Spherical NiFeCo Metal Powder for Additive Manufacturing
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Solution Overview
Problem
Current metal powders used in additive manufacturing, thermal spraying, and laser coating processes lack optimal performance in terms of handling properties, strength, and wear resistance, necessitating the development of a powder with enhanced characteristics.
Innovation Solution
A metal powder composed of spherical particles primarily made of Ni, Fe, and Co, with a specific particle size distribution and surface area, ensuring excellent fluidity and packing properties, which results in high-strength objects and wear-resistant coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal powder is used in additive manufacturing processes, then the basic manufacturing capability is maintained, but the handling properties and strength of the resulting objects are insufficient
Solution Approach 1:
The invention changes the particle size distribution parameters to achieve optimal handling properties. Specifically, it defines a metal powder with D10 of 4 μm or more, D50 of 15 μm to 50 μm, and D60 of 70 μm or less, which improves both flowability and packing density, leading to enhanced handling properties and stronger shaped objects without requiring additional additives
Solution Approach 2:
The invention creates a composite particle structure where spherical metal particles with specific size distribution act as the base material. This composite approach, combining optimized particle morphology and size distribution, achieves both excellent handling properties and high strength in the final shaped object
2Strength
If conventional metal powder is used for thermal spraying processes, then the basic coating formation is achieved, but the wear resistance of the coating layer is insufficient
Solution Approach 1:
The invention optimizes particle size parameters (D10 ≥ 4 μm, D50: 15-50 μm, D60 ≤ 70 μm) to achieve optimal coating formation during thermal spraying. This parameter optimization ensures excellent fluidity for uniform coating distribution and high packing density for dense, wear-resistant coating layers, eliminating the need for complex multi-step processes or additional reinforcement materials
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 achieves improved handling properties and high-strength, wear-resistant coatings due to its tailored composition and particle characteristics, eliminating the need for additional additives like low-melting-point metals or aggregation prevention particles.
Implementation Method 1
spread metal powder is irradiated with a laser beam or an electron beam. The irradiation melts the metal
Implementation Method 2
spread metal powder is irradiated with a laser beam or an electron beam. The irradiation melts the metal
Implementation Method 3
The irradiation melts the metal. Then, the metal solidifies
Implementation Method 4
The irradiation melts the metal. Then, the metal solidifies
Implementation Method 5
powder particles are accelerated. The acceleration is carried out using compressed gas
Implementation Method 6
powder particles are accelerated. The acceleration is carried out using compressed gas
Implementation Method 7
The particles that are accelerated and are traveling are heated by a heating means. Examples of heating means include gas combustion flame, plasma
Implementation Method 8
The particles that are accelerated and are traveling are heated by a heating means. Examples of heating means include gas combustion flame, plasma
Implementation Method 9
These particles are collided against an object and solidified
Implementation Method 10
These particles are collided against an object and solidified
Data Source
AI summary
A problem to be solved is to provide a metal powder having a variety of excellent performances, and, in order to solve such a problem, the present invention provides a metal powder that is composed of many spherical particles; that includes at least one of Ni, Fe, and Co, in which the total content (T.C.) of the Ni, the Fe, and the Co is 50 mass% or more; that has a cumulative 10 vol% particle size D10 of 1.0 µm or more; and in which a value Y is 7.5 to 24.0 as calculated by the following mathematical equation: Y = D50 × ρ × S, where D50 represents a cumulative 50 vol% particle size of the powder, ρ represents a true density of the powder, and S represents a specific surface area of the powder.