3D Metal Particles Density via Binder Penetration
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Solution Overview
Problem
Existing three-dimensional shaped article production methods face challenges in achieving high density and large size due to voids in metal powder layers and aggregation issues with particle sizes, as well as difficulties in binder escape during sintering.
Innovation Solution
A method involving the supply of a first metal powder with larger particles, a binder liquid containing smaller particles for penetration, and a second binder liquid without metal powder for surface layer void formation, followed by sintering to produce a dense and large metal-made three-dimensional shaped article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If only metal powder of large particles is used to form a layer, then the packing density of the powder becomes small and the powder cannot be spread thin and uniformly, but using metal powder of small particles causes aggregation of the metal powder and deteriorated fluidity
Solution Approach 1:
The patent applies parameter changes by controlling the particle size distribution within specific ranges (D10-D90 of 40-150 μm for main powder, D10-D90 of 10-50 μm for auxiliary powder) and adjusting the mixing ratio (auxiliary powder 1-10 wt%) to optimize both packing density and fluidity. This quantitative parameter control resolves the contradiction between achieving high density and maintaining good spreading properties.
2Manufacturing precision
If a metal powder of small particles is sprayed to fill voids among particles of metal powder of large particles, then the density increases, but the metal powder of small particles does not effectively penetrate into voids and a three-dimensional shaped article having a high density cannot be produced
Solution Approach 1:
The patent applies local quality by using binder liquid that selectively penetrates into void regions among metal powder particles. The binder liquid with controlled viscosity and surface tension properties targets specifically the void spaces, allowing small particles to be deposited where needed without aggregation, thereby achieving effective void filling and high density.
Solution Approach 2:
The binder liquid serves as an intermediary that facilitates the penetration and uniform distribution of small metal particles into voids among large particles. The binder reduces surface tension and enables the small particles to disperse and fill gaps effectively, overcoming the limitation of direct spraying without adequate penetration.
3Manufacturing precision
If a three-dimensional shaped article having a high density is produced, then the density increases, but it becomes difficult to produce a large three-dimensional shaped article because a vaporized binder or the like cannot escape from the surface layer when sintering
Solution Approach 1:
The patent applies porous materials by intentionally forming a porous structure in the surface layer through controlled binder distribution. This porous surface structure creates escape pathways for vaporized binder during sintering, allowing high-density internal structure to be achieved while enabling efficient binder removal through the porous surface channels.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively increases the density of the three-dimensional shaped article by filling voids with smaller particles and allows for binder removal from the surface layer, enabling the production of large, high-density metal articles.
Implementation Method 1
a first liquid supply step of supplying a first liquid containing a binder and a second metal powder having a second average particle diameter that is an average particle diameter 1/10 or more and 1⁄2 or less the first average particle diameter to at least a portion of a constituent region of the three-dimensional shaped article in the layer
Implementation Method 2
a sintering step of sintering a metal in the constituent region by heating a stacked body of the layers
Implementation Method 3
it becomes difficult to produce a large three-dimensional shaped article because a vaporized binder or the like cannot escape from the surface layer of the three-dimensional shaped article having a high density when sintering the stacked body
Data Source
AI summary
A three-dimensional shaped article production method is a three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers and includes a first metal powder supply step of supplying a first metal powder having a first average particle diameter to a shaping table, a layer formation step of forming the layer by compressing the first metal powder supplied to the shaping table, a first liquid supply step of supplying a first liquid containing a binder and a second metal powder having a second average particle diameter that is an average particle diameter 1/10 or more and ½ or less the first average particle diameter to at least a portion of a constituent region of the three-dimensional shaped article, a second liquid supply step of supplying a second liquid that contains a binder, but does not contain a metal powder to at least a portion of a surface layer region in the constituent region, and a sintering step of sintering a metal in the constituent region by heating a stacked body.