Hierarchical composite wear section with structural reinforcement

Abstract

The present invention relates to a hierarchical composite wear part comprising a reinforcement portion, the reinforcement portion comprising a triple periodic minimal curve ceramic lattice structure reinforcement comprising a plurality of cell units, the cell units comprising voids and microporous ceramic cell walls, the pores of the cell walls containing sintered or cast metal, the ceramic lattice structure being embedded in a bi-continuous structure with a cast metal matrix.

Description

[Technical Field]

[0001] The present invention discloses a hierarchical composite wear component obtained by casting technology, the wear component having improved resistance to combined delamination and impact stress and superior resistance to fracture. The wear component comprises a three-dimensional reinforced network structure based on a triple-period minimal surface (TPMS) lattice structure, more specifically, based on a TPMS-type lattice structure additionally manufactured by a 3D printing device. [Background technology]

[0002] This invention relates to wear parts used in grinding and crushing industries such as cement plants, quarries, and mines. Such parts are subjected to high mechanical stress in most cases and high wear due to delamination on the working surface. Therefore, it is desirable that these parts exhibit high delamination resistance and some ductility to withstand mechanical stress, such as impact.

[0003] Given the difficulty in matching these two properties with the same material composition, composite wear parts have been proposed in the past, consisting of a base material made of a relatively ductile alloy embedded with ceramic inserts that offer superior wear resistance.

[0004] Patent Document 1 discloses a hierarchical composite material comprising a ferroalloy reinforced with titanium carbide in the form of particle aggregates that penetrated during the casting of the ferroalloy. The reinforced structure is positioned on the surface most exposed to wear.

[0005] Patent Document 2 relates to a composite impactor for an impact-type crusher, the impactor comprising, on the most stressed surface of the wear portion, an alloy iron reinforced with at least partially titanium carbide according to a defined geometric shape.

[0006] Patent Document 3 relates to a composite tooth for acting on the ground or rock, wherein the tooth has an iron alloy that is at least partially reinforced by an insert, and the portion reinforced by the insert makes it possible to obtain, after an in-situ reaction, a macro / microstructure consisting of alternating millimeter-sized areas of concentrated micrometer-sized titanium carbide particles separated by millimeter-sized areas of almost no micrometer-sized titanium carbide particles, wherein the concentrated areas of micrometer-sized titanium carbide particles form a microstructure in which the micrometer-sized spacing between the particles is also occupied by the iron alloy, and the macro / microstructure produced by the insert is spaced at least 2 mm, preferably at least 3 mm, from the distal surface of the tooth.

[0007] Various experiments have shown that the composition or arrangement of ceramics or elements within a reinforced wear area is crucial not only for the important mechanisms to be concentrated, but also for the geometry of the reinforcing material itself, or more precisely, for the appropriate selection of a reinforcing material geometry adapted to the specific wear area.

[0008] In this context, various three-dimensional reinforced lattice structures based on triple periodic minimum surfaces (TPMS) embedded in the alloy iron matrix of specific wear areas are tested.

[0009] According to Schnering and Nesper (Schnering's 1991 paper), the surfaces of some typical triple-periodic minimal surface structures (TPMSs) can be approximated by simplified equations, and these structures are named in the following list. D side: cos(X)·cos(Y)·cos(Z)-sin(X)·sin(Y)·sin(Z)=C Gyroid: sin(X)·cos(Y)+sin(Y)·cos(Z)+cos(X)·sin(Z)=C I‐WP:2·(cos(X)·cos(Y)+cos(X)·cos(Z)+cos(Y)·cos(Z))-cos(2X)+cos(2Y)+cos(2Z)=C Ridinoid: sin(2X) cos(Y) sin(Z)+sin(2Y) cos(Z) sin(X)+sin(2Z) cos(X) sin(Y)-cos(2X) cos(2Y)-cos(2Y) cos(2Z)-cos(2Z) cos(2X)=C Neobius:3·(cos(X)+cos(Y)+cos(Z))+4·cos(X)·cos(Y)·cos(Z)=C P-plane: cos(X)+cos(Y)+cos(Z)=C C is constant (generally = 0) for the surface excluding its thickness. For the purposes of this invention, not only TPMS as commonly described in the literature, but also its primary coupling will be considered.

[0010] The above formula represents the (iso)surface excluding thickness. Non-Patent Documents 1, 2, and 3 describe methods used to generate a skeleton (without wall thickness) based on triple periodic minimal surfaces (TPMS). A specific example of such a skeletal structure is illustrated in Figure 1.

[0011] Patent Document 4 discloses an additively manufactured gyroid lattice structure. For the purpose of defining a “triple-periodic minimal surface structure,” and more specifically, for the purpose of defining a gyroid structure, Patent Document 4 is incorporated by reference in this disclosure.

[0012] Patent Document 5 discloses a porous AI2O3 structure based on a gyroid curved surface. The ceramic and the method for preparing the ceramic are based on a triple periodic minimal surface (TPMS) that is continuous and three-dimensionally connected. The prepared porous AI2O3 ceramic gyroid structure has high hardness, high temperature resistance and high corrosion resistance.

[0013] In this disclosure, the expression “triple-periodic minimal surface” should not be interpreted strictly as a mathematical concept relating to a surface, but rather as a lattice structure (skeleton) of connectable unit cells, where each unit cell has cell walls and voids, the cell walls occupy a specific volume of the unit cell, the voids occupy a balanced portion of that volume, and the lattice structure exhibits periodicity along all three dimensions. For this reason, we use the expressions “three-dimensional lattice structure of or based on a triple-periodic minimal surface (TPMS),” or simply “TPMS lattice structure.” The cell walls exhibit variable microporosity according to the manufacturing method and composition of the TPMS. In a TPMS skeleton structure, the surface has substantially continuous curvature at any point in the structure, i.e., not only within a unit cell but also at the junction between two unit cells. Figure 20 shows an example of an assembly of three P-plane unit cells. The discontinuity of surface curvature is important for the mechanical resistance of this reinforced structure because it represents areas of high stress and therefore vulnerable regions. The TPMS lattice structure is not an assembly of different volumes, and the volume surfaces do not coincide tangentially. In such a scaffolding assembly, the curvature at the joints of different volumes is discontinuous. Figure 21 shows an example of an assembly of a sphere and a horizontal cylinder. At the joint 1 between the two volumes, the curvature 2 of the sphere is not equal to the curvature 3 of the cylinder. The TPMS lattice structure is not a foamed structure, but is made of cells of random size and shape that extend in all directions.

[0014] Patent Document 6 discloses a periodic structure made of an assembly of spherical, cylindrical, or cubic elements. However, these elements are not joined at a continuous curvature. At the joint, the curvature of the two elements is not continuous. The disclosed periodic structure is therefore not a TPMS grid (skeleton) structure as disclosed in this document (see Figure 21).

[0015] Patent Document 7 discloses a hemisphere or a sphere having a foamed structure. Therefore, it is not periodic and is different from the TPMS lattice (skeleton) structure disclosed in the present invention.

[0016] Patent Document 8 discloses an open-cell foam structure that is not periodic, which is different from the TPMS lattice (skeleton) structure disclosed in the present invention.

