum nitride, zirconia, titania, silica, silicon nitride, silicon carbide, and boron nitride.

[0052] In some embodiments, the joining material can further include a binder that helps improve the strength of the joined green body parts. In some embodiments, the binder can include multiple reactive monomers. A thermoplastic or thermosetting polymer formed by polymerization of the reactive monomers imparts strength to the joined green parts by binding them together. In some embodiments, the formed thermoplastic polymer is selected from a class of thermoplastic polymers that generally decompose into small oligomers, carbon dioxide, and water without requiring the presence of oxygen. Thus, in embodiments, the resulting thermoplastic polymer can be cleanly and easily removed during curing of the joining material. In embodiments where a thermoplastic polymer is desired, the multiple reactive monomers can include monofunctional monomers. In embodiments where clean combustion is not required and char may be present, the multiple reactive monomers can include difunctional monomers to produce a thermosetting polymer.

[0053] In embodiments, the plurality of reactive monomers may include at least one of epoxy monomers, acrylate monomers, and vinyl ether monomers.

[0054] In embodiments, the epoxy monomer may include at least one of 3,4-epoxycyclohexylmethyl 3,4-epoxycyclohexanecarboxylate, diglycidyl 1,2-cyclohexanedicarboxylate, 1,2,7,8-diepoxyoctane (e.g., 97% 1,2,7,8-diepoxyoctane), dicyclopentadiene dioxide (e.g., 97% mixture of endo and exo isomers), 1,2-butanediol diglycidyl ether (e.g., 1,4-butanediol diglycidyl ether technical grade, 60% or ≧95%), and 1,2-epoxydodecane (e.g., 90% 1,2-epoxydodecane).

[0055] In embodiments, the acrylate monomer may include at least one of cyanoacrylate (e.g., Permabond 919, Permabond 922), allyl aldehyde acrylate, alkyl anaacrylate, neopentyl glycol propoxylate (1PH / OH) diacrylate, di(ethylene glycol) diacrylate, 1,6-hexanediol diacrylate, and tri(propylene glycol) diacrylate. In some embodiments, the acrylate monomer may not require an initiator for curing, as the acrylate monomer may crosslink with moisture catalyzed by moisture present on the interfacial bonding surface.

[0056] In some embodiments, the vinyl ether monomer can include at least one of cyclohexyl vinyl ether and diethylene glycol divinyl ether.

[0057] In embodiments, the binder may further include a thickener. In embodiments where the plurality of reactive monomers includes a monofunctional monomer, the binder may include a thickener to increase its viscosity. In embodiments, the thickener may include at least one of polystyrene, polycarbonate, and polyvinylpyrrolidone. In some embodiments, the thickener may have a molecular weight of 10,000 g / mol or more and 50,000 g / mol or less.

[0058] In embodiments, the weight ratio of powder to binder in the joining material is from 3:1 to 8:1, from 3.5:1 to 8:1, from 4:1 to 8:1, from 3:1 to 7:1, from 3.5:1 to 7:1, from 4:1 to 7:1, from 3:1 to 6:1, from 3.5:1 to 6:1, or even from 4:1 to 6:1, or any and all subranges formed from any of these endpoints.

[0059] In some embodiments, the joining material can include 75% to 88% by weight (wt%) powder and 12% to 25% by weight binder. In embodiments, the joining material can include any and all portions formed from 75% to 88% by weight, 75% to 86% by weight, 75% to 84% by weight, 77% to 88% by weight, 77% to 86% by weight, 77% to 84% by weight, 80% to 88% by weight, 80% to 86% by weight, 80% to 86% by weight, 80% to 84% by weight, or any of these endpoints. The binder may comprise a powder in the range of from 12% to 25% by weight, from 12% to 23% by weight, from 12% to 20% by weight, from 14% to 25% by weight, from 14% to 23% by weight, from 14% to 20% by weight, from 16% to 25% by weight, from 16% to 23% by weight, from 16% to 20% by weight, from 16% to 23% by weight, from 16% to 20% by weight, or any and all subranges formed from any of these endpoints.

