Metal material composition for additively manufactured parts

Abstract

The invention relates to a method for producing precise components, preferably machining tools or cold forming tools, cold extrusion punches and dies, by laser melting or laser sintering or laser deposit welding or FDM or binder jetting of a powder material, which consists of a mixture of at least two powder elements, the powder mixture being formed by the primary component iron powder and additional powder alloying elements, which are present in elemental, pre-alloyed or partially pre-alloyed form, the powder elements each being added separately or in arbitrary combination in the following quantities according to the standard DIN EN 10027-2 no. 1.33XX or DIN EN 10027-2 no. 1.27XX, in particular according to the standard DIN EN 10027-2 no. 1.3343 with the short name HS6-5-2C or DIN EN 10027-2 no. 1.2709, a powder alloy being created from said powder elements over the course of the laser sintering process, wherein the following powder elements, present in elemental, alloyed or pre-alloyed form, are each additionally added to the alloy separately or in arbitrary combination: tungsten in the range of between 35, 10 and 0.7 mass%, preferably 10 mass%, titanium in the range of between 0.2, 3.2 to 10.7 mass%, preferably 3.2 mass%, carbon in the range of between 0.08, 1.23 up to 4.1 mass%, preferably 1.23 mass%, O in the range of between 0.00 up to 0.02 mass%, N in the range of between 0.00 up to 0.02 mass%, undefined residual substances at less than 0.1 mass%.

Claims

1. Method for producing precise components, preferably machining tools or cold forming tools, cold extrusion punches and dies, by laser melting or FDM or binder jetting of a powder material, which consists of a mixture of at least two powder elements, the powder mixture being formed by the primary component iron powder and additional powder alloying elements, which are present in elemental, pre-alloyed or partially pre-alloyed form, the powder elements each being added separately or in arbitrary combination in the following quantities according to the standard DIN EN 10027-2 no. 1.33XX or DIN EN 10027-2 no. 1.27XX, the combination XX being a two-digit number, and the powder elements being added in particular according to DIN standard EN 10027-2 no. 1.3343 with the short name HS6-5-2C or DIN EN 10027-2 no. 1.2709 with the short name X3NiCoMoTi18-9-5: 1.1 Iron: up to 79.75 mass%, 1.2 Carbon: from 0.86 to 0.94 mass%, 1.3 Chromium: from 3.80 to 4.50 mass%, 1.4 Manganese: less than 0.40 mass%, 1.5 Phosphorus: up to 0.03 mass%, 1.6 Sulfur: up to 0.03 mass%, 1.7 Silicon: less than 0.45 mass%, 1.8 Vanadium: from 1.70 up to 2.00 mass%, 1.9 Tungsten: from 5.9 up to 6.7 mass%, 1.10 Molybdenum: from 4.7 to 5.2 mass%, a powder alloy being created from said powder elements over the course of the laser sintering process, characterized in that the following powder elements, present in elemental, alloyed or pre-alloyed form, are each additionally added to the alloy separately or in arbitrary combination: 1.11 Tungsten: in the range of between 0.7, 10 and 35 mass%, preferably 10 mass%, 1.12 Titanium: in the range of between 0.2, 3.2 to 10.7 mass%, preferably 3.2 mass%, 1.13 Carbon: in the range of between 0.08, 1.23 up to 4.1 mass%, preferably 1.23 mass%, 1.14 O: in the range of between 0.00 up to 0.02 mass%, 1.15 N: in the range of between 0.00 up to 0.02 mass%, 1.16 Undefined residual substances at less than 0.05 mass%.