Prior Art Documents

Patent Documents

[0017]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Patent Document 5

Patent Document 6

Patent Document 7

Patent Document 8

Patent Document 9

Patent Document 10

Patent Document 11

Patent Document 12

Non-Patent Documents

[0018] [Non-Patent Document 1] Yuan Jin, Haoyu Kong, Xueyong Zhou, Guangyong Li and Jianke Du, “Design and Characterization of Sheet-Based Gyroid Porous Structures with Bioinspired Functional Gradients”, Materials, 2020, 13, 3844; doi: 10.3390 / ma13173844 [Non-Patent Document 2] Jiho Kim and Dong-Jin Yoo, “3D printed compact heat exchangers with mathematically defined core structures”, Journal of Computational Design and Engineering, 2020, 7(4), 527-550; doi: 10.1093 / jcde / qwaa032 [Non-Patent Document 3] R. Tino, M. Leary, A. Yeo, M. Brandt and T. Kron, “Technical Note: Gyroid structures for 3D-printed heterogeneous Radiotherapy phantoms”, Physics in Medicine & Biology, 2019, Volume 64, Number 21; DOI: 10.1088 / 1361~6560 / ab48ab [Non-Patent Document 4] Shixiang Yu et al., Shenzhen Key Laboratory for Additive Manufacturing of High-Performance Materials、Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen, “Investigation of functionally graded TPMS structures fabricated by additive manufacturing”, Materials and Design 182 (2019) 108021

Non-Patent Document 5

Non-Patent Document 6

Non-Patent Document 7

[0019] The present invention aims to provide a hierarchical composite wear part obtained by casting technology, comprising a three-dimensional reinforced network structure based on a triple periodic minimal surface (TPMS) lattice structure, preferably additively manufactured by 3D printing of ceramic or ceramic metal powders selected from the group consisting of carbides, borides, and nitrides, particularly titanium carbide, tungsten carbide, and titanium carbonitride. [Means for solving the problem]

[0020] The present invention discloses a hierarchical composite wear component comprising a reinforced portion, the reinforced portion comprising a triple-periodic minimal curved ceramic lattice structure comprising a plurality of cell units, the cell units comprising voids and microporous ceramic cell walls, the micropores of the cell walls containing sintered metal or cast metal, and the ceramic lattice structure embedded in a double continuous structure with a cast metal matrix.

[0021] Preferred embodiments of the present invention disclose at least one or a suitable combination of the following features: - The triple-period minimal curved lattice structure is selected from the group consisting of gyroid, lydinoid, neobius, P-plane, diamond (D-plane), and I-WP or combinations and derivatives thereof. - The size of the cell unit is between 10 and 60 mm, preferably between 15 and 50 mm, and the thickness of the cell wall is between 1 and 15 mm, preferably between 2 and 10 mm. - The concentration of ceramic material within the reinforced area is controlled by the variation in cell wall thickness and / or cell unit size across the reinforced area. - The ceramic material is selected from the group consisting of metal carbides, borides, nitrides, or combinations thereof. - The ceramic material is selected from the group consisting of titanium carbide, titanium carbonitride, titanium chromium carbide, titanium boride, and tungsten carbide. - The cast metal base material must be an alloy iron base material containing steel or cast iron. - The sintered metal present in the micropores of the cell wall is selected from the group consisting of titanium, tungsten, chromium, steel, and cast iron or a combination thereof. - The concentration of the ceramic material within the lattice structure is in the range of 30 to 90 volume%, preferably 40 to 80 volume%, - The concentration of the ceramic material within the reinforced portion is in the range of 5 to 50 volume%, preferably 10 to 40 volume%,

[0022] The present invention relates to a method for manufacturing hierarchical composite wear parts, - A step of manufacturing a ceramic lattice structure with a triple-periodic minimal surface geometry via a powder mixture containing ceramic particles, - The step of sintering a ceramic lattice structure at least partially, - The step of placing a ceramic lattice structure inside the mold, - To obtain the reinforced hierarchical composite wear part described in claim 1, the steps include casting ferroalloy and Further disclosures include methods that include the following.

[0023] Preferred embodiments of the method of this disclosure disclose at least one of the following features, or a suitable combination thereof: - The step of at least partially sintering a reinforced ceramic lattice structure includes, before placement in a mold and final casting, substantially complete filling of the micropores of the cell walls of the structure with a metal selected from the group consisting of titanium, tungsten, chromium, steel, and cast iron or a combination thereof. - The step of at least partial sintering is followed by a hot isostatic pressing step or a post-penetration step. - The step of manufacturing a reinforced ceramic lattice structure based on a triple-periodic minimal surface geometry is additive manufacturing by binder jetting technology followed by binder curing at temperatures exceeding 150°C. - The ceramic powder particles are contained in a particle size D between 1 and 150 μm, preferably between 5 and 100 μm, as measured by laser diffraction technique. 50 Having

[0024] The present invention further discloses the use of the hierarchical composite wear components described in claims 1 to 10 as impact crushers and groove teeth. [Brief explanation of the drawing]