[0060] In some embodiments, the bonding material can have a viscosity of 100 centipoise (cP) or more and 50,000 cP or less. In some embodiments, the bonding material can have a viscosity of 100 cP or more, 200 cP or more, 500 cP or more, or even 1000 cP or more. In some embodiments, the bonding material can have a viscosity of 50,000 cP or less, 10,000 cP or less, 2,000 cP or less, or even 1,000 cP or less. In some embodiments, the bonding material has a viscosity of 100 cP to 50,000 cP, 100 cP to 10,000 cP, 100 cP to 2,000 cP, 100 cP to 1,000 cP, 200 cP to 50,000 cP, 200 cP to 10,000 cP, 200 cP to 2,000 cP, 200 cP to 1,000 cP, 500 cP to 50, 500 cP or less, 500 cP or more and 10,000 cP or less, 500 cP or more and 2,000 cP or less, 500 cP or more and 1,000 cP or less, 1,000 cP or more and 50,000 cP or more, 1,000 cP or more and 10,000 cP or more, and even 1,000 cP or more and 2,000 cP or less, or any and all subranges formed from any of these endpoints.

[0061] The viscosity of the joining material can be adjusted depending on how the joining material is applied to the green part. For example, in embodiments where a dip coating process is used to apply the joining material, the joining material can have a viscosity of 100 cP or more and 1,000 cP or less. In other embodiments where the joining material is applied directly to the green part, the joining material can have a viscosity of 1,000 cP or more and 2,000 cP or less.

[0062] In some embodiments, the bonding material can further include a thermal initiator to initiate curing of the bonding material. In some embodiments, the bonding material can include 0.01% to 2% by weight of the thermal initiator. In some embodiments, the bonding material can include 0.1% by weight or more, 0.2% by weight or more, 0.3% by weight or more, 0.4% by weight or more, or even 0.5% by weight or more of the thermal initiator. In some embodiments, the bonding material can include 2% by weight or less, 1.5% by weight or less, or 1% by weight or less of the thermal initiator. In embodiments, the bonding material can include from 0.1 wt % to 2 wt %, from 0.1 wt % to 1.5 wt %, from 0.1 wt % to 1 wt %, from 0.2 wt % to 2 wt %, from 0.2 wt % to 1.5 wt %, from 0.2 wt % to 1 wt %, from 0.3 wt % to 2 wt %, from 0.3 wt % to 1.5 wt %, from 0.3 wt % to 1 ...4 wt % to 2 wt %, from 0.4 wt % to 1.5 wt %, from 0.4 wt % to 1 wt %, from 0.5 wt % to 2 wt %, from 0.5 wt % to 1.5 wt %, or from 0.5 wt % to 1 wt %, or any and all subranges formed from any of these endpoints of thermal initiator.

[0063] In some embodiments, the thermal initiator can include at least one of a blocked ammonium antimony hexafluoride catalyst (e.g., K-PURE CXC-1612), 1,1′-azobis(cyclohexanecarbonitrile) (ACHN), 2,2′-azobis(2-methylpropionitrile), (4-hydroxyphenyl)methyl(2-methylbenzyl)sulfonium hexafluoroantimonate, and benzyl(4-hydroxyphenyl)methylsulfonium hexafluoroantimonate.

[0064] In some embodiments, the thermal initiator can have a thermal decomposition temperature of 40° C. or more and 150° C. or less. In some embodiments, the thermal initiator has a thermal decomposition temperature of 65° C. or more and 100° C. or less. In some embodiments, the thermal initiator can have a thermal decomposition temperature of 40° C. or more, 50° C. or more, 60° C. or more, or even 65° C. or more. In some embodiments, the thermal initiator can have a thermal decomposition temperature of 150° C. or less, 125° C. or less, or even 100° C. or less. In certain embodiments, the thermal initiator can be 40° C. or more and 150° C. or less, 40° C. or more and 125° C. or less, 40° C. or more and 100° C. or less, 50° C. or more and 150° C. or less, 50° C. or more and 125° C. or less, 50° C. or more and 100° C. or less, 60° C. or more and 125° C. or less, 60° C. or more and 150° C. or less, 65° C. or more and 125° C. or less, or 65° C. or more and 100° C. or less, or any subrange formed by these endpoints.

