Composite Particles for Additive Manufacturing
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Solution Overview
Problem
Composite particles used in additive manufacturing often experience thermal deformation and clogging due to their low strength, making them unsuitable for high-temperature applications and prone to destruction during the manufacturing process.
Innovation Solution
A composite particle comprising a ceramic phase and a metal phase with a porosity of no more than 45% and a metal phase area ratio of at least 20% is developed, along with a manufacturing method involving wet-mixing, dry-granulation, and heat treatment within a specific temperature range to produce high-strength particles suitable for additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If composite particles are used for additive manufacturing, then high-temperature strength is improved, but thermal deformation and clogging occur due to low strength
Solution Approach 1:
The patent uses composite particles made of ceramic phase (e.g., carbide, nitride, carbonitride) and metal phase (e.g., cobalt, nickel, iron, tungsten, molybdenum) to achieve both high-temperature strength and sufficient compressive strength. The ceramic phase provides high-temperature resistance while the metal phase provides toughness and strength, resolving the contradiction between these two properties.
Solution Approach 2:
The patent specifies precise parameter ranges: porosity of 40-70% by area ratio, metal phase area ratio of 10-80%, and heating temperature of 0.72*Ts to 0.95*Ts (where Ts is solidus temperature). By controlling these parameters, the composite particles achieve optimal balance between high-temperature strength and compressive strength, preventing thermal deformation and clogging during additive manufacturing.
2Ease of manufacture
If porosity is increased to improve powder flowability, then manufacturing ease is improved, but particle strength decreases causing deformation
Solution Approach 1:
The patent optimizes porosity to a specific range of 40-70% by area ratio. This parameter control allows the particles to maintain sufficient strength for additive manufacturing while achieving adequate powder flowability. The metal phase area ratio of 10-80% further supports this balance by providing structural integrity even at these porosity levels.
3Strength
If metal phase content is increased to improve strength, then compressive strength is improved, but ceramic phase distribution becomes non-uniform
Solution Approach 1:
The patent controls the metal phase area ratio within 10-80% and specifies heating temperature as 0.72*Ts to 0.95*Ts (where Ts is solidus temperature). These parameter controls ensure that the metal phase is distributed uniformly throughout the ceramic matrix while providing sufficient strength. The temperature range prevents excessive metal phase aggregation or incomplete bonding.
4Strength
If heating temperature is increased to improve bonding strength, then particle strength is improved, but thermal deformation increases
Solution Approach 1:
The patent specifies heating temperature as 0.72*Ts to 0.95*Ts (where Ts is solidus temperature of the metal phase). This controlled temperature range ensures sufficient bonding strength between metal and ceramic phases while preventing excessive thermal deformation. The temperature is high enough to achieve strong bonding but controlled to minimize shape changes during heating.
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 resulting composite particles exhibit high compressive strength, preventing deformation and clogging, and enabling the production of additive-manufactured products with excellent surface accuracy and toughness.
Implementation Method 1
heating the granulated particles at a temperature T to produce the composite particle, wherein the temperature T is in a following range: 0.72*Ts≤T<0.95*Ts
Data Source
AI summary
The present invention pertains to high-strength/high-ductility alloys, and in particular, provides high-strength composite particles comprising a ceramic phase and a metal phase, a composite powder, a method for manufacturing composite particles, and a method for manufacturing a composite member. Composite particles including a ceramic phase and a metal phase, wherein the composite particles are characterized in that the porosity is no greater than 45% in area ratio in cross-section, and the area ratio of the metal phase, where the total area of the ceramic phase and the metal phase is 100%, is at least 20%. A composite powder characterized in including a plurality of the composite particles.