[0025] [Figure 1] This figure illustrates a TPMS grid structure obtained through CAD modeling, and potentially derived structures, representing a non-restrictive selection. [Figure 2] This diagram illustrates a conceptual representation of a gyroid unit cell of a gyroid-type ceramic metal lattice structure (Volume 1) embedded in a metal matrix (Volume 2), which connects to a composite structure linking two complementary Volumes 1+2. [Figure 3]This is a conceptual representation of a gyroid unit cell with a gyroid-type ceramic lattice structure embedded in a metal matrix, showing a sheet thickness (cell wall thickness) that increases the apparent volume of the reinforced structure from 4 to 40 volume percent. The combination of the patterned 3D gyroid-type lattice structure with the complementary volume of the metal matrix is ​​represented as a perfect cube and a diagonal cut of the cube. [Figure 4] This figure shows a gyroid-type structure of porous titanium carbide structures of various sizes, comprising a base plate used as a penetrating insert for reinforcing wear parts according to the present invention. [Figure 5] This figure shows an unworn cast tooth suitable for reinforcement according to the concept of the present invention. [Figure 6] This is a diagram illustrating a worn cast tooth. [Figure 7] This diagram illustrates a reinforced tooth contour where a typical conventional penetrating porous ceramic-metal insert is placed in the most stressed area. [Figure 8] This figure shows the same tooth contour as in Figure 7, equipped with a permeable gyroid-type ceramic metal lattice structure according to the present invention. [Figure 9] This figure shows the anvil ring of a MAG'Impact 270 milling machine, which was tested on an anvil prepared with a TPMS-type structural reinforcement according to the present invention. In this machine, the applicant positioned an anvil comprising the TPMS ceramic metal reinforcement according to the present invention such that one side of the reinforced anvil was surrounded by conventional ceramic inserts according to the prior art. [Figure 10] This figure shows an unworn cast anvil suitable for reinforcement according to the concept of the present invention. [Figure 11] This is a diagram showing a worn cast anvil. [Figure 12] This figure shows the contour of a reinforced anvil equipped with a gyroid-type ceramic metal insert structure according to the present invention, positioned in the most stressed area of ​​a wear component. [Figure 13]This figure shows the contour of a reinforced anvil with a conventional particle aggregate ceramic-metal insert structure at the same location as shown in Figure 12. [Figure 14] This figure shows a 150×100×30mm insert (A) and a gyroid unit cell with a wall thickness of 3mm and a length of 11mm in an oblique cut representation (B). [Figure 15] This diagram shows a gyroid unit cell with a wall thickness of 8 mm and a length of 29 mm, represented by a 150 x 100 x 30 mm insert (A) and an oblique cut representation (B). [Figure 16] This diagram shows a 150 x 100 x 30 mm insert (A) and a diamond unit cell with a wall thickness of 7 mm and a length of 30 mm in an oblique cut representation (B). [Figure 17] This is a detailed diagram of a 3D-printed pyramidal TPMS reinforcement material placed in a mold for tooth casting. [Figure 18] Figure 18a is a diagram representing the gyroid-type lattice structures of Examples 5 and 6 with variable cell wall thickness. Figure 18b is a diagram representing the gyroid-type lattice structures of Examples 5 and 6 with variable cell wall thickness in a vertical section representation shown as a combination of complementary volumes. Figure 18c is a diagram representing the gyroid-type lattice structures of Examples 5 and 6 with variable cell wall thickness in a vertical section representation shown as a combination of complementary volumes. Figure 18d is a diagram representing the gyroid-type lattice structures of Examples 5 and 6 with variable cell wall thickness in a vertical section representation shown as a combination of complementary volumes. [Figure 19]Figure 19a is a diagram representing the gyroid-type grid structure with variable cell wall thickness for the grid structures of Examples 7 and 8. Figure 19b is a diagram representing the gyroid-type grid structure with variable cell wall thickness for the grid structures of Examples 7 and 8 in a vertical section representation. Figure 19c is a diagram representing the gyroid-type grid structure with variable cell wall thickness for the grid structures of Examples 7 and 8 in a vertical section representation. Figure 19d is a diagram representing the gyroid-type grid structure with variable cell wall thickness for the grid structures of Examples 7 and 8 in a vertical section representation. [Figure 20] This figure illustrates the continuous curvature at the joints of unit cells in a TPMS grid structure. [Figure 21] This figure shows a structure disclosed in Patent Document 6, which is not a TPMS lattice structure, but rather a discontinuous curvature at the junction of two unit elements. [Modes for carrying out the invention]

[0026] A triple periodic minimal surface structure (TPMS), which separates space into two labyrinthine passages coinciding in opposite directions, can be described according to the approximate formula mentioned above. Once embedded in the metal matrix of the cast hierarchical composite wear section, the ceramic or ceramic-metal composite and the cast metal jointly form a continuous structure.

[0027] When TPMS-type lattice structures are manufactured in a 3D skeleton lattice structure, they exhibit high compressive strength and high resistance to bending, which, as mentioned above, are used in the present invention to reinforce wear areas that are subjected to high mechanical stress in most areas and high wear due to delamination on the work surface.

[0028] The selection of TPMS-type structures (gyroids, ridinoids, P-planes, etc., and combinations thereof) is guided, for example, by investigations into the mechanical properties of additively fabricated polymer structures in relevant literature, which demonstrate that the fabricated structures have advantages over conventional honeycomb elements when used as shock-absorbing layers that accept impact loads.

[0029] Non-patent documents 4 and 5 show the selection of TPMS types.

[0030] While it is difficult to directly apply the results obtained in the above publications to wear parts manufactured by casting in the context of ceramic-metal TPMS lattice structures, diamond-type TPMS structures theoretically appear to have higher collision resistance than gyroid-type lattice structures. Therefore, both structures were compared in anvils to test this hypothesis.

[0031] In the present invention, the TPMS type structure is additionally manufactured by any type of 3D printing using ceramic or carbide-containing ceramic metal, carbonitride and boride powder, preferably titanium carbide, tungsten carbide or titanium carbonitride powder.

[0032] Description of additive manufacturing steps and casting of wear parts To manufacture the TPMS insert of the present invention, it is necessary to create a digital 3D model structure and construct it in powder within a 3D printing (additive manufacturing) device. The technique used in this case is preferably binder jetting, but is not limited thereto.

[0033] A general overview of various ASTM standards related to 3D printing technology, characterization, and methods is published in Non-Patent Document 6. This overview summarizes the contents of 10 representative academic papers related to 3D printing technology, representing the knowledge of those skilled in the art, in 22 pages. For this purpose, this publication is incorporated herein by reference.

[0034] Binder jetting technology is disclosed in particular in Patent Documents 9 and 10.

[0035] Recent academic papers, specifically Non-Patent Literature 7, provide a complete overview of the relevant parameters for ceramic binder jetting technology.

[0036] This academic paper investigates the steps and applications of binder jet printing of ceramics, considering key factors such as the influence of powder, binder, print parameters, equipment, and post-processing processes, as well as the particle shape and size distribution of the ceramic powder. The influence of additional factors such as the binder droplet formation mechanism and droplet penetration kinetics is also described. Furthermore, this document considers print parameters such as layer thickness, saturation, print orientation, equipment, and post-processing. For the purpose of explaining binder jetting technology, this academic paper is incorporated into this application as a reference.

[0037] One crucial element of binder jetting technology is the selection of the appropriate type of binder, taking into account its compatibility with the relevant ceramic or ceramic-metal powder. Various prior art literatures have investigated different types of binders and ceramic powders.

[0038] Patent Document 11 discloses a specific amine-containing adhesive polymer and a binder jet addition method for manufacturing the object. The method comprises the steps of separately supplying a powder to be manufactured and a solution containing an adhesive polymer dissolved in a solvent to an addition device, wherein the adhesive polymer is an amine-containing polymer having a molecular weight of at least 200 g / mol, which binds particles together and generates a preform of the object to be manufactured by distributing selectively positioned droplets of the adhesive polymer from the print head of the addition device onto a bed of powder.

[0039] Patent Document 12 discloses a method for indirect addition of an object, wherein the powder to be manufactured and either a difunctional curable monomer or an adhesive polymer binder are separately supplied to an addition manufacturing device, and selectively disposed droplets of the difunctional curable monomer or adhesive polymer binder are distributed from the print head of the addition manufacturing device onto a bed of powder to bond the powder with the difunctional curable monomer or adhesive polymer binder to produce a curable preform having the shape of the object to be manufactured, wherein, in the case of a difunctional curable monomer, the curable preform is cured to form a crosslinked object. This document lists a range of available curable monomers at their curing temperatures. This document is incorporated herein by reference.