[0065] Referring now to Figure 5, a system for producing joined parts via additive manufacturing using joining materials according to embodiments described herein is shown at 300. To facilitate description of embodiments of method 300, reference is also made to Figures 6 and 7, which include block diagrams illustrating embodiments of additive manufacturing equipment 320 that may be used to perform method 300. The method begins in block 302 with providing a first green part and a second green part. The first and second green parts may be provided by any method known to those skilled in the art.

[0066] For example, the step 302 of providing a green part may begin in block 302a with depositing a layer 314 of granular material 316 (i.e., a first granular material or a second granular material) on a work surface, as shown in FIG. 7. In embodiments, the layer 314 may have a thickness 318 of at least 10 microns (μm) and at most 200 μm. The granular material 316 used to print the part may vary depending on the type of part and the end use of the part. In some embodiments, the powder of the joining material may include the same elements as at least one of the first granular material and the second granular material.

[0067] In particular, the particulate material 316 can include nickel alloys (e.g., Inconel 625, Inconel 718, Rene'108, Rene'80, Rene'142, Rene'195, and Rene'M2, Marm-247), cobalt alloys (e.g., Hans 188, L605, X40, X45, FSX414), cobalt-chromium alloys, titanium alloys, aluminum alloys, tungsten alloys, stainless steel alloys (e.g., SS316L, SS304, Alloy Steel 8620, Alloy Steel 4140, Alloy 17-4PH, Stainless Steel 300 Series, Stainless Steel 400 Series), low-carbon steels (e.g., steels containing 0.05% to 0.3% carbon), and copper. In an embodiment, the metal particulate material can include particles having a particle size distribution of 1 micron (μm) or greater and 75 μm or less. Such granular materials may be used to print metal articles including, by way of example and not limitation, fuel tips, fuel nozzles, shrouds, micromixers, or turbine blades.

[0068] In some embodiments, the particulate material 316 can include a ceramic particulate material such as at least one of alumina, aluminum nitride, zirconia, titania, silica, silicon nitride, silicon carbide, and boron nitride. In some embodiments, the ceramic particulate material can include particles having a particle size distribution of 0.1 μm or more and 100 μm or less. Such particulate materials can be used to print ceramic articles for use in the medical and transportation industries, by way of example and not limitation.

[0069] 5, in step 302b, following the deposition of the granular material 316, step 302 continues with selectively depositing a printed binder in accordance with a pattern onto portions of the layer 314. For example, the printed binder may be selectively printed onto the layer 314 of the granular material 316 using a printhead operated by a controller based on a CAD design including a representation of the layer of the consolidated part to be printed.

[0070] For example, as shown in FIG. 6, the additive manufacturing equipment 320 may be a binder jet printer that selectively deposits a binder onto the layer 314 according to the operation of 302b (FIG. 5). In some embodiments, the additive manufacturing equipment 320 may include a work surface 322 that supports the layer 314 of granular material 316, a reservoir 324 that stores the printed binder 326, and a printer head 328 fluidly coupled to the reservoir 324. The printer head 328 selectively deposits the printed binder 326 onto the layer 314 of granular material 316 to print the printed binder 326 onto the layer 314 in a pattern that represents the layer of consolidated portion being printed. In some embodiments, the additive manufacturing equipment 320 may include a control system 330 for controlling the operation of the additive manufacturing equipment 320. The control system 330 may include a fully or partially automated distributed control system (DCS) or any computer-based workstation. In embodiments, the control system may be any suitable device using a general-purpose computer or application-specific device, which may generally include a memory circuit 332 that stores one or more instructions for controlling the operation of the additive manufacturing equipment 320, and a processor. The memory circuit 332 may store a CAD design representing the structure of the integrated part to be printed. The processor may include one or more processing devices (e.g., microprocessor 334), and the memory circuit 332 may include one or more tangible, non-transitory, machine-readable media that collectively store instructions executable by the processor to control the operations described herein.

[0071] After deposition, the printed binder 326 at least partially coats the outer surfaces of the particulate material 316, thereby creating binder-coated particles.

