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WO2002011929A1 - Method for producing exact parts by means of laser sintering - Google Patents

Method for producing exact parts by means of laser sintering Download PDF

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Publication number
WO2002011929A1
WO2002011929A1 PCT/DE2001/002887 DE0102887W WO0211929A1 WO 2002011929 A1 WO2002011929 A1 WO 2002011929A1 DE 0102887 W DE0102887 W DE 0102887W WO 0211929 A1 WO0211929 A1 WO 0211929A1
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WO
WIPO (PCT)
Prior art keywords
powder
mass
elements
particles
microns
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/DE2001/002887
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German (de)
French (fr)
Inventor
Abdolreza Simchi
Frank Petzoldt
Haiko Pohl
Holger LÖFFLER
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Fraunhofer Gesellschaft zur Foerderung der Angewandten Forschung eV
Original Assignee
Fraunhofer Gesellschaft zur Foerderung der Angewandten Forschung eV
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Priority to AU2001279573A priority Critical patent/AU2001279573A1/en
Priority to EP01957742A priority patent/EP1307312A1/en
Publication of WO2002011929A1 publication Critical patent/WO2002011929A1/en
Anticipated expiration legal-status Critical
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0207—Using a mixture of prealloyed powders or a master alloy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to a method for producing precise components according to the preamble of the main claim.
  • a component is then produced using the laser sintering method by sintering metal powder mixtures with three components.
  • the most important aim of the invention is to increase the melting temperature of the finished component.
  • the invention has for its object to produce metallic components in the laser sintering process inexpensively with very good mechanical properties and in high quality.
  • the powder mixture with which components are to be produced in the laser sintering process consists of the main component iron and further powder components, which can be in elementary, pre-alloyed or partially pre-alloyed form. From these powder alloy elements there is a powder alloy in the course of the laser sintering process.
  • the following additional powder elements are added individually or in any combination to the main component iron of the powder mixture: carbon C, silicon Si, copper Cu, tin Sn, nickel Ni, molybdenum Mo, manganese Mn, chromium Cr, cobalt Co, Tungsten W, Vanadium V, Titanium Ti, Phosphorus P, Boron B.
  • These powder components can be added individually or in any combination, depending on the requirements for the properties of the prefabricated component or the manufacturing process, in the following quantities: carbon C: 0.01-2% by mass, silicon Si: up to 1% by mass , Copper Cu: up to 10% by mass, tin Sn: up to 2% by mass, nickel Ni: up to 10% by mass, molybdenum Mo: up to 6% by mass, manganese Mn: up to 2% by mass or 10-13% by mass, chromium Cr: up to 5% by mass or 12-18% by mass, cobalt Co: up to 2% by mass, tungsten W up to 5% .-%, vanadium V: up to 1% by mass, titanium Ti: up to 0.5% by mass, phosphorus P: up to 1% by mass, boron B: up to 1% by mass.
  • the invention provides that the individual powder components are in elementary, alloyed or partially alloyed form. These can be powder particles that are alloyed with the main component iron. In this case they are e.g. Ferrobor, ferrochrome, ferrophosphorus or iron silicide. Further powder elements in alloyed or pre-alloyed form can also be added, e.g. Copper phosphide, which, however, are not listed