2. Method for producing precise components, preferably high-strength components for the aerospace industry in order to achieve high strength with good toughness at a low density, good hot formability and weldability, by laser melting or laser sintering or laser deposit welding or FDM or binder jetting of a powder material, which consists of a mixture of at least two powder elements, the powder mixture being formed by the primary component titanium powder and additional powder alloying elements, which are present in elemental, pre-alloyed or partially pre-alloyed form, the powder elements each being added separately or in arbitrary combination in the following quantities according to the standard DIN EN 10027-2 no. 3.71XX, in particular according to the standard DIN EN 10027-2 no. 3.7165 with the short name Titan Grade 5: 2.1 Titanium: in the range of between 88.74 and 91 mass%, 2.2 Aluminum: in the range of between 5.50 and 6.75 mass%, 2.3 Vanadium: in the range of between 3.50 and 4.50 mass%, 2.4 Hydrogen (H): less than 0.02 mass%, a powder alloy being created from said powder elements over the course of the laser melting process, characterized in that the following powder elements, present in elemental, alloyed or pre-alloyed form, are each additionally added to the alloy separately or in arbitrary combination: 2.5 Tungsten: in the range of between 0.7, 10 and 35 mass%, preferably 10 mass%, 2.6 Titanium: in the range of between 0.2, 3.2 to 10.7 mass%, preferably 3.2 mass%, 2.7 Carbon: in the range of between 0.08, 1.23 up to 4.1 mass%, preferably 1.23 mass%, 2.8 O: in the range of between 0.00 up to 0.02 mass%, 2.9 N: in the range of between 0.00 up to 0.02 mass%, 2.10 Undefined residual substances at less than 0.05 mass%.

3. Method for producing precise components, preferably machining tools or cold forming tools, in particular high-performance cutting tools (dies and punches); milling cutters, broaches; sectioning, punching and cutting tools; thread rolling and rolling tools; woodworking tools; machine knives; plastics molds, measuring tools, tools for stamping technology; drawing, deep-drawing and extrusion tools; pressing tools for the ceramic and pharmaceutical industry; cold rolls for multi-roll stands; forming and bending tools, by laser melting or laser sintering or laser deposit welding or FDM or binder jetting of a powder material, which consists of a mixture of at least two powder elements, the powder mixture being formed by the primary component iron powder and additional powder alloying elements, which are present in elemental, pre-alloyed or partially pre-alloyed form, the powder elements each being added separately or in arbitrary combination in the following quantities according to the standard DIN EN 10027-2 no. 1.23XX, in particular according to the standard DIN EN 10027-2 no. 1.2379 with the short name X155CrVMo12-1 and the chemical composition C 1.55 / Si 0.4 / Mn 0.3 / Cr 11.8 / Mo 0.75 / V 0.82, or other chromium-nickel steels being added, in particular if the chemical composition is quantified as follows: 3.1 Iron: up to 84.05 mass%, 3.2 Carbon: up to 1.55 mass%, 3.3 Chromium: up to 12.00 mass%, 3.4 Molybdenum: up to 0.80 mass%, 3.5 Vanadium: up to 0.90 mass%, 3.6 Silicon: up to 0.40 mass%, 3.7 Manganese: up to 0.30 mass%, characterized in that the following powder elements, present in elemental, alloyed or pre-alloyed form, are each additionally added to the alloy separately or in arbitrary combination: 3.8 Tungsten: in the range of between 0.7, 10 and 35 mass%, preferably 10 mass%, 3.9 Titanium: in the range of between 0.2, 3.2 to 10.7 mass%, preferably 3.2 mass%, 3.10 Carbon: in the range of between 0.08, 1.23 up to 4.1 mass%, preferably 1.23 mass%, 3.11 O: in the range of between 0.00 up to 0.02 mass%,.

