Ceramic-Metal Composite Die Material With Remelting for Void Reduction
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Solution Overview
Problem
Composite powders containing ceramic and metal used in additive manufacturing for forging dies often have voids that reduce the strength of the resulting material due to porosity, making it challenging to achieve high temperature strength and durability.
Innovation Solution
A method involving the use of composite powder with ceramic and metal, where additive manufacturing is performed with repeated melting and solidifying steps, followed by a remelting process to reduce voids and enhance strength, and subsequent heat treatment to improve structure and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If composite powder containing ceramic and metal is used for additive manufacturing, then high temperature strength is improved, but voids are generated in the powder leading to decreased strength of the composite material
Solution Approach 1:
The patent applies preliminary action by performing a remelting step after the initial additive manufacturing process. This remelting step is designed to eliminate voids that were inevitably generated during the granulation process of composite powder. By preemptively addressing the void formation issue through an additional melting and solidification cycle, the method ensures that the final composite material achieves both high temperature strength and high structural integrity without the strength-reducing effect of voids.
2Manufacturing precision
If tool steel is used for warm/hot forging dies, then near net shapability is improved, but the die softens at temperatures of 800°C or higher reducing operational life
Solution Approach 1:
The patent applies composite materials by creating a composite alloy consisting of ceramic particles dispersed in a metal matrix. This composite structure combines the advantages of both materials: the ceramic provides high temperature stability and strength, while the metal matrix provides ductility and near net shapability. The resulting composite die material maintains its mechanical properties at temperatures of 800°C and above, solving the softening problem of conventional tool steel while preserving the near net shaping capability.
Solution Approach 2:
The patent applies local quality by creating a microstructure where ceramic particles are distributed throughout the metal matrix. This local distribution of ceramic reinforcement throughout the material provides localized high temperature strength where needed, while the surrounding metal matrix maintains ductility and formability. This heterogeneous microstructure allows the material to exhibit different properties in different phases, combining the benefits of both ceramic and metal.
3Temperature
If cemented carbide is used for high temperature strength, then strength at 800°C or more is improved, but ductility is lower than tool steel making it difficult to apply to dies
Solution Approach 1:
The patent applies local quality by creating a microstructure where ceramic particles are distributed throughout the metal matrix. This local distribution of ceramic reinforcement throughout the material provides localized high temperature strength where needed, while the surrounding metal matrix maintains ductility and formability. This heterogeneous microstructure allows the material to exhibit different properties in different phases, combining the benefits of both ceramic and metal.
Solution Approach 2:
The patent applies composite materials by creating a composite alloy consisting of ceramic particles dispersed in a metal matrix. This composite structure combines the advantages of both materials: the ceramic provides high temperature stability and strength, while the metal matrix provides ductility and near net shapability. The resulting composite die material maintains its mechanical properties at temperatures of 800°C and above, solving the softening problem of conventional tool steel while preserving the near net shaping capability.
4Reliability
If sintering process is used for cemented carbide, then cutting tool performance is improved, but thermal deformation during sintering requires large post-process cutting
Solution Approach 1:
The patent applies mechanics substitution by replacing the conventional sintering process with an additive manufacturing process. Instead of using thermal sintering that causes significant thermal deformation and requires extensive post-processing, the invention uses selective laser melting or electron beam melting to directly form the die with high dimensional accuracy. This substitution of the manufacturing mechanism eliminates the thermal deformation problem inherent in sintering while maintaining the ability to produce complex near-net-shape components.
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 method results in a composite material with reduced voids and increased high-temperature strength, improved shape accuracy, and enhanced mechanical properties, suitable for high-temperature applications like forging dies.
Implementation Method 1
an additive manufacturing method for forming an additively manufactured part with a three-dimensional shape by locally melting and solidifying powder using a heat source and thus repeatedly forming solidified layers in a stacked manner
Implementation Method 2
locally melting and solidifying powder using a heat source and thus repeatedly forming solidified layers
Implementation Method 3
repeatedly performing melting and solidifying steps thereon
Implementation Method 4
repeatedly performing melting and solidifying steps thereon
Implementation Method 5
subsequent heat treatment to improve structure and accuracy
Data Source
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AI summary
An object of the present invention is to provide an additively manufactured part with high temperature strength and high ductility that can be suitably used for hot forging even in the temperature range of 800 °C or more, and a manufacturing method therefor. The manufacturing method for the additively manufactured part in accordance with the present invention includes an additive manufacturing step of using composite powder containing ceramic and metal and having voids therein to form a composite material containing the ceramic and the metal by repeating steps of melting and solidifying the composite powder; and a remelting step of remelting the surface of the composite material.