Nitride-Eutectic Oxide Powder for Additive Modeling
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Solution Overview
Problem
Ceramic powder bed fusion methods face challenges in achieving accurate modeling and high mechanical strength due to the difficulty in melting ceramic powders and their non-homogeneous melting behavior, which affects the density and structural integrity of the resulting ceramic components.
Innovation Solution
A powder composition for additive modeling that includes a nitride with a lower average density than the eutectic oxide, combined with a eutectic oxide system, where the nitride has an average diameter of 5 μm or more, and an absorber for efficient laser beam absorption, allowing for precise temperature control and reduced density through controlled laser irradiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramic powder is melted using high energy to achieve dense structure, then mechanical strength is improved, but modeling accuracy deteriorates due to non-homogeneous melting and light diffusion
Solution Approach 1:
The patent employs a composite powder system consisting of ceramic particles (e.g., Al2O3, SiC) combined with metal particles (e.g., Al, Cu) that have lower melting points. This composite approach allows the metal component to melt first and facilitate homogeneous energy distribution, while the ceramic component provides the desired mechanical strength and thermal properties in the final structure.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the powder material by creating a multi-component system with different melting points, thermal conductivities, and densities. This parameter optimization enables controlled melting behavior where the lower-melting-point component acts as a flux to improve overall melting homogeneity and reduce light diffusion effects.
2Strength
If high density ceramic material is used to improve mechanical strength, then strength is improved, but specific rigidity deteriorates due to high weight
Solution Approach 1:
The patent applies local quality by creating a heterogeneous microstructure where different materials are distributed at different locations within the ceramic component. High-strength ceramic particles are positioned to provide structural integrity, while lower-density metal particles are distributed to reduce overall weight, achieving optimal specific rigidity through spatial optimization of material properties.
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 solution enables the production of ceramic structures with improved mechanical strength, reduced density, and enhanced thermal shock resistance, suitable for high-specific-rigidity components like semiconductor device components, by maintaining the nitride's inherent properties and achieving a surface roughness of 0.1 mm or less.
Implementation Method 1
a technique of realizing a structure that is accurate and excellent in the mechanical strength by reducing a melting point with the use of an Al2O3—ZrO2 eutectic system
Implementation Method 2
the powder of a material is effectively melted and becomes a solidification structure group
Implementation Method 3
the powder of a material is effectively melted and becomes a solidification structure group
Data Source
AI summary
A material powder for additive modeling including a nitride, and a eutectic oxide, the nitride having an average density lower than an average density of the eutectic oxide, is used to produce a structure using an additive modeling method.