4. Method for producing precise components from austenitic stainless steel 1.4404 (316 L) with good acid resistance, preferably for chemical apparatus construction, in sewage treatment plants and in the paper industry, for mechanical components with increased requirements for corrosion resistance, in particular in media containing chloride and for hydrogen, by laser melting or laser sintering or laser deposit welding or FDM or binder jetting of a powder material, which consists of a mixture of at least two powder elements, the powder mixture being formed by the primary component iron powder and additional powder alloying elements, which are present in elemental, pre-alloyed or partially pre-alloyed form, the powder elements each being added separately or in arbitrary combination in the following quantities according to the standard DIN EN 10027-2 no. 1.44XX, in particular according to the standard DIN EN 10027-2 no. 1.4404 with the EN short name X2CrNiMo17-12-2: 4.1 Iron: up to 62.80 mass%, 4.2 Carbon: up to 0.03 mass%, 4.3 Silicon: up to 1.00 mass%, 4.4 Manganese: up to 2.00 mass%, 4.5 Phosphorus: up to 0.05 mass%, 4.6 Sulfur: up to 0.02 mass%, 4.7 Chromium: in the range of between 16.50 and 18.50 mass%, 4.8 Molybdenum: in the range of between 2.00 up to 2.50 mass%, 4.9 Nickel: in the range of between 10.00 up to 13.00 mass%, 4.10 Nitrogen: up to 0.11 mass%, characterized in that the following powder elements, present in elemental, alloyed or pre-alloyed form, are each additionally added to the alloy separately or in arbitrary combination: 4.11 Tungsten: in the range of between 0.7, 10 and 35 mass%, preferably 10 mass%, 4.12 Titanium: in the range of between 0.2, 3.2 to 10.7 mass%, preferably 3.2 mass%, 4.13 Carbon: in the range of between 0.08, 1.23 up to 4.1 mass%, preferably 1.23 mass%, 4.14 O: in the range of between 0.00 up to 0.02 mass%, 4.15 N: in the range of between 0.00 up to 0.02 mass%, 4.16 Undefined residual substances at less than 0.05 mass%.

5. Method for producing precise components from an iron-nickel-chromium-molybdenum alloy with the addition of nitrogen, preferably for use in chemistry and petrochemistry, in ore digestion plants, in environmental and marine technology, and in oil and gas extraction, by laser melting or laser sintering or laser deposit welding or FDM or binder jetting of a powder material, which consists of a mixture of at least two powder elements, the powder mixture being formed by the primary component iron powder and additional powder alloying elements, which are present in elemental, pre-alloyed or partially pre-alloyed form, the powder elements each being added separately or in arbitrary combination in the following quantities according to the standard DIN EN 10027-2 no. 1.45XX, in particular according to the standard DIN EN 10027-2 no. 1.4562 with the EN material short name X1NiCrMoCu32-28-7: 5.1 Iron: up to 60.92 mass%, 5.2 Carbon: up to 0.02 mass%, 5.3 Silicon: up to 0.30 mass%, 5.4 Manganese: up to 2.00 mass%, 5.5 Phosphorus: up to 0.02 mass%, 5.6 Sulfur: up to 0.10 mass%, 5.7 Chromium: in the range of between 26.00 and 28.00 mass%, 5.8 Copper: in the range of between 1.00 and 1.40 mass%, 5.9 Nickel: in the range of between 30 and 32 mass%, 5.10 Molybdenum: in the range of between 6.00 and 7.00 mass%, 5.11 Nitrogen: in the range of between 0.15 and 0.25 mass%, characterized in that the following powder elements, present in elemental, alloyed or pre-alloyed form, are each additionally added to the alloy separately or in arbitrary combination: 5.12 Tungsten: in the range of between 0.7, 10 and 35 mass%, preferably 10 mass%, 5.13 Titanium: in the range of between 0.2, 3.2 to 10.7 mass%, preferably 3.2 mass%, 5.14 Carbon: in the range of between 0.08, 1.23 up to 4.1 mass%, preferably 1.23 mass%, 5.15 O: in the range of between 0.00 up to 0.02 mass%, 5.16 N: in the range of between 0.00 up to 0.02 mass%, 5.17 Undefined residual substances at less than 0.05 mass%.

