Spherical Precious Metal Powder for Dense 3D Printed Components
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Solution Overview
Problem
Challenges exist in producing precious metal components with high density and low porosity using additive manufacturing, as existing powders often compromise between flowability, powder application quality, and component density, particularly with high-melting platinum metals like iridium.
Innovation Solution
Development of a spherical precious metal powder with specific particle size distribution (d10 ≥ 10.0 µm and d90 ≤ 80.0 µm) and average crystallite size ≥ 200 nm, produced through atomization and classification processes, ensuring high flowability and quality in additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional powders are used in additive manufacturing of precious metals, then flowability may be improved, but component density and porosity are compromised
Solution Approach 1:
The patent applies parameter changes by precisely controlling particle size distribution (d10 ≥ 10.0 μm and d90 ≤ 80.0 μm) and crystallite size (≥ 200 nm) of the powder. This optimization of physical parameters enables the powder to achieve both high flowability for easy handling and high packing density for low porosity components, resolving the contradiction between ease of operation and manufacturing precision
Solution Approach 2:
The patent employs spherical powder particles with a sphericity of at least 0.90. The spherical shape inherently improves flowability by reducing interparticle friction and enabling smoother movement during powder application. Simultaneously, the uniform spherical geometry promotes efficient packing during additive manufacturing, leading to high component density and low porosity, thus resolving the contradiction between flowability and manufacturing precision
2Manufacturing precision
If powder particle size is reduced to improve packing density, then component porosity decreases, but flowability deteriorates
Solution Approach 1:
The patent optimizes the particle size distribution parameters by setting d10 ≥ 10.0 μm and d90 ≤ 80.0 μm, avoiding excessively fine particles that would harm flowability while maintaining a distribution that ensures good packing density. The crystallite size is controlled at ≥ 200 nm to balance sintering behavior and final component density, resolving the contradiction between manufacturing precision and ease of operation
3Ease of operation
If spherical powder with narrow size distribution is used to improve flowability, then powder application quality may improve, but component density decreases
Solution Approach 1:
The patent optimizes the particle size distribution parameters by setting d10 ≥ 10.0 μm and d90 ≤ 80.0 μm, avoiding excessively fine particles that would harm flowability while maintaining a distribution that ensures good packing density. The crystallite size is controlled at ≥ 200 nm to balance sintering behavior and final component density, resolving the contradiction between manufacturing precision and ease of operation
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 powder enables the production of components with high relative density (low porosity) and improved edge sharpness and surface roughness, effectively addressing the limitations of existing powders in additive manufacturing for complex 3D structures.
Implementation Method 1
the spherical precious metal particles can be produced via atomization processes
Implementation Method 2
the precious metal particles obtained via atomization can subsequently be subjected to a classification process such as sieving, air classification, or centrifugation
Implementation Method 3
the precious metal particles obtained via atomization can subsequently be subjected to a classification process such as sieving, air classification, or centrifugation
Implementation Method 4
Using a sufficiently high energy input, for example, in the form of a laser or electron beam, the powder is at least partially melted at the points specified by the computer-generated design data
Implementation Method 5
Using a sufficiently high energy input, for example, in the form of a laser or electron beam, the powder is at least partially melted at the points specified by the computer-generated design data
Implementation Method 6
the powder is at least partially melted at the points specified by the computer-generated design data. The build platform is then lowered, and another layer of powder is applied. This additional powder layer is again at least partially melted and bonds to the layer below
Data Source
AI summary
The present invention relates to a powder of spherical precious metal particles with a particle size distribution that has a d10 value of ≧10.0 μm and a d90 value of ≦80.0 μm.