[0040] Methodology for Manufacturing Wear Parts of the Present Invention A preferred method for manufacturing wear parts reinforced with ceramic or ceramic metal TPMS skeleton inserts, also known as ceramic or ceramic metal TPMS lattice structures, is to create a digital 3D model structure of multiple unit cells, construct it in a 3D printing device, partially or completely sinter the additionally manufactured structure, place the insert in a sand mold, and pour in hot liquid base metal (high-chromium cast iron or steel) to penetrate the voids and, if present, the micropores of the insert to obtain a sufficiently high-density wear part. The TPMS lattice manufacturing steps are as follows:

[0041] Digital 3D Model Structure - Numerical 3D models of ceramic TPMS inserts are generated with the help of computer-aided design (CAD) software (e.g., nTopology https: / / ntopology.com / generative-design-software / ) and converted to a format that can be handled by 3D printing devices, such as the STL (stereolithography) format. Engineering performance requirements (such as wear or mechanical properties) often vary throughout much of the design, requiring variable control of important parameters such as lattice thickness or size (cell wall thickness or cell size). In nTopology, field-driven design can be used to spatially vary parameters of the lattice structure, such as wall thickness or cell size. - The file is then processed by slicing software, which slices it into 2D layers of a predetermined thickness, allowing the model to be printed.

[0042] Additive manufacturing (AM) process - In this process, ceramic powder is supplied through a hopper to build a single layer, for example, about 100 μm thick, at once. The ceramic powder contains carbides (e.g., TiC), borides, or nitrides, and possibly some other metallic elements. Particle size (D 50 ) typically fall between 1 and 150 μm, preferably between 2 and 50 μm, and most preferably between 4 and 16 μm, as measured by a laser diffraction particle size analyzer such as the Malvern Mastersizer 2000 according to Mie theory. - If the particle size distribution of the powder does not match the target particle size distribution (adjusted by flowability and print resolution), a sieving step may be required. - The ceramic powder is fed into the hopper of the 3D printing device to build the insert layer by layer (vibrating and topcoat rollers may be used to increase the packing density of the layers, mainly for fine or poorly flowable powders). - Depending on the additive manufacturing technique, a moving head generates powder aggregates in specific regions on a layer by binder jetting or by forming powder particles into clumps in a melting process (e.g., by melt bed laser technology). Clamps also occur in the previous layer directly below the current layer. In the case of binder jetting, the moving head deposits the liquid binder as droplets in specific regions of the layer according to 2D rows. An important parameter is defining the appropriate saturation level to obtain proper adhesion between particles in the layer, as well as between previously printed layers. Preferred binders are, for example, aqueous-dispersible glycol-acrylic binders, such as tetraethylene glycol dimethacrylate, tetraethylene glycol diacrylate, triethylene glycol dimethacrylate, diethylene glycol, 2-methoxyethanol, or preferably a mixture that can be dispersed in water and cured at 200°C for about 2 hours per cm of material to be cured, suitable for forming an interconnected molecular network structure. - The next layer is then deposited, and the above steps are repeated until the entire insert is constructed within the powder bed.

[0043] Hardening and sintering - If a crosslinkable monomer binder is selected, it needs to be cured. The complete square is heated in a curing oven at a temperature of approximately 200°C to give strength to the part (via polymerization, crosslinking, solvent deposition or some other mechanism) for a specific period of time depending on the volume of the square, ensuring uniformity of temperature (e.g., between approximately 2 hours / cm). - The rectangle is then left to cool completely, allowing the unprocessed portion to be handled safely without the risk of damage. - Excess powder is removed from the square by brushing, vacuuming, or blowing in compressed air. - The raw TPMS lattice structure is then placed in a furnace and heated to a high temperature (usually above 1000°C) under a controlled atmosphere (usually argon or vacuum) to perform the sintering step. Sintering may be whole or partial, depending on the desired porosity of the final insert wall. In the case of partial sintering, the lattice structure may also be further penetrated by capillary action of the metal during the same or a different heat treatment.

[0044] Manufacturing of wear parts - The finished ceramic or ceramic-metal TPMS lattice structure is placed in the sand mold at locations where wear resistance and fracture resistance are required. - Liquid metal is poured into the mold. The liquid metal penetrates the TPMS lattice structure, and together the ceramic TPMS structure, embedded in the cast metal base material, forms a continuous reinforced structure. - In the case of partially sintered TPMS inserts with remaining micropores, the liquid metal penetrates the cell walls of the TPMS lattice structure, resulting in an extremely homogeneous ceramic / metallic bond. - The liquid metal is left to cool until the casting is completely solidified. The sand mold is then removed, and the final part is cleaned from the remaining sand and can be followed by the usual finishing foundry process steps known to those skilled in the art (knockout, shot blasting, grinding, additional heat treatment (annealing, quenching, tempering, etc.)). - In some cases, a final machining step may be required to achieve the target final dimensions.

[0045] Example - Wear parts of anvils and teeth Anvil Example 1 Average particle size D of 11 μm 50 A mixture of 93 wt% titanium carbide powder having the following properties is blended in an argon-inactivated blender with an average particle size of 40 μm D 50 It was mixed with 7 wt% titanium powder for 15 minutes.

[0046] The homogeneous mixture was then used to print a 150 × 100 × 30 mm gyroid lattice structure with a cell unit size of approximately 11 mm and a cell wall thickness of approximately 3 mm (as shown in Figure 14) on an EXone X1 25 Pro 3D binder jet printer. An aqueous binder based on a mixture of diethylene glycol as a dispersion in an aqueous solution of 2-butoxyethanol was used to print this portion (BA005 EXone).

[0047] The key parameters of the AM process were as follows: - Each printed layer is approximately 100 μm thick. - Print speed is 90 seconds per layer. - The binder saturation of the powder pores is 90%. - The powder filling density is approximately 49%.

[0048] After completion, the entire printed rectangle is cured in an oven at approximately 200°C for 2 hours per centimeter of height, with the residence time depending on the number of lattice structures, as multiple items can be manufactured in a single process. After cooling, the printed rectangle is brushed and the powder is removed by vacuum to obtain the raw gyroid lattice structure.

[0049] The obtained unprocessed gyroid lattice structure was placed in a furnace and heated at approximately 1150°C for 2 hours under an argon atmosphere.

[0050] The gyroid lattice structure contains approximately 74 volume percent of empty space in total (approximately 47 volume percent due to voids within the gyroid lattice structure (cell unit) and an additional 27 volume percent of micrometer pores inside the cell wall) that is available for ferroalloy infiltration, with the remaining 26 volume percent within the cell wall being titanium carbide + metallic titanium.

[0051] The resulting gyroid lattice structure is then placed in a sand mold within the region of wear to be reinforced (a hierarchical wear region as shown in Figure 12).

[0052] High-temperature liquid high-chromium iron white is then poured into a mold, filling 47% by volume of the gyroid lattice voids and penetrating 27% by volume of the micrometer pores between the particles in the cell wall.

[0053] After injection, 53 vol% of the reinforced volume contains a high concentration of approximately 49 vol% titanium carbide (powder packing density). The overall volume content of titanium carbide in the reinforced portion of the wear area is therefore approximately 26 vol%.

[0054] Example 2 Example 2 is performed in the same way as Example 1, but with different cell unit sizes and cell wall thicknesses.

[0055] A homogeneous powder mixture was used to print a 150 × 100 × 30 mm gyroid lattice structure with a cell unit size of approximately 29 mm and a cell wall thickness of approximately 8 mm (as shown in Figure 15) using the same equipment as used for Example 1. An aqueous binder based on a mixture of diethylene glycol as a dispersion in an aqueous solution of 2-butoxyethanol was used to print this section (BA005 EXone).