[0072] Step 302 may continue to repeat the actions of blocks 302a and 302b to build the part layer by layer until the desired number of layers 314 (ie, first plurality of layers or second plurality of layers) have been printed.

[0073] 8, following deposition of layer 314 and printing of printed binder 326 as shown in blocks 302a and 302b of FIG. 5, method 300 proceeds to block 302c, where printed binder 326 is cured to form green portion 340 (i.e., first green portion 340a or second green portion 340b). For example, printed binder 326 may include a solvent. While some of the solvent in printed binder 326 may evaporate during deposition (e.g., printing) of printed binder 326, some solvent may remain in layer 314 of granular material 316. Thus, printed binder 326 may be heat-cured at a temperature suitable to evaporate any remaining solvent in printed layer 314 and effectively bond printed layer 314 to form green portion 340.

[0074] Heat may be applied to the printed part using IR lamps or a heating plate (e.g., on-machine), or may be performed by placing the printed part in an oven (e.g., off-machine). In some embodiments, curing the print binder 326 on-machine includes heating the print layer 314 to between 25°C and 100°C, between 30°C and 90°C, between 35°C and 80°C, and even between 40°C and 70°C, or any and all subranges formed from any of these endpoints. In embodiments, the temperature range for heating the print layer 314 on-machine may differ from the off-machine temperature range.

[0075] Unbound particles from the granular material layer (e.g., granular material 316 not bound by print binder 326) can be removed after curing to prepare the green part 340 for post-printing steps such as soaking, curing, debinding, and sintering.

[0076] After curing, green portion 340 may undergo an optional drying step (not shown) to remove any residual solvent or other volatile material that may remain within green portion 340. For example, green portion 340 may be dried under vacuum, in an inert atmosphere (e.g., nitrogen (N), or argon (Ar)), or in air, at slightly elevated temperatures or at room temperature.

[0077] Although one particular embodiment of additive manufacturing equipment 320 is described herein, it is contemplated that the joining materials described herein can be used in conjunction with other additive manufacturing devices. Thus, the embodiments described herein are not necessarily limited to the methods of making green parts described herein.

[0078] 5 and 9-10, after providing first green portion 340a and second green portion 340b, method 300 proceeds to block 304, where joining material 350 is applied onto surface 352 of first green portion 340a. Joining material 350, surface 352 of first green portion 340a may be dipped or coated with joining material 350 using any method known to one of ordinary skill in the art. Joining material 350 may be a joining material according to one or more embodiments described herein.

[0079] 5 proceeds to block 306 with contacting the second green portion 340b with the joining material 350 on the surface 352 of the first green portion 340a to form a joined green body part 360 having an interfacial bond 362 between the first and second green portions 340a, 340b, as shown in FIG. 10. As described herein, the joining material 350 includes a powder having a relatively narrow particle size distribution (e.g., 1 μm to 50 μm) such that the peaks and valleys at the interfacial bond 362 are filled to form a seamless bond, thereby improving the bond strength and overall strength of the part.

[0080] As shown in FIG. 10 , the interface bond 362 can have at least one curved portion 364. The at least one curved portion 364 can enable self-alignment of the first green portion 340 a and the second green portion 340 b. The at least one curved portion 364 can also prevent crack propagation and control the flow of joining material within the interface bond 362. Referring now to FIGS. 11-17 , additional embodiments of an interface bond 362 having at least one exemplary curved portion are shown. In other embodiments, the interface bond may be angled relative to the normal of the joined green body components.

[0081] 5 proceeds to block 308, where the bonded green body parts are heated to a temperature to cure the bonding material. During curing, any solvent present in the bonding material may evaporate and any monomers present in the bonding material may crosslink, thereby imparting strength to the bonded green body parts.

[0082] In some embodiments, heat is applied to the bonded green body parts 360 using IR lamps or heating plates (e.g., on-machine), or curing can be performed by placing the bonded green body parts 360 in an oven (e.g., off-machine). In some embodiments, to cure the bonding material, the bonded green body parts may be heated to a temperature of from 65° C. to 140° C., from 65° C. to 125° C., from 65° C. to 110° C., from 80° C. to 140° C., from 80° C. to 125° C., or from 80° C. to 110° C., or any and all subranges formed from any of these endpoints.