6. Method for producing precise components, preferably machining tools as high-speed steel with high toughness and good cutting performance or cold forming tools, in particular high-performance cutting tools (dies and punches); milling cutters, broaches; sectioning, punching and cutting tools; thread rolling and rolling tools; woodworking tools; machine knives; plastics molds, measuring tools, tools for stamping technology; drawing, deep-drawing and extrusion tools; pressing tools for the ceramic and pharmaceutical industry; cold rolls for multi-roll stands; forming and bending tools, by laser melting or laser sintering or laser deposit welding or FDM or binder jetting of a powder material, which consists of a mixture of at least two powder elements, the powder mixture being formed by the primary component iron powder and additional powder alloying elements, which are present in elemental, pre-alloyed or partially pre-alloyed form, the powder elements each being added separately or in arbitrary combination in the following quantities according to the standard DIN EN 10027-2 no. 1.33XX, in particular according to the standard DIN EN 10027-2 no. 1.3343 with the short name HS6-5-2C, or other chromium-nickel steels being added, in particular if the chemical composition is quantified as follows: 6.1 Iron: up to 79.75 mass%, 6.2 Carbon: in the range of between 0.86 and 0.94 mass%, 6.3 Chromium: in the range of between 3.80 and 4.50 mass%, 6.4 Manganese: less than 0.40 mass%, 6.5 Phosphorus: less than 0.03 mass%, 6.6 Sulfur: up to 0.03 mass%, 6.7 Silicon: less than 0.45 mass%, 6.8 Vanadium: in the range of between 1.70 up to 2.00 mass%, 6.9 Tungsten: in the range of between 5.9 up to 6.7 mass%, 6.10 Molybdenum: in the range of between 4.7 up to 5.2 mass%, characterized in that the following powder elements, present in elemental, alloyed or pre-alloyed form, are each additionally added to the alloy separately or in arbitrary combination: 6.11 Carbon in the form of diamond powder: in the range of between 1.15 to 50 mass%, preferably 15 mass%.

7. Method for producing precise components, preferably machining tools as high-speed steel with high toughness and good cutting performance or cold forming tools, in particular high-performance cutting tools (dies and punches); milling cutters, broaches; sectioning, punching and cutting tools; thread rolling and rolling tools; woodworking tools; machine knives; plastics molds, measuring tools, tools for stamping technology; drawing, deep-drawing and extrusion tools; pressing tools for the ceramic and pharmaceutical industry; cold rolls for multi-roll stands; forming and bending tools, by laser melting or laser sintering or laser deposit welding or FDM or binder jetting of a powder material, which consists of a mixture of at least two powder elements, the powder mixture being formed by the primary component iron powder and additional powder alloying elements, which are present in elemental, pre-alloyed or partially pre-alloyed form, the powder elements each being added separately or in arbitrary combination in the following quantities according to the standard DIN EN 10027-2 no. 1.33XX, in particular according to the standard DIN EN 10027-2 no. 1.3343 with the short name HS6-5-2C, or other chromium-nickel steels being added, in particular if the chemical composition is quantified as follows: 7.1 Iron: up to 79.75 mass%, 7.2 Carbon: in the range of between 0.86 and 0.94 mass%, 7.3 Chromium: in the range of between 3.80 and 4.50 mass%, 7.4 Manganese: less than 0.40 mass%, 7.5 Phosphorus: less than 0.03 mass%, 7.6 Sulfur: up to 0.03 mass%, 7.7 Silicon: less than 0.45 mass%, 7.8 Vanadium: in the range of between 1.70 up to 2.00 mass%, 7.9 Tungsten: in the range of between 5.9 up to 6.7 mass%, 7.10 Molybdenum: in the range of between 4.7 up to 5.2 mass%, characterized in that the following powder elements, present in elemental, alloyed or pre-alloyed form, are each additionally added to the alloy separately or in arbitrary combination: 7.11 Boron: up to 56.18 mass%, 7.12 Nitrogen: up to 43.53 mass%.

8. Method according to claim 1, characterized in that powdered boron nitrides and/or a powdered diamond powder and/or a powdered carbide powder are added to the powder composition according to claim 1.

9. Method according to claim 8, characterized in that the boron nitride and/or carbide and/or diamond powder bodies used have a cubic shape (CBN) and/or a broken shape with a grain size in the range of between 1 to 40 micrometers.

10. Method according to claim 1, characterized in that the melting temperature of the ceramic and/or carbide powder composition used is far above the melting temperature of the metal powder compositions and only the metal powder compositions are melted in the SLM or SLS or laser deposit welding or FDM or binder jetting process.

11. Method for producing precise components, preferably machining tools or cold forming tools, cold extrusion punches and dies, by laser melting or laser sintering or laser deposit welding or FDM or binder jetting of a powder material, which consists of a mixture of at least two powder elements, characterized by the following method steps: 1. Processing a material 1.33XX or 3.71XX or 1.23XX or 1.44XX or 1.45XX or 1.27XX in the SLM or SLS method 2. Mixing the 1.33XX or 3.71XX or 1.23XX or 1.44XX or 1.45XX or 1.27XX material with carbides 3. In particular, mixing the 1.33XX or 3.71XX or 1.23XX or 1.44XX or 1.45XX or 1.27XX material with 1% to 50% carbides 4. Mixing the base material with carbides according to number 3 in the SLM or SLS method 5. Mixing the selected materials mentioned here with carbides 6. Mixing powder components according to numbers 2 to 5 with boron nitrides 7. General mixing of base material with carbides for additive manufacturing (FDM, LAS...) 8. Adding diamond powder to all powder preparations according to numbers 1 to 7.