[0056] The AM process and key curing parameters were the same as in Example 1 (cured at 200°C for 2 hours, then the furnace was heated to 1150°C).

[0057] This gyroid lattice structure is again obtained with a powder packing density of 49%, and contains a total of approximately 74 volume percent of empty space available for ferroalloy infiltration (approximately 46 volume percent due to voids within the gyroid lattice structure (cell unit) and an additional 28 volume percent of micrometer pores inside the cell wall), with the remaining 26 volume percent within the cell wall being titanium carbide + metallic titanium.

[0058] The resulting gyroid lattice structure is then placed in a sand mold within the region of wear to be reinforced (a hierarchical wear region as shown in Figure 12).

[0059] High-temperature liquid high-chromium iron white is then poured into a mold, filling 46% by volume of the gyroid lattice voids and penetrating 28% by volume of the micrometer pores between the particles in the cell walls.

[0060] After injection, 54 vol% of the reinforced volume contains a high concentration of approximately 49 vol% titanium carbide (powder packing density). The overall volume content of titanium carbide in the reinforced portion of the wear area is therefore approximately 26 vol%.

[0061] Example 3 Average particle size D of 11 μm 50 A mixture of 93 wt% titanium carbide powder having the following properties is blended in an argon-inactivated blender with an average particle size of 40 μm D 50 It was mixed with 7 wt% titanium powder for 15 minutes.

[0062] A homogeneous mixture was used to print a 150 × 100 × 30 mm diamond lattice structure with a cell unit size of approximately 30 mm and a wall thickness of approximately 7 mm (as shown in Figure 16) using the same equipment used for Example 1. An aqueous binder based on a mixture of diethylene glycol as a dispersion in an aqueous solution of 2-butoxyethanol was used to print this section (BA005 EXone).

[0063] The key parameters of the AM process were the same as in the previous example (curing at 200°C for 2 hours, followed by heating in the furnace at 1150°C).

[0064] This diamond lattice structure is obtained with a powder packing density of 49% and contains a total of approximately 73 volume percent of empty space available for ferroalloy infiltration (approximately 45 volume percent due to voids within the diamond lattice structure (cell unit) and an additional 28 volume percent of micrometer pores inside the cell walls), with the remaining 27 volume percent within the cell walls being titanium carbide + metallic titanium.

[0065] The resulting diamond lattice structure is then placed in a sand mold within the region of the wear area to be reinforced (a hierarchical wear area as shown in Figure 13).

[0066] High-temperature liquid high-chromium iron white is then poured into a mold, filling 45% by volume of the diamond lattice voids and penetrating 28% by volume of the micrometer pores between the particles in the cell walls.

[0067] After injection, 55% of the reinforced volume contains a high concentration of approximately 49% titanium carbide (powder packing density). The overall volume content of titanium carbide in the reinforced portion of the wear area is therefore approximately 27%.

[0068] Example 4 90 wt% TiC with an average particle size of 7 μm 0.5 N 0.5 The powder mixture was mixed with 10 wt% titanium powder having an average particle size of 40 μm in an argon-inactivated blender for approximately 15 minutes.

[0069] The homogeneous mixture was used again to print a 150 × 100 × 30 mm diamond lattice structure with a cell size of approximately 30 mm and a thickness of 7 mm (as shown in Figure 16) using the same equipment used for Example 1.

[0070] The key parameters of the print process were as follows: - Each printed layer is 100 μm thick. - Print speed is 90 seconds per layer. - Binder saturation is 100%, and - The powder filling density is approximately 50%.

[0071] After completion, the entire printed rectangle was cured in an oven at 200°C for 2 hours per centimeter of height. After cooling, the printed rectangle was vacuum-cleaned to remove the powder and brushed to obtain the raw diamond lattice structure.

[0072] The unprocessed diamond lattice structure was placed in the furnace and heated at approximately 1150°C for approximately 3 hours under an argon atmosphere (99.5%) to allow most of the binder to burn off.

[0073] This diamond lattice structure is obtained by a powder packing density of 50%, and contains a total of approximately 73 volume percent of empty space available for ferroalloy infiltration (approximately 45 volume percent due to voids within the diamond lattice structure (cell units) and an additional 28 volume percent of micrometer pores inside the cell walls), with the remaining 27 volume percent within the cell walls being titanium carbonitride + metallic titanium. High-temperature liquid high-chromium ferroalloy is then poured into a mold.

[0074] High-temperature liquid high-chromium cast iron thus fills approximately 45 volume percent of the diamond lattice structure, and subsequently fills 28 volume percent of the micrometer pores between the particles. By reaction with carbon from cast iron, the remaining titanium particles are converted into titanium carbide particles. After injection, 55 volume percent of the reinforced volume contains titanium carbonitride with a high concentration of approximately 50 volume percent titanium carbide. The overall volume content of titanium carbonitride and titanium carbide particles in the reinforced portion of the wear area is therefore approximately 28 volume percent.

[0075] The anvil wear section used in the vertical shaft impactor was fabricated from a TPMS-reinforced grid structure obtained according to Examples 1, 2, 3, and 4 of the present invention.

[0076] These were compared to abrasion sections made with fine grains according to Patent Document 1, with an overall volume percentage of approximately 28 volume% titanium carbide particles in the reinforced volume.

[0077] The following raw material powders were used: - Titanium HCSTARCK, Amperit 155.066, less than 200 mesh, - Graphite-carbon GK Kropfmuhl, UF4, >99.5%, less than 15μm, - Iron in the form of HSS M2 steel, less than 25 μm. A powder mixture of 15% graphite carbon, 63% titanium and 22% iron in the form of M2 steel by weight is mixed in a Lindor mixer for 15 minutes under an argon atmosphere.

[0078] Granulation is carried out in a Sahut-Conreur granulator, and a strip is created by compressing the powder at a pressure of 200 MPa on a roll to 75% of the theoretical density. The strip is then crushed into fine grains. The fine grains are sieved to obtain a fine grain size ranging from 1.4 to 4 mm.

[0079] This composition and the resulting specific relative density provide a volume fraction of about 50% by volume of titanium carbide hard particles in the infiltrated fine grains after reaction, according to TABLE 5 of Patent Document 1 (Table 1 below).

[0080]

Table 1

[0081] The fine grains are mixed with 6 wt% of an organic phenolic resin-based adhesive and placed in a mold of the desired shape (e.g., within silicone). After the adhesion has solidified (achieved at 100 °C for a sufficient time), the core can be hardened and removed from the mold.

[0082] The core contains 45% by volume of voids (at millimeter intervals) within a 3D interconnected network structure where the adhesive fine grains are interconnected. According to TABLE 6 of Patent Document 1 (Table 2 below), a bulk density of about 1.8 g / cm 3 is obtained (45% space between the fine grains plus 25% pores within the fine grains).

[0083]

Table 2

[0084] The core is placed in a sand mold within the region of the wear area to be reinforced (a hierarchical wear area as shown in Figure 13), and the wear area therefore contains 55 volume% porous fine grains. After the reaction, in the reinforced portion, a 55 volume% region having a high concentration of about 50% spherical titanium carbide, i.e., about 28 volume% of the total titanium carbide in the reinforced macromicrostructure of the wear area, is obtained according to TABLE 4 of Patent Document 1 (Table 3 below).