[0083] The method 300 of Figure 5 proceeds to block 310, where the joined green body component 360 is heated above a first temperature to sinter at least a portion of the powder of the joining material 350, as shown in Figure 18, such that the sintered powder forms a neck region 366 between the first granular material 316a and the second granular material 316b, thereby forming a joined brown body component 370, as shown in Figure 19. The neck region 366 bridges the first granular material 316a and the second granular material 316b, thereby increasing the brown strength of the joined brown body component 370 prior to consolidation (i.e., sintering) of the granular materials 316a, 316b. During heating at the first elevated temperature, at least a portion of the binder present in the first granular material 316a, the second granular material 316b, or the joining material 350 is removed (i.e., debinding).

[0084] In some embodiments, the first temperature is from 60°C to 700°C, from 70°C to 600°C, from 75°C to 500°C, or from 80°C to 400°C, or any and all subranges formed from any of these endpoints.

[0085] In some embodiments, heating the bonded green body components 360 above the first temperature can include heating the bonded green body components in an oxygen-free environment (e.g., in a vacuum chamber / under an inert atmosphere) or in air.

[0086] 5 concludes at block 312 by heating the joined brown body parts 370 above a second temperature to sinter the first particulate material 316a and the second particulate material 316b, thereby forming a joined consolidated portion 380. In embodiments, the second temperature is equal to or greater than the temperature at which the first particulate material 316a and the second particulate material 316b sinter. Thus, by heating the joined brown body parts 370 above the second temperature, the particulate materials 316a, 316b sinter with the neck region 366 (FIG. 19), thereby forming a sintered phase 382 of the sintered particulate materials 316a, 316b and the sintered powder of the joining material 350, as shown in FIG. 20.

[0087] In some embodiments, the second temperature is 75°C to 1500°C, 75°C to 1450°C, 75°C to 1400°C, 100°C to 1500°C, 100°C to 1450°C, 100°C to 1400°C, 200°C to 1500°C, 200°C to 1450°C, 200°C to 1400°C, 300°C to 1500°C, 300°C to 1450°C, 300°C to 1400°C, 400°C to 1500°C, 400°C to 1450°C, 400°C to 1400°C, or any subrange formed by any of the endpoints thereof.

[0088] In some embodiments, heating the joined brown body parts 370 above the second temperature can include heating the joined brown body parts in an oxygen-free environment (e.g., vacuum chamber / inert atmosphere).

[0089] In embodiments, at least two of blocks 308, 310, and 312 may be performed in a single step (eg, place the joined green parts in an oven).

[0090] Although various aspects described herein are described with reference to method 300, it should be understood that the joining aspects described herein can be used with a variety of methods known and used by those skilled in the art. In particular, forming the green subpart can be accomplished in many different ways, in many different steps, and in many different locations. 〔example〕 Aspects will be further elucidated by the following examples, which should be understood as not being limited to the above aspects.

[0091] Examples of bonding materials Control junction JPC1: 21 and 22, a second green part GP2 formed from 316L stainless steel was placed on top of a first green part GP1 formed from 316L stainless steel. Now referring to FIG. 23, the assembled parts were heated in a furnace at 1390°C for 6 hours to produce a controlled joined part JPC1. As shown in FIG. 23, joining the first and second green parts without the use of a joining material resulted in a fractured and separated microstructure between the first and second green parts.

[0092] Exemplary joining parts JPE1 and JPE2: 24-27, exemplary joint parts JPE1 and JPE2 were manufactured using a technique similar to that used to manufacture control joint part JPC1. However, referring back to FIG. 21, prior to placing second green part GP2 on top of first green part GP1, 0.5 g of 316L stainless steel powder having a particle size distribution of approximately 25 μm was uniformly applied to groove G of first green part GP1A.

[0093] Referring now to Table 1, microhardness testing was performed at five points along the interface bond using a Wilson VH3300 automatic hardness tester to measure the bulk material of exemplary joints JPE1 and JPE2 on the Vickers scale using a 500 g load force. The joints of joined parts JPE1 and JPE2 had average hardnesses of 76 and 72, respectively, which were similar to the average hardnesses of the bulk of joined parts JPE1 and JPE2, which were 74 and 73. This similar hardness indicates that joined parts JPE1 and JPE2 have little or no porosity.

