Refractory Metal Additive Manufacturing Oxygen Reduction
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Solution Overview
Problem
Refractory metals pose challenges in additive manufacturing due to their high affinity for oxygen, leading to high oxygen content in produced components, which results in brittleness and reduced conductivity, especially with materials like niobium where high purity is required but is complex and costly to achieve.
Innovation Solution
An additive manufacturing method using electron beam melting with refractory metal powders having high oxygen content (at least 500 mol ppm) where each powder layer is selectively melted and cooled, resulting in a significant reduction of oxygen content in the final molding, achieving high purity and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-purity refractory metal powders (low oxygen content) are used, then component purity and mechanical strength are improved, but production complexity and cost increase significantly
Solution Approach 1:
The invention changes the oxygen content parameter of the powder from low (high-purity) to high (easier to produce), while compensating through process parameters (electron beam melting under vacuum/protective atmosphere) to achieve the desired component purity
Solution Approach 2:
The invention converts the harmful high oxygen content in the powder into a beneficial situation by using electron beam melting to remove oxygen during processing, ultimately achieving pure components through a simpler powder production process
2Manufacturing precision
If high-purity refractory metal powders are used, then component purity is improved, but processing and storage complexity increase
Solution Approach 1:
The invention changes the powder purity parameter to be easier to manufacture (higher oxygen content), while using electron beam processing parameters to achieve the final desired purity level in the component
Solution Approach 2:
The invention uses cheaper, easier-to-produce powders that can be handled more easily, accepting that some oxygen is present but will be removed during the electron beam melting process
3Productivity
If refractory metal powders with high surface area are used, then additive manufacturing is enabled, but oxygen contamination increases
Solution Approach 1:
The invention uses vacuum or protective atmosphere during electron beam melting to prevent oxygen contamination of the high-surface-area powder, while still enabling additive manufacturing
Solution Approach 2:
The invention accepts the high surface area powder with its oxygen absorption tendency, but uses electron beam melting to actively remove oxygen and convert this potential harm into a manageable process
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 method effectively reduces oxygen content in the final product by at least 15 mol % to 100 mol % compared to the starting powder, producing high-purity refractory metal components with improved mechanical properties and reduced brittleness.
Implementation Method 1
selectively melting at least a portion of the powder layer by means of electron beam
Implementation Method 2
melting at least a portion of the powder layer by means of electron beam
Implementation Method 3
cooling the melt below the solidification temperature to obtain a first material layer
Data Source
AI summary
Additive manufacturing method for producing moldings comprising or consisting of an element selected from the group of refractory metals, wherein refractory metal powder having an oxygen content of at least 500 mol ppm is used for the additive manufacturing method.