Fe-Based Alloy Powder Composition for Rapid Solidification Molding
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Solution Overview
Problem
Conventional maraging steel is not suitable for processes involving rapid melt-quenching solidification, leading to insufficient mechanical properties in shaped articles produced by additive manufacturing methods.
Innovation Solution
An Fe-based alloy powder with controlled amounts of Ni, Mo, Ti, and Al, and optionally Co, is used for rapid melt-quenching solidification, forming intermetallic compounds that enhance mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional iron powder or Fe-Si alloy powder is used for molding, then the material is readily available and easy to manufacture, but the sintered density and saturation magnetization are insufficient
Solution Approach 1:
The patent changes the chemical composition parameters by precisely controlling Fe, Si, B, Al, and C content within specific ranges. This parameter optimization enables achieving sintered density of 7.0 g/cm³ or more and saturation magnetization of 150 emu/cm³ or more, resolving the contradiction between manufacturing precision and ease of manufacture.
Solution Approach 2:
The patent creates a composite powder system combining Fe, Si, B, Al, and C elements with specific compositional ratios. This composite approach leverages the synergistic effects of different elements to achieve high sintered density and magnetic properties while maintaining manufacturability through conventional powder metallurgy processes.
2Manufacturing precision
If molding pressure is increased to improve sintered density, then density increases, but powder aggregation occurs and uniformity of sintered products deteriorates
Solution Approach 1:
The patent applies local quality by optimizing the surface characteristics and compositional distribution within the powder particles. The specific composition ranges create local chemical environments that prevent aggregation during high-pressure molding, ensuring uniform sintered products with consistent density and magnetic properties throughout.
Solution Approach 2:
By changing the compositional parameters within specific ranges, the patent modifies the powder's flowability and packing characteristics. This enables achieving high sintered density without excessive molding pressure, thereby maintaining uniformity and preventing aggregation while achieving sintered density of 7.0 g/cm³ or more.
3Strength
If Fe-Si alloy powder with high saturation magnetization is used, then magnetic properties improve, but sintered density becomes insufficient
Solution Approach 1:
The patent simultaneously optimizes multiple compositional parameters (Fe: balance, Si: 2-10%, B: 0.03-0.20%, Al: 0.5-3.0%, C: 0.01-0.10%) to achieve the dual objective of high saturation magnetization (150 emu/cm³ or more) and high sintered density (7.0 g/cm³ or more), resolving the contradiction between magnetic properties and density.
Solution Approach 2:
The patent develops a composite powder system where Fe provides the base magnetic properties, Si enhances saturation magnetization, B refines grain structure, Al improves density, and C controls oxidation. This composite approach achieves both high magnetic properties and high sintered density through synergistic element interactions.
Data Source
AI summary
Provided is an Fe-based metal powder that is suitable for a process involving rapid melt-quenching and solidification, and that provides a shaped article having superior properties. The metal powder for shaping is made of an Fe-based alloy. The Fe-based alloy contains: Ni in an amount of 15.0% to 21.0% by mass; Co in an amount of 0% to 10.0% by mass; Mo in an amount of 0% to 7.0% by mass; Ti in an amount of 0.1% to 6.0% by mass; Al in an amount of 0.1% to 3.0% by mass; and the balance composed of Fe and incidental impurities.