[0094] As shown in Figures 25 and 27 and as shown in Table 1, when 316L stainless steel powder was used as the joining material, a clean microstructure with no seams was obtained between the first and second green parts with a particle size distribution of about 25 μm.

[0095] "Table 1" [Table 1]

[0096] Referring to control joint part JPC2 and exemplary joint parts JPE3-JPE8, referring to FIGS. 28-30, control joint part JPC2 and exemplary joint parts JPE3-JPE8 were fabricated using a technique similar to that used to fabricate control joint part JPC1. However, referring back to FIG. 21, prior to placing second green part GP2 on top of first green part GP1, 6 g of a joint material consisting of 316L stainless steel powder and Permabond 922 binder was uniformly applied to groove G of first green part GP1A. For control joint part JPC2, a weight ratio of 1.67:1 316L stainless steel powder to Permabond 922 binder was applied. For example, for joint parts JPE3, JPE4, and JPE5, a weight ratio of 3.33:1 Permabond 922 binder to 16L stainless steel powder was applied. For example, joints JPE6, JPE7, and JPE8 were applied with a 5:1 weight ratio of 316L stainless steel to Permabond 922 binder.

[0097] As shown in FIG. 28, joining the first and second green parts using a joining material lacking a sufficient powder-to-binder ratio (i.e., 3:1 to 8:1) resulted in a fractured and separated microstructure between the first and second green parts.

[0098] Now, with reference to Table 2, microhardness evaluations were performed at five locations along the interface bond and on the bulk material of exemplary bonded components JPE3-JPE8.

[0099] "Table 2" [Table 2]

[0100] Table 2 (continued) [Table 3]

[0101] As shown in Figures 29 and 30 and as shown in Table 2, when 316L stainless steel and Permabond 922 binder in a weight ratio of 3.33:1 and a weight ratio of 5:1 were used as joining materials, a seamless and clean microstructure was obtained between the first and second green parts.

[0102] Exemplary connecting parts JPE9 to JPE11: Referring now to Table 3, density evaluations were performed by joining two single coupons using a joining material having the powder and binder weight ratios shown in Table 3 and subjecting the joint to an Archimedes density test. The Archimedes density of the single coupon was 98.23%. The Archimedes densities of parts JPE9, JPE10, and JPE11 were 98.84%, 98.83%, and 98.86%, respectively. Thus, as shown in Table 3, using joining materials as described herein to join parts results in joined parts having densities similar to the single parts.

[0103] "Table 3" [Table 4]

[0104] Connection design example 31-34, the control joint component JPC3 and the exemplary joint component JPE9 were fabricated by providing first and second green parts formed from Rene'108 nickel alloy powder, applying Permabond 922 binder to the first green part, and contacting the first and second green parts. The assembled parts were heated in an oven at 1300°C for 12 hours to produce a bonded part. As shown in FIGS. 31 and 33, the interface bond of the control joint JPC3 was not angled, while the interface bond of the exemplary joint JPE9 was angled.

[0105] Referring now to Figures 32 and 34, a three-point beam bending experiment was conducted. Control joint JPC3 failed at the joint at a failure load of 24.4 kg. Joint JPE9 failed at a similar failure load of 23.8 kg, but did not fail at the seam. As shown by Figures 31-34, it can be beneficial for the interface joint to be angled to prevent failure at the interface joint.

[0106] As described herein, various embodiments of the green body part include a joining material including a powder having a particle size distribution of 1 μm or more and 50 μm or less, resulting in a seamless interfacial bond and improved strength of the joint and the entire part.

[0107] Further aspects of the present disclosure are provided by the following subject matter:

[0108] 1. a first green part including a first plurality of layers of a first particulate material; a second green portion including a second plurality of layers of a second particulate material; an interfacial bond between the first green portion and the second green portion; a bonding material disposed within the interface bond; Including, The bonding material includes a powder having a particle size distribution of 1 μm or more and 50 μm or less. Green body parts.

