A cost-effective way to obtain complex-shaped parts.

Abstract

The present invention relates to a method for manufacturing complex-shaped parts and / or components made of metal. The method is particularly applicable to high-performance parts. A method is disclosed for cost-effective production of complex-shaped and larger, high-performance metal components. The method also applies to the assembly of parts with internal features and voids. The method is also useful for lightweight construction. The method enables topological performance optimization for the replication of biomimetic and other advanced structures.

Claims

1. A method for manufacturing at least a part of an element comprising metal, comprising the following steps: - A step of providing a mold manufactured at least partially by additive manufacturing, - A step of filling the mold with a powder or powder mixture having at least a powdered metal or metal alloy, - A forming step, wherein the element is formed by applying pressure and / or temperature treatment to the mold, - A binder removal step to remove at least a portion of the above type, - An adjustment step following the binder removal step, wherein the levels of oxygen and / or nitrogen in the metal portion of the element are set, and - Consolidation step to which consolidation treatment is applied A method for manufacturing at least a portion of an element comprising metal.

2. The oxygen content after the adjustment step satisfies %O < KYS × (%Y + 1.98 × %Sc + 2.47 × %Ti + 0.67 × %REE), The method according to claim 1, wherein %O represents the weight percentage of oxygen in the metallic part of the element, %Y represents the weight percentage of yttrium in the metallic part of the element, %Sc represents the weight percentage of scandium in the metallic part of the element, %Ti represents the weight percentage of titanium in the metallic part of the element, %REE represents the total weight percentage of lanthanides and actinides in the metallic part of the element, and KYS is a dimensionless quantity of 2100.

3. The densification step further comprises applying high temperature and high pressure treatment after the consolidation step, The consolidation step is carried out at a pressure of at least 160 bar and less than 4900 bar, and at a temperature of 0.45 × Tm or more and 0.92 Tm or less. The method according to claim 1 or 2, wherein Tm is the lowest melting point of the metal powder in the powder or powder mixture, and the unit of Tm is Kelvin.

4. The method according to any one of claims 1 to 3, further comprising the step of applying heat treatment and / or machining to the obtained element after the consolidation step.

5. The method according to any one of claims 1 to 4, wherein the consolidation step is applied to achieve an apparent density greater than 81% and less than 99.6%.

6. The method according to any one of claims 1 to 5, wherein the forming step comprises the step of applying a pressure between 60 MPa and 1200 MPa.

7. The method according to any one of claims 1 to 6, wherein the oxygen content in the powder or powder mixture is greater than 620 ppm.

8. The method according to any one of claims 1 to 7, wherein the oxygen content in the metal portion of the element after the adjustment step is greater than 0.2 ppm and less than 390 ppm.

9. The method according to any one of claims 1 to 8, wherein the amount of oxygen in the powder or powder mixture is greater than 250 ppm, and the amount of oxygen in the metal portion of the element after the preparation step is greater than 0.2 ppm and less than 140 ppm.

10. After the adjustment step, the %NMVS in the metal portion of the element exceeds 31%, where %NMVS = (Volume of NMVS / Volume of NMVT) × 100, where the volume of NMVS is the volume of voids located inside the metal portion of the element that is directly accessible from the surface of the element, and the volume of NMVT is the total volume of voids within the element, with all volumes measured in units of m. 3 The method according to any one of claims 2 to 9.

11. The %NMVC in the metal portion of the element after the densification step is less than 9%, where %NMVC = (volume of NMVC / total volume of the element) × 100, where the volume of %NMVC is the volume of voids located inside the metal portion of the element that is directly accessible from the surface of the element, and all volumes are in units of m 3 The method according to any one of claims 3 to 10.

12. The method according to any one of claims 1 to 11, wherein a metal-containing powder mixture containing carbonyl iron powder is used.

13. The powder mixture comprises at least two powders mixed with a difference in the content of at least one major element. The method according to any one of claims 1 to 12, wherein the main element is an element selected from Cr, Mn, Ni, V, Ti, Mo, W, Al, Zr, Si, Sn, Mg, Cu, C, B, and N.

14. The method according to any one of claims 1 to 13, wherein at least one of the forming step, debinding step, adjustment step and compaction step includes microwave heating.

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