Metal Powder Nanoparticle Adhesion for Additive Manufacturing
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Solution Overview
Problem
In layered manufacturing processes using metal powders, the formation of heterogeneous structures within three-dimensional shaped articles due to factors beyond energy beam irradiation, such as powder material properties, leads to defects and voids, which are difficult to suppress, affecting the homogeneity and quality of the final product.
Innovation Solution
A metal powder material comprising metal particles with a specific diameter range and nanoparticles adhered or mixed with them, where the nanoparticles reduce attractive forces between particles, enhance fluidity, and improve packing density, thereby stabilizing the powder bed and reducing defects during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional metal powder is used in layered manufacturing, then the manufacturing process can be conducted, but heterogeneous structures and defects form in the three-dimensional shaped article
Solution Approach 1:
Nanoparticles are introduced as intermediary substances between metal particles to modify interparticle interactions. The nanoparticles reduce attractive forces between metal particles, preventing agglomeration and ensuring homogeneous distribution during powder bed formation and sintering processes, thereby eliminating defects and voids in the final shaped article
Solution Approach 2:
The invention changes the physical and chemical parameters of the powder material system by controlling particle diameter (10-100 μm), circularity (0.90 or more), and nanoparticle content (0.01-10 mass%). These parameter optimizations ensure smooth powder flow, stable powder bed formation, and homogeneous sintering, preventing heterogeneous structure formation
2Productivity
If powder material is supplied to form a powder bed, then the layered manufacturing process can proceed, but powder material may not be uniformly spread leading to heterogeneous structure
Solution Approach 1:
The metal particles are engineered with specific parameters: diameter of 10-100 μm for optimal flow characteristics, and circularity of 0.90 or more for smooth movement. These parameter changes enable the powder to be uniformly spread across the build plate without clumping, ensuring homogeneous powder bed formation for high-precision manufacturing
3Ease of manufacture
If metal particles are supplied through a nozzle in powder deposition method, then three-dimensional shaped article can be formed, but nozzle clogging occurs
Solution Approach 1:
The metal particles are designed with diameter of 10-100 μm and high circularity (0.90 or more), which optimizes their flow properties. These parameter changes prevent particle agglomeration and ensure smooth flow through the nozzle during powder deposition, eliminating clogging issues while maintaining ease of manufacturing three-dimensional shaped articles
4Ease of operation
If powder material is packed in lower density, then handling is easier, but solidification shrinkage increases during energy beam irradiation
Solution Approach 1:
Nanoparticles serve as intermediary agents that reduce attractive forces between metal particles, enabling the powder to maintain high packing density without excessive agglomeration. This allows the powder to be densely packed in the powder bed, minimizing void spaces and reducing solidification shrinkage during energy beam irradiation while remaining easy to handle
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 metal powder material ensures stable and homogeneous supply of powder, reduces clogging in nozzles, and enhances the quality of three-dimensional shaped articles by minimizing solidification shrinkage and defects, leading to improved fluidity and packing density, resulting in high-quality products.
Implementation Method 1
the nanoparticles are adhered to or mixed with the metal particles... reduce attractive forces between particles
Implementation Method 2
energy beam such as laser beam or electron beam is irradiated on a predetermined position of the powder bed... the powder material of the region having received the irradiation solidifies through melting and resolidification
Implementation Method 3
energy beam such as laser beam or electron beam is irradiated on a predetermined position of the powder bed
Implementation Method 4
the powder material of the region having received the irradiation solidifies through melting and resolidification
Data Source
AI summary
The present invention relates to a metal powder material containing: metal particles having a particle diameter d10 of 10 μm or more and 100 μm or less; and nanoparticles containing a metal or a metal compound, in which the particle diameter d10 is a particle diameter at which an under-sieve cumulative fraction in a mass base distribution of particle diameter reaches 10%, and the nanoparticles are adhered to or mixed with the metal particles.