[0109] 2. The powder comprises a metal powder; the metal powder comprises at least one of a nickel alloy, a stainless steel alloy, a cobalt-chromium alloy, an aluminum alloy, an iron alloy, a titanium alloy, a copper alloy, and a copper-nickel alloy; A green body part as described above.

[0110] 3. The powder comprises a ceramic powder; the ceramic powder comprises at least one of alumina, aluminum nitride, zirconia, titania, silica, silicon nitride, silicon carbide, and boron nitride; A green body part as described above.

[0111] 4. The bonding material further comprises a binder; the binder comprises a plurality of reactive monomers; A green body part as described above.

[0112] 5. The binder further comprises a thickener. A green body part as described above.

[0113] 6. The thickening agent comprises at least one of polystyrene, polycarbonate, and polyvinylpyrrolidone; A green body part as described above.

[0114] 7. The thickener has a molecular weight of 10,000 g / mol or more and 50,000 g / mol or less. A green body part as described above.

[0115] 8. The weight ratio of the powder to the binder in the bonding material is 3:1 to 8:1. A green body part as described above.

[0116] 9. The bonding material contains 75% by weight or more and 88% by weight or less of a powder and 12% by weight or more and 25% by weight or less of a binder. A green body part as described above.

[0117] 10. The bonding material has a viscosity of 100 cP or more and 50,000 cP or less. A green body part as described above.

[0118] 11. The plurality of reactive monomers comprises at least one of an epoxy monomer, an acrylate monomer, and a vinyl ether monomer; A green body part as described above.

[0119] 12. The epoxy monomer comprises at least one of 3,4-epoxycyclohexylmethyl 3,4-epoxycyclohexanecarboxylate, diglycidyl 1,2-cyclohexanedicarboxylate, 1,2,7,8-diepoxyoctane, dicyclopentadiene dioxide, 1,2-butanediol diglycidyl ether, and 1,2-epoxydodecane; A green body part as described above.

[0120] 13. The acrylate monomer comprises at least one of cyanoacrylate, allyl cyanoacrylate, alkyl cyanoacrylate, neopentyl glycol propoxylate (1PH / OH) diacrylate, di(ethylene glycol) diacrylate, 1,6-hexanediol diacrylate, and tri(propylene glycol) diacrylate; A green body part as described above.

[0121] 14. The vinyl ether monomer comprises at least one of cyclohexyl vinyl ether and diethylene glycol divinyl ether. A green body part as described above.

[0122] 15. The bonding material further comprises 0.01% by weight or more and 2% by weight or less of a thermal initiator; the thermal initiator comprises at least one of a blocked ammonium antimony hexafluoride catalyst, 1,1′-azobis(cyclohexanecarbonitrile), 2,2′-azobis(2-methylpropionitrile), (4-hydroxyphenyl)methyl(2-methylbenzyl)sulfonium hexafluoroantimonate, and benzyl(4-hydroxyphenyl)methylsulfonium hexafluoroantimonate; A green body part as described above.

[0123] 16. The interface bond has at least one curved portion. A green body part as described above.

[0124] 17. The powder comprises the same elements as at least one of the first granular material and the second granular material; A green body part as described above.

[0125] 18. At least one of the first particulate material and the second particulate material comprises at least one metal particulate material; the metal particulate material comprises a nickel alloy, a cobalt alloy, a cobalt-chromium alloy, a titanium alloy, an aluminum-based alloy, a tungsten alloy, a stainless steel alloy, a low carbon steel, and copper; A green body part as described above.

[0126] 19. At least one of the first particulate material and the second particulate material comprises a ceramic material; the ceramic material comprises at least one of alumina, aluminum nitride, zirconia, titania, silica, silicon nitride, silicon carbide, and boron nitride; A green body part as described above.

[0127] 20. Providing a first green part including a first plurality of layers of a first particulate material and a second green part including a second plurality of layers of a second particulate material; Applying a bonding material onto a surface of the first green portion; the joining material includes powder having a particle size distribution of 1 μm or more and 50 μm or less, contacting the second green part with the joining material on a surface of the first green part to form a joined green body part having an interfacial bond between the first green part and the second green part. Manufacturing method for joined parts.

