3D Printing Powder Composition for Dense Cermet Carbide Bodies
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Solution Overview
Problem
Current three-dimensional printing methods face challenges in achieving homogeneous composition and minimizing porosity in cermet and cemented carbide bodies, which are crucial for high-demanding applications like cutting tools and wear parts.
Innovation Solution
A powder with a specific particle size distribution and porosity, comprising 30-70 vol% of particles <10 µm in diameter and 10-40 vol% porosity in particles ≥20 µm, is used, along with a method involving mixing, spray drying, milling, and sintering to create a dense and homogeneous cermet or cemented carbide body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional three-dimensional printing methods are used, then the manufacturing process can be performed, but the final product exhibits non-homogeneous structure and high porosity
Solution Approach 1:
The invention changes the physical and chemical parameters of the powder particles by controlling porosity (10-40 vol%) and particle size distribution (D90/D10 ratio of 1.5-3.0) of the cermet/cemented carbide particles before printing. These parameter modifications enable better packing density and more uniform binder distribution during the printing process, resulting in homogeneous structure and reduced porosity in the final printed body.
Solution Approach 2:
The invention uses composite powder particles consisting of cermet or cemented carbide material with controlled internal porosity. This composite structure allows the particles to pack more efficiently and enables uniform binder penetration during printing, solving the homogeneity and porosity issues while maintaining the high hardness and toughness properties of the original cermet/cemented carbide materials.
2Productivity
If standard powder is used in three-dimensional printing, then the printing process can proceed, but the sintering activity is insufficient and porosity remains high
Solution Approach 1:
The invention performs preliminary porosity control during powder preparation, creating particles with optimized porosity (10-40 vol%) and size distribution before the printing and sintering processes. This preliminary action ensures that the powder is pre-conditioned for optimal sintering activity, enabling better densification and reduced final porosity without requiring excessive sintering energy or time.
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
The approach results in three-dimensional printed bodies with reduced porosity and improved sintering activity, achieving a dense and homogeneous structure with enhanced mechanical properties, suitable for applications requiring high hardness and toughness.
Implementation Method 1
mixing, spray drying, milling, and sintering to create a dense and homogeneous cermet or cemented carbide body
Implementation Method 2
mixing, spray drying, milling, and sintering to create a dense and homogeneous cermet or cemented carbide body
Data Source
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AI summary
The present invention relates to a powder for three dimensional printing of a cermet or a cemented carbide body, said powder comprising 30-70 vol% of the particles that are <10 µm in diameter. The present invention also relates to a method of making a cermet or cemented carbide body, said method comprising the steps of forming said powder, 3D printing a body using said powder together with a printing binder and thereby form a 3D printed cermet or cemented carbide green body and subsequently sintering said green body and thereby form a cermet or cemented carbide body.