[0085] [Table 3]

[0086] Performance comparison with conventional anvil technology The anvil ring of the vertical shaft impact crusher on which these tests were conducted is illustrated in Figure 9.

[0087] In this machine (MAG'Impact 2700), the applicant arranged an anvil equipped with the reinforcing material according to the present invention, surrounded on either side by an anvil reinforced with the latest technology reinforcing material in fine grain, prepared according to Patent Document 1, in order to evaluate the wear behavior under identical conditions. The material to be crushed is ejected at high speed onto the working surface of the anvil (individual un-abraded anvils are shown in Figure 10). During crushing, the working surface wears down (individual abraded anvils are shown in Figure 11).

[0088] Weight loss is measured for each anvil after use. % weight loss = ((final weight - initial weight) / initial weight) × 100 The performance indicator is defined as follows, where the reference weight loss is the average weight loss of the portion created according to the anvil of Patent Document 1 on each side of the test anvil. PI = Reference % weight loss / Test anvil % weight loss A performance index greater than 1 means that the test anvil (invention) does not wear down more than the standard, while a value less than 1 means that the test anvil wears down more than the standard. The key parameters for the four examples are shown in TABLE A (Table 4 below). While not bound by any particular theory, they can be considered as follows: - The superior performance of Example 2 can be explained by the gyroid TPMS structure, which has a design that is extremely different from conventional technical standards. - The superior performance of Example 1 compared to Example 2 can probably be explained by the reduced wear rate due to the smaller cell unit and mesh configuration. - The superior performance of Example 3 compared to Example 2 can be explained simply by the difference in TPMS. - The superior performance of Example 4 compared to Example 3 can be explained by the superior wear resistance of titanium carbonitride compared to titanium carbide.

[0089] [Table 4]

[0090] teeth The teeth that engage with the ground, used in rope shovels and bulldozer buckets, are cast in a sand mold with reinforced sections featuring a ceramic TPMS lattice structure according to the present invention (Figure 8). These were compared to wear sections (Figure 7) made of a reinforcement material made of fine grains enclosed in a metal container in the shape of a top-cut rectangular pyramidal with a central cylindrical perforation, prepared according to Patent Document 3, which provides an overall volume percentage of approximately 27 volume% titanium carbide in the reinforced area.

[0091] Mechanical properties are important parameters in applications involving teeth that engage with the ground. The TPMS-type grid structure of this invention is designed according to the following rules. - The volume percentage of the TPMS lattice structure relative to the cast metal ratio in the tooth reinforcement portion gradually decreases toward the surface of that portion by using variable cell wall thickness or variable cell unit size. In contrast to prior art Patent Document 3, the reinforcement should preferably be positioned at least 2 to 6 mm below the surface, and the present invention makes it possible to position the reinforcement core directly on the surface of the wear portion without forming significant stress or cracks, by controlling and variable amounts of reinforcement. Such possibility makes it possible to increase the reinforced volume using the same amount of material, reduce the overall volume ratio of hard particles within the reinforced area, and thus further reduce mechanical stress due to thermal expansion mismatch between the reinforcement material and the cast metal. - The thickness of the cell wall gradually increases away from the surface towards the inner core of the tooth, whereas the size of the cell unit remains nearly constant or simply increases towards the surface of the worn area. - To ensure the mechanical properties of the tooth above a specified depth below the outer surface, the reinforcement ratio to metal also decreases towards the tooth core. - In the intermediate range, the reinforcement ratio to the metal is kept high to maximize wear resistance.

[0092] This type of design can be easily produced by additive manufacturing, and it also allows for strengthening the initial surface of the tooth without creating significant stress, while increasing bulk wear resistance while maintaining the core with high mechanical resistance. In this method, the ceramic concentration can be controlled through variable cell unit size and / or variable cell wall thickness.

[0093] For gyroid lattice structures with thin cell walls capable of withstanding turbulent injection of liquid metal, higher strength may be required than that of a partially sintered core. High-density ceramic TPMS lattice structures are obtained through complete densification during sintering (with or without the help of an additional hot isostatic pressing step) or post-infiltration.

[0094] Example 5 88 wt% tungsten carbide and 12 wt% cobalt composition, with an average particle size of 25 μm, D 50 Spray-dried granular powder having the same binder as in the previous example was used to print a gyroid lattice structure, as shown in Figure 18, with complementary volumes on an Innovent 3D binder jet printer from EXone, with a constant unit cell size of 25 mm (after sintering) and a variable cell wall thickness between 2 and 6 mm (after sintering).

[0095] The key parameters of the print process were as follows: - Each printed layer is 100 μm thick. - Print speed is 90 seconds per layer. - Binder saturation is 60%, and - Powder filling accounts for approximately 45%.

[0096] After completion, the entire printed rectangle was cured in an oven at 200°C for approximately 1 hour / cm of the thickness of the item.

[0097] After cooling, the printed rectangles were vacuum-cleaned to remove powder and brushed to obtain the raw gyroid lattice structure.

[0098] The raw gyroid structure was placed in a furnace and heated at 1485°C for 45 minutes under vacuum with a 5 mbar argon atmosphere to allow for partial sintering and burning of most of the binder until all micropores in the cell walls were closed. It was then further isotropically heated and pressurized at 1485°C for 10 minutes under an argon pressure of 1.8 MPa to achieve a relative density of 99%.

[0099] Represented by complementary volumes in cross-sectional views in Figures 18b, 18c, and 18d, this sintered gyroid lattice structure contains approximately 74% by volume of voids in total, and its material is dense (significant micropores no longer exist within the cell walls). It is placed in a sand mold within a portion of the wear area to be reinforced (as shown in Figure 8).

[0100] The high-temperature liquid carbon steel is then poured into the mold at 1630°C. The high-temperature liquid carbon steel thus fills 74 volume percent of the voids in the gyroid lattice structure. After injection, approximately 97% of the reinforced portion (100% of the top of the pyramid cut off minus 3% of the central cylindrical hole) contains approximately 26 volume percent of the high-concentration approximately 80 volume percent tungsten carbide. The overall volume content of tungsten carbide in the reinforced macromicrostructure of the wear portion is therefore approximately 21 volume percent.

[0101] Example 6 A powder mixture with an average particle size of 5 μm, consisting of 75 wt% titanium carbide powder, 19.5 wt% iron powder, 4 wt% manganese powder, 1 wt% nickel powder, and 0.5% molybdenum powder, was used to print a gyroid lattice structure with a constant cell size of 25 mm (after sintering) and a variable thickness of 2 to 6 mm (after sintering), using the following parameters, similar to Example 5.

[0102] The key parameters of the print process were as follows: - Each printed layer is 50 μm thick. - Print speed is 90 seconds per layer. - Binder saturation is 100%, and - Powder filling accounts for approximately 45%.

[0103] After completion, the entire printed rectangle was cured in an oven at 200°C for 2 hours per centimeter of height. After cooling, the printed rectangle was vacuum-cleaned to remove powder and brushed to obtain a raw gyroid lattice structure.

