Printable hard iron metal alloy for additive manufacturing using direct energy deposition (DEP) processes.

Formulating iron alloys with specific elemental compositions for DED processes enhances mechanical properties in 3D printed metal parts, achieving high strength, hardness, and ductility, addressing the limitations of existing DED processes.

JP7864639B2Active Publication Date: 2026-05-25MACLEAN FOGG CO
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Patent Information

Authority / Receiving Office
JP Β· JP
Patent Type
Patents
Current Assignee / Owner
MACLEAN FOGG CO
Filing Date
2021-04-14
Publication Date
2026-05-25

AI Technical Summary

Technical Problem

Existing direct energy deposition (DED) processes for metal 3D printing struggle to produce metal parts with high hardness, strength, and ductility, particularly in steel alloys like 316L, 17-4PH, and H13, which are not optimized for these properties.

Method used

Formulating iron alloy compositions with specific elemental concentrations (Fe, Cr, Nb, Mo, C, and optional Ni, Cu, Si, W, Mn, N, B) to achieve high hardness (45 HRC to 58 HRC), strength (700 MPa to 1500 MPa), and ductility (4% to 20%) in the as-built state, using DED processes.

Benefits of technology

The formulated alloys exhibit superior mechanical properties, including tensile strength of 1300 MPa to 2200 MPa, yield strength of 700 MPa to 1500 MPa, and elongation of 4% to 20%, with minimal defects such as cracks and porosity, suitable for high-performance applications.

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Abstract

A printed metal part is provided, the alloy having a composition by weight of 69.2% to 89.1% Fe, 7.25% to 16.0% Cr, 0.01% to 10.0% Nb, 0.5% to 4.0% Mo, 0.03% to 0.4% C, and optionally any one or more of Ni, Cu, Si, W, Mn, N, and B. The printed metal part has a tensile strength of at least 1300 MPa, a yield strength of at least 700 MPa, an elongation of at least 4.0%, and a hardness of at least 45 HRC.
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