12. Method according to claim 11, characterized by the following method steps: 1. Processing the material 1.3343 or 3.7165 or 1.2379 or 1.4404 or 1.4562 or 1.2709 in the SLM or SLS method 2. Mixing the 1.3343 or 3.7165 or 1.2379 or 1.4404 or 1.4562 or 1.2709 material with carbides 3. In particular, mixing the 1.3343 or 3.7165 or 1.2379 or 1.4404 or 1.4562 or 1.2709 material with 1% to 50% carbides 4. Mixing the base material with carbides according to number 3 in the SLM or SLS or laser deposit welding or FDM or binder jetting method 5. Mixing the selected materials mentioned here with carbides 6. Mixing powder components according to numbers 2 to 5 with boron nitrides 7. General mixing of base material with carbides for additive manufacturing (FDM, LAS...) 8. Adding diamond powder to all powder preparations according to numbers 1 to 7.

13. Metal powder alloys, the at least one metal powder composition being composed of powders according to the following material classes, the generalization XX corresponding to the following DIN standard classes, the letter sequence XX substituting a two-digit combination on the end of the relevant DIN standard, the powder composition being characterized by the following material classes alone or in any combination with one another and from any composition according to the following material classes: DIN 1.33XX, preferably, but not limited to DIN 1.3343 DIN 3.71XX, preferably, but not limited to DIN 3.7165 DIN 1.23XX, preferably, but not limited to DIN 1.2379 DIN 1.44XX, preferably, but not limited to DIN 1.4404 DIN 1.45XX, preferably, but not limited to DIN 1.4562 DIN 1.27XX, preferably, but not limited to DIN 1.2709 DIN 3.23XX, preferably, but not limited to DIN 1.2383 DIN 2.08XX, preferably, but not limited to DIN 2.0855 INCONEL XXX, preferably, but not limited to INCONEL 718.

14. Metal workpieces produced using metal powder alloys according to claim 13.

15. Metal workpieces which are produced according to the method of claim 1.

Description

[0088] In the following, the invention is explained in more detail on the basis of tables that merely show several possible embodiments. Further features and advantages of the invention that are essential to the invention are clear from the drawings and the description thereof.

[0089] In the tables and drawings:

[0090] FIG. 1: schematically shows a method sequence for the laser melting method.

[0091] FIG. 2: is a schematic sectional view through a workpiece manufactured according to the SLM method.

[0092] FIG. 3: is an approximately identical representation to FIG. 2.

[0093] Table 3: Presentation of the powder composition based on the material 1.3343 in combination with a ceramic powder additive mixture.

[0094] Table 3A: shows the powder composition obtained from Table 3 with details of the admixture ranges, with minimum admixture values being indicated in a sub-table and maximum admixture values indicated in another sub-table.

[0095] Tab. 4: Presentation of the powder composition based on the material 3.7165 in combination with a ceramic powder additive mixture.

[0096] Table 4A: shows the powder composition obtained from Table 4 with details of the admixture ranges, with minimum admixture values being indicated in a sub-table and maximum admixture values indicated in another sub-table.

[0097] Tab. 5: Presentation of the powder composition based on the material 1.2379 in combination with a ceramic powder additive mixture.

[0098] Table 5A: shows the powder composition obtained from Table 5 with details of the admixture ranges, with minimum admixture values being indicated in a sub-table and maximum admixture values indicated in another sub-table.

[0099] Tab. 6: Presentation of the powder composition based on the material 1.4404 in combination with a ceramic powder additive mixture.

[0100] Table 6A: shows the powder composition obtained from Table 6 with details of the admixture ranges, with minimum admixture values being indicated in a sub-table and maximum admixture values indicated in another sub-table.

