Ceramic-Metal Powder Composition for Dense Additive Manufacturing
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Solution Overview
Problem
Conventional powder rapid prototyping manufacturing techniques face challenges in achieving high density in metal and ceramic parts due to issues with porosity and relative density, particularly in the core and shell regions of manufactured articles, leading to inefficient manufacturing processes and suboptimal material properties.
Innovation Solution
A novel additive manufacturing material comprising a granulated powder with a ceramic main component and a metal component, where the ceramic primary particles are three-dimensionally bound to form granulated particles with voids, and a metal powder with a lower melting point is used to promote melting and binding, allowing for the production of dense articles without the need for reduced laser scanning speeds or additional infiltration processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional powder materials with uniform grain size and spherical particles are used, then manufacturing precision is improved, but relative density remains less than 100% due to inevitable voids between particles
Solution Approach 1:
The invention intentionally creates a porous core structure using expanded powder particles with internal voids, then uses liquid phase infiltration to fill these pores with metal or ceramic material, achieving high density throughout the entire article including the core region
Solution Approach 2:
The invention uses composite powder materials containing both expandable particles (for core formation) and filler particles (for density enhancement), creating a multi-phase composite structure that achieves high relative density while maintaining manufacturing precision
2Reliability
If high-power laser is used to manufacture core region with high density, then relative density is improved, but manufacturing time increases extremely due to thin laminate requirements
Solution Approach 1:
The invention pre-forms the powder particles with expanded structure and internal voids before manufacturing, so that the core region naturally forms with appropriate porosity during lamination, eliminating the need for slow thin-laminate manufacturing to achieve density control
3Strength
If powder materials with high melting point ceramics are used, then mechanical strength is improved, but bonding control becomes difficult and relative density remains low
Solution Approach 1:
The invention changes the physical and chemical parameters of the powder material by incorporating expandable particles that undergo phase transformation during processing, creating liquid phase that facilitates bonding of high melting point ceramic particles and improves bonding control
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 enables the efficient manufacturing of dense, high-density articles with improved mechanical properties by effectively melting and binding the ceramic and metal components, reducing porosity and enhancing the relative density of the final product.
Implementation Method 1
a metal powder with a lower melting point is used to promote melting and binding
Implementation Method 2
effectively melting and binding the ceramic and metal components
Data Source
Figure 1
Figure 2(a)~2(b)
AI summary
Provided is a novel material for shaping, with which it is possible to more effectively shape a shaped article that has high density while containing a ceramic. The present invention provides a material for shaping in order for use in powder additive manufacturing. This material for shaping includes a first powder that is a granulated powder containing a ceramic, and a second powder containing a metal. The second powder constitutes 10-90% by mass (exclusive) of the total of the first powder and the second powder.