[0104] The raw gyroid structure was placed in a furnace and heated at 1430°C for 3 hours under vacuum with a 4 mbar argon atmosphere to allow for partial sintering, where most of the binder was burned out until all the micropores in the cell walls were closed. It was then further isotropically heat-pressurized at 1430°C for 10 minutes under an argon pressure of 1.8 MPa to achieve a relative density of 99%.

[0105] This sintered gyroid lattice structure, represented by complementary volumes in cross-sectional views in Figures 18b, 18c, and 18d, contains approximately 74% by volume of voids due to the gyroid lattice. It is placed in a sand mold within the area of ​​wear to be reinforced (as shown in Figure 8). High-temperature liquid carbon steel is then poured into the mold.

[0106] The high-temperature liquid carbon steel thus fills 74 volume percent of the gyroid lattice voids. After injection, approximately 97% of the reinforced portion (100% of the top of the pyramid cut off minus 3% of the central cylindrical hole) contains approximately 26 volume percent of the high-concentration titanium carbide of approximately 82 volume percent. The overall volume content of titanium carbide in the reinforced portion of the wear area is therefore approximately 21 volume percent.

[0107] Example 7 Average particle size D of 11 μm 50 The titanium carbide powder was used to print a gyroid lattice structure with a constant cell size of 20 mm and a variable cell wall thickness of 2 to 7 mm, as shown in Figure 19, with complementary volumes, using the following parameters.

[0108] The key parameters of the print process were as follows: - Each printed layer is 100 μm thick. - Print speed is 90 seconds per layer. - Binder saturation is 100%, and - Powder filling accounts for approximately 50%.

[0109] After completion, the complete printed rectangles were cured in an oven at 200°C for 2 hours per centimeter of height. After cooling, the printed rectangles were vacuum-cleaned to remove powder and brushed to obtain the raw gyroid lattice structure.

[0110] The raw gyroid lattice structure was placed in a furnace in a molten pool containing sufficient 4140 steel powder (composition of Cr: 1.11 wt%, Mn: 1.04 wt%, C: 0.4 wt%, Si: 0.24 wt%, Mo: 0.23 wt%, Fe: equilibrium composition), filling 50 volume percent of the lattice structure's micropores, allowing complete penetration of the porous shape by capillary action, and subsequently heated at 1430°C for 10 minutes under a vacuum of 0.001 mbar to achieve a relative density of 98%.

[0111] This gyroid lattice structure, whose different cross-sectional views are represented by complementary volumes in Figures 19b, 19c, and 19d, contains approximately 56% voids in total due to the gyroid lattice. It is placed in a sand mold within the area of ​​wear to be reinforced (as shown in Figure 8). High-temperature liquid carbon steel is then poured into the mold.

[0112] The high-temperature liquid carbon steel thus fills 56 volume percent of the gyroid lattice voids. After injection, approximately 97% of the reinforced portion (100% of the pyramid with the top cut off minus 3% of the central cylindrical hole) contains approximately 44 volume percent of the high-concentration titanium carbide of approximately 50 volume percent. The overall volume content of titanium carbide in the reinforced portion of the wear area is therefore approximately 21 volume percent.

[0113] Example 8 Average particle size D of 11 μm 50 A mixture of 86 wt% titanium carbide powder having the specified properties was mixed with 14 wt% titanium powder having an average particle size of 40 μm for 15 minutes in an argon-inactivated blender.

[0114] A homogeneous mixture was used to print a gyroid lattice structure with a constant cell size of 20 mm and a variable cell wall thickness of 2 to 7 mm on an EXone X1 25 Pro 3D binder jet printer. An aqueous binder based on a mixture of diethylene glycol dispersed in an aqueous solution of 2-butoxyethanol was used to print this part (BA005 EXone).

[0115] The key parameters of the AM process were as follows: - Each printed layer is approximately 100 μm thick. - Print speed is 90 seconds per layer. - The binder saturation of the powder pores is 90%, and - The powder filling density is approximately 49%.

[0116] After completion, the entire printed rectangle is cured in an oven at approximately 200°C for 2 hours per centimeter of height, with the residence time depending on the number of lattice structures, as multiple items can be manufactured in a single process. After cooling, the printed rectangle is brushed and the powder is removed by vacuum to obtain the raw gyroid lattice structure.

[0117] The resulting unprocessed gyroid-type lattice structure was placed in a furnace and heated at approximately 1150°C for 2 hours under an argon atmosphere to allow most of the binder to burn off.

[0118] This gyroid lattice structure is obtained with a powder packing density of 49% and contains a total of approximately 78 volume percent of empty space available for ferroalloy infiltration (approximately 56 volume percent due to voids within the gyroid lattice structure (cell unit) and an additional 22 volume percent of micrometer pores inside the cell wall), with the remaining 22 volume percent within the cell wall being titanium carbide + metallic titanium.

[0119] The resulting gyroid lattice structure is then placed in a sand mold within the area of ​​wear to be reinforced. High-temperature liquid carbon steel is then poured into the mold. The high-temperature liquid carbon steel fills 56 volume percent of the gyroid lattice voids and penetrates 22 volume percent of the micrometer pores between the particles of the cell walls.

[0120] Different cross-sectional views of the gyroid lattice structure are represented by complementary volumes in Figures 19b, 19c, and 19d.

[0121] After injection, approximately 97% of the reinforced portion (100% of the pyramid with the top cut off minus 3% of the central cylindrical hole) contains approximately 44% by volume of the high-concentration titanium carbide (powder packing density) of approximately 49% by volume. The overall volume content of titanium carbide in the reinforced area of ​​the wear portion is therefore approximately 21% by volume.

[0122] The tooth wear portion is created according to Examples 5, 6, 7, and 8 of the present invention, as shown in Figure 8. The tooth wear portion according to the present invention is compared to the tooth wear portion obtained according to Patent Document 3, with a total volume percentage of approximately 27 volume% of titanium carbide particles in the reinforced volume.

[0123] The following raw material powders were used: - Titanium HCSTARCK, Amperit 155.066, less than 200 mesh, - Graphite-carbon GK Kropfmuhl, UF4, >99.5%, less than 15μm, - Iron in the form of HSS M2 steel, less than 25 μm A powder mixture of 15% graphite-carbon, 63% titanium, and 22% iron in the form of M2 steel is mixed in a Lindor mixer for 15 minutes under an argon atmosphere.

[0124] Granulation is carried out in a Sahut-Conreur granulator, where strips are created by compressing the powder to a theoretical density of 75% at a pressure of 200 MPa on rolls. The strips are then ground into fine particles. The fine particles are sieved to obtain particle sizes ranging from 1.4 to 4 mm.

[0125] The resulting composition and unique relative density provide, after the reaction, a volume ratio of approximately 50 volume% of hard titanium carbide particles in the penetrating granules, according to Table 2 of Patent Document 3 (Table 5 below).

[0126] [Table 5]

[0127] The fine particles are placed inside a perforated metal container. The volume occupied by the particles is shaped like a rectangular pyramid with the top cut off (large cylindrical base 150 × 90 mm, small base 50 × 25 mm, height 190 mm) and has a perforated cylindrical hole in the center with a diameter of 15 mm.