[0101] Tab. 7: Presentation of the powder composition based on the material 1.4562 in combination with a ceramic powder additive mixture.

[0102] Table 7A: shows the powder composition obtained from Table 7 with details of the admixture ranges, with minimum admixture values being indicated in a sub-table and maximum admixture values indicated in another sub-table.

[0103] Tab. 8: Presentation of the powder composition based on the material 1.3343 in combination with a diamond powder additive mixture.

[0104] Table 8A: shows the powder composition obtained from Table 8 with details of the admixture ranges, with minimum admixture values being indicated in a sub-table and maximum admixture values indicated in another sub-table.

[0105] Tab. 9: Presentation of the powder composition based on the material 1.3343 in combination with a boron nitrite powder additive mixture.

[0106] FIG. 1 is a broad representation of a powder composition consisting of a metal powder composition 2 which is stored in a first container 1. A ceramic powder composition 4 according to the invention is provided for this metal powder composition in another container 3 and is mixed together and homogenized in a homogenizing machine 6 so as to form a powder mixture 5.

[0107] The final powder mixture 5 is fed by means of the belt 7 to a 3D laser melting machine 20, where it is poured into a tank 8.

[0108] To produce the new type of workpiece 14, a material jet 10 is then directed from the tank 8 in the direction of a construction plate 13 and, at the same time, this material composition is irradiated with the laser beam 11 by a laser gun 9, such that a vertically built-up layer structure 12 is produced.

[0109] By way of example, each layer may have a thickness of 40 micrometers. However, the invention is not restricted to this. Other layer thicknesses may be used, it being preferred for the individual layers to merge homogeneously with one another and form a uniform, homogeneous workpiece.

[0110] The workpiece 14 produced in the layer structure is shown schematically in FIG. 2 and, according to the invention, its primary component consists of a matrix material 15 that corresponds to the metal base material of the metal powder composition 2, the ceramic particles 16 of the ceramic powder composition 4 now evenly melted into the material composite of the matrix material.

[0111] It is therefore a combination material, the internal structure of which has been significantly improved by admixing or embedding a ceramic powder composition, the ceramic particles having a particle size of between 1 and 45 micrometers.

[0112] The density of the ceramic particles in the matrix material 15 is in the range of from 1.0 to 5.0, but preferably 3.80 g/cm.sup.3.

[0113] The particles may be embedded in a spherical shape, i.e. in a ball, cone or other ball-like shape, but they may also be provided as broken particles, which exhibit even better adhesion and bonding in the metal material.

[0114] It is obvious that the mechanical properties of the workpiece 14 later produced with said particles can also be altered depending on whether the ball shape or broken shape is used.

[0115] A workpiece 14 of this kind is shown, for example, in FIG. 3, which is designed as a material punch 17, for example.

[0116] The sectional image 18 shows the material structure in the tool punch 17 in a merely schematic manner.

[0117] Instead of a tool punch 17 of this kind, any other metal workpieces 14 having the superior properties can be produced, such as inserts for tools, inserts for drills, wearing parts in the food industry, in particular stirrers, mixers, nozzles and the like. In the oil and pipeline industry, too, nozzles are used, the parts of which that are exposed to wear are made from the superior material of the workpiece 14.

[0118] With the production of a new type of workpiece 14, the invention can accordingly be used in all areas where particularly hard and wear-resistant metal parts that can also be machined easily are to be used.

[0119] It is particularly advantageous that the method according to the invention substantially does not change the basic properties (hardness, toughness, rigidity, flexural fatigue strength) of the metal material used; this produces the advantage that only minor changes to the conditions of use have to be taken into account during processing and use. Nevertheless, a material similar to hard metal is produced, the abrasiveness of which is significantly increased.

TABLE-US-00017 Reference sign list 1. Container 2. Metal powder composition 3. Container 4. Ceramic powder composition 5. Powder mixture 6. Homogenizing machine 7. Path 8. Tank 9. Laser gun 10. Material jet 11. Laser beam 12. Layer structure 13. Construction plate 14. Workpiece 15. Matrix material 16. Ceramic particles 17. Tool punch 18. Sectional view 19. – 20. 3D laser melting machine