Composite Ceramic Powder for Low-Dispersion Additive Manufacturing
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Solution Overview
Problem
Existing powder materials for additive manufacturing are prone to dispersion when energy is applied, leading to manufacturing difficulties and reduced accuracy.
Innovation Solution
A powder material composed of composite particles, including a first material with ceramics and a second material such as magnesium, zinc, molybdenum, tungsten, copper, aluminum, carbon, or silicon, which are integrated to reduce dispersion risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a powder material is thinly layered and energy is applied to attach or sinter the powder material, then a shaped object can be manufactured, but the powder material may disperse making manufacturing difficult and reducing accuracy
Solution Approach 1:
The patent applies composite materials by combining ceramic particles with metal particles in a powder mixture. The metal particles serve as a binding phase that reduces dispersion of ceramic particles during energy application. This composite structure allows the powder material to maintain its integrity while being processed, thereby improving manufacturing accuracy without sacrificing the beneficial properties of ceramic materials.
Solution Approach 2:
The patent merges ceramic particles and metal particles into a unified powder material system. The metal particles are combined with ceramic particles in specific proportions to create a mixed powder that exhibits reduced dispersion characteristics. This merging of different material types creates a synergistic effect where the metal phase stabilizes the ceramic phase during additive manufacturing processes.
2Reliability
If ceramic powder is used as a major component, then goods can be produced with desired properties, but the powder material easily disperses at application of energy
Solution Approach 1:
The patent creates a composite powder material where ceramic particles (providing desired properties) are combined with metal particles (providing dispersion resistance). The metal particles act as a matrix or supporting phase that holds the ceramic particles together during energy application, preventing their dispersion while maintaining the ceramic's functional properties in the final product.
Solution Approach 2:
The metal particles serve as an intermediary phase between the ceramic particles and the energy field. Instead of the ceramic particles directly interacting with the energy field (which causes dispersion), the metal particles mediate this interaction, absorbing and distributing the energy in a way that prevents ceramic particle dispersion while still allowing sintering to occur.
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 composite particles minimize dispersion, enhance flowability, and improve manufacturing accuracy and productivity by forming conductive pathways that mitigate charging and dispersion during energy application.
Implementation Method 1
forming conductive pathways that mitigate charging and dispersion during energy application
Data Source
AI summary
Provided is a technology that allows reduction in risk of dispersion of a powder material by application of energy in a process of additive manufacturing. The powder material for additive manufacturing disclosed herein contains a first material constituted with ceramics, and a second material constituted with at least one of magnesium (Mg), zinc (Zn), molybdenum (Mo), tungsten (W), copper (Cu), aluminum (Al), carbon (C), and silicon (Si). The powder material is constituted with composite particles including a mixture of the first material and the second material.