[0128] 21. The powder comprises a metal powder; the metal powder comprises at least one of a nickel alloy, a stainless steel alloy, a cobalt-chromium alloy, an aluminum alloy, an iron alloy, a titanium alloy, a copper alloy, and a copper-nickel alloy; Any of the methods described above.

[0129] 22. The bonding material further comprises a binder; the binder comprises a plurality of reactive monomers; Any of the methods described above.

[0130] 23. Further comprising heating the joined green body components at a temperature of 65°C or more and 140°C or less to cure the joining material. Any of the methods described above.

[0131] 24. Heating the joined green body component above a first temperature to remove at least a portion of the binder and sintering at least a portion of the powder, the sintered powder forming a neck region between the first particulate material and the second particulate material to form a joined green body component; heating the joined brown body components above a second temperature to sinter the first particulate material and the second particulate material to form a joined consolidated component. Any of the methods described above.

[0132] The above embodiments, and features of the above embodiments, are exemplary and may be provided alone or in any combination with any one or more features of the other embodiments provided herein without departing from the scope of the present disclosure.

[0133] It will be apparent to those skilled in the art that various modifications and variations can be made to the present disclosure without departing from the spirit and scope of the disclosure. Thus, it is intended that the present disclosure cover the modifications and variations of the present disclosure provided they come within the scope of the appended claims and their equivalents.

Claims

1. an additively manufactured first green part (340a) comprising a first plurality of layers (314) of a first particulate material (316a); a second additively manufactured green part (340b) including a second plurality of layers (314) of a second particulate material (316b); an interface bond (362) between the first green portion (340a) and the second green portion (340b); a bonding material (350) disposed at the interface bond (362); Including, The joining material (350) includes a powder having a particle size distribution of 1 μm or more and 50 μm or less. Green body parts (360).

2. the powder comprises a metal powder; the metal powder comprises at least one of a nickel alloy, a stainless steel alloy, a cobalt-chromium alloy, an aluminum alloy, an iron alloy, a titanium alloy, a copper alloy, and a copper-nickel alloy; The green body component (360) of claim 1.

3. the powder comprises a ceramic powder; the ceramic powder comprises at least one of alumina, aluminum nitride, zirconia, titania, silica, silicon nitride, silicon carbide, and boron nitride; The green body component (360) of claim 1.

4. the joining material (350) further comprises a binder; the binder comprises a plurality of reactive monomers; The green body part (360) according to any one of claims 1 to 3.

5. the binder further comprises a thickener; the thickening agent comprises at least one of polystyrene, polycarbonate, and polyvinylpyrrolidone; The green body component (360) of claim 4.

6. The thickener has a molecular weight of 10,000 g / mol or more and 50,000 g / mol or less. The green body component (360) of claim 5.

7. The weight ratio of the powder to the binder of the joining material (350) is 3:1 to 8:

1. The green body component (360) of claim 4.

8. providing an additively manufactured first green part (340a) comprising a first plurality of layers (314) of a first particulate material (316a) and an additively manufactured second green part (340b) comprising a second plurality of layers (314) of a second particulate material (316b); Applying a bonding material (350) to a surface (352) of the first green part (340a); The joining material (350) includes a powder having a particle size distribution of 1 μm or more and 50 μm or less, contacting the second green part (340b) with the joining material (350) on the surface (352) of the first green part (340a) to form a joined green body part (360) having an interfacial bond (362) between the first green part (340a) and the second green part (340b); A method for manufacturing a joining component (360).

9. further comprising heating the joined green body components (360) at a temperature of 65°C or higher and 140°C or lower to cure the joining material (350). The method of claim 8.

10. heating the joined green body component (360) above a first temperature to remove at least a portion of the binder and sintering at least a portion of the powder, such that the sintered powder forms a neck region (366) between the first particulate material (316a) and the second particulate material (316b), thereby forming a joined brown body component (370); heating the joined brown body components (370) above a second temperature to sinter the first particulate material (316a) and the second particulate material (316b) to form a joined consolidated component (380); The method according to claim 8 or claim 9.

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