[0128] The fine granule stack contains 45% by volume of voids (at millimeter intervals) within the 3D interconnected network structure of the fine granules. According to Table 3 of Patent Document 3 (Table 6 below), 1.8 g / cm³ 3 This bulk density can be achieved (45% space between fine particles plus 25% pores within the fine particles).

[0129] [Table 6]

[0130] A perforated metal container containing 55 volume percent of porous fine particles is placed in a sand mold within the area of ​​the wear region to be reinforced (a hierarchical wear region as shown in Figure 7), 5 mm away from either of the tip surfaces of the tooth. After the reaction, a 55 volume percent area is obtained with a high concentration of approximately 50% spherical titanium carbide, i.e., 97% of the reinforced portion (100% of the pyramid with the top cut off minus 3% of the central cylindrical hole) containing approximately 27 volume percent of the total titanium carbide in the reinforced macromicrostructure of the wear region.

[0131] The inventors conducted these tests by placing multiple teeth equipped with the gyroid insert according to the present invention (as shown in Figure 8) next to multiple teeth according to the prior art Patent Document 3 (as shown in Figure 7) in a bucket of a rope shovel, in order to evaluate wear under exactly the same conditions.

[0132] The teeth of the bucket are subjected to wear due to excavating material in the shaft. New teeth are shown in Figure 5. Worn teeth are shown in Figure 6. For each example, weight loss is measured by weighing each tooth before and after use. % weight loss = ((final weight - initial weight) / initial weight) × 100 The performance indicator is defined as follows, and the reference weight loss is the average weight loss of teeth as described in Patent Document 1. PI = Average % weight loss of standard teeth / Average % weight loss of test teeth A performance index greater than 1 means the test tooth does not wear down more than the standard, while a value less than 1 means the test tooth wears down more than the standard. The performance metrics for the example referenced above are shown in Table B (Table 7 below). In this case, under harsh conditions, the heavily reinforced material of conventional technical standards would be damaged by chipping, whereas the TPMS design allows for significantly superior wear resistance without failure.

[0133] While not bound by any particular theory, the following can be considered: - The superior performance of Example 8 compared to conventional technology can be explained by the extremely different design of the gyroid TPMS structure and the reinforcing material that starts from the tooth surface without damaging the teeth. - The superior performance of Example 7 compared to Example 8 can be explained by the superior properties of titanium carbide that has been pre-impregnated with iron before casting, compared to the porous shape of titanium carbide that is impregnated in a less controlled environment. - The superior performance of Example 6 compared to Example 7 can be explained by the even better properties of the titanium carbide-metal composite due to the high-density hot isostatic pressurization step. - The superior performance of Example 5 compared to Example 6 can be explained by the well-known wear advantage of tungsten-cobalt carbide composites over titanium carbide-type composites, which have lower density and are much cheaper.

[0134] [Table 7]

Claims

1. A hierarchical composite wear component used in the grinding and crushing industry, wherein the hierarchical composite wear component comprises a reinforced portion, the reinforced portion comprises a ceramic lattice structure of triple periodic minimal curves, the lattice structure comprises a plurality of cell units, the cell units comprising voids and cell walls of microporous ceramic, the micropores of the cell walls comprising sintered metal or cast metal, the lattice structure is embedded in a double continuous structure with a cast metal base material, the cast metal base material being an alloy iron base material including steel or cast iron.

2. The hierarchical composite wear component according to claim 1, wherein the triple-periodic minimum surface lattice structure is selected from the group consisting of gyroid, ridinoid, neobius, P-plane, diamond (D-plane), I-WP, combinations thereof, and derivatives thereof.

3. The hierarchical composite wear component according to claim 1 or 2, wherein the size of the cell unit is 10 mm to 60 mm, and the thickness of the cell wall is 1 mm to 15 mm.

4. The hierarchical composite wear component according to claim 3, wherein the size of the cell unit is 15 mm to 50 mm and the thickness of the cell wall is 2 mm to 10 mm.

5. The hierarchical composite wear component according to any one of claims 1 to 4, wherein the concentration of the ceramic in the reinforced portion is controlled by a change in the thickness of the cell wall and / or the size of the cell unit in the reinforced portion.

6. The hierarchical composite wear component according to any one of claims 1 to 5, wherein the ceramic is selected from the group consisting of metal carbides, borides, nitrides and combinations thereof.

7. The hierarchical composite wear component according to any one of claims 1 to 6, wherein the ceramic is selected from the group consisting of titanium carbide, titanium carbonitride, titanium chromium carbide, titanium boride, and tungsten carbide.

8. The hierarchical composite wear component according to any one of claims 1 to 7, wherein the sintered metal present in the micropores of the cell wall is selected from the group consisting of titanium, tungsten, chromium, steel, cast iron, and combinations thereof.

9. The hierarchical composite wear component according to any one of claims 1 to 8, wherein the concentration of ceramic in the lattice structure is in the range of 30 volume% to 90 volume%.

10. The hierarchical composite wear component according to claim 9, wherein the concentration of ceramic in the lattice structure is in the range of 40 volume% to 80 volume%.

11. The hierarchical composite wear component according to any one of claims 1 to 9, wherein the concentration of the ceramic in the reinforced portion is in the range of 5 volume% to 50 volume%.

12. The hierarchical composite wear component according to claim 11, wherein the concentration of the ceramic in the reinforced portion is in the range of 10 volume% to 40 volume%.

13. A method for manufacturing a hierarchical composite wear component according to any one of claims 1 to 12, A step of adding a ceramic lattice structure with a triple-periodic minimal surface geometric shape via a powder mixture containing ceramic particles, The steps include: sintering at least partially the ceramic lattice structure; The steps include: arranging the ceramic lattice structure within the mold; A method comprising the step of casting a ferroalloy to obtain the hierarchical composite wear part described in claim 1.

14. The method according to claim 13, wherein the step of at least partially sintering the ceramic lattice structure includes substantially filling the micropores of the cell walls of the ceramic lattice structure with a metal selected from the group consisting of titanium, tungsten, chromium, steel, cast iron and combinations thereof, before placing it in a mold and performing final casting.

15. The method according to claim 13 or 14, wherein the step of at least partially sintering the ceramic lattice structure is followed by a hot isostatic pressing step or a penetration step.

16. The method according to any one of claims 13 to 15, wherein the step of additively manufacturing a ceramic lattice structure having a triple-periodic minimal surface geometric shape via a powder mixture containing the ceramic particles is additive manufacturing by binder jetting technology followed by binder curing at a temperature above 150°C, or additive manufacturing by molten bed laser technology.

17. The ceramic particles have a particle size D of 1 μm to 150 μm, as measured by laser diffraction technology. ５０ The method according to any one of claims 13 to 16, comprising:

18. The method according to claim 17, wherein the ceramic particles have a particle size D 50 of 5 μm to 100 μm as measured by laser diffraction technology.

19. Use of a hierarchical composite wear component according to any one of claims 1 to 12 as teeth for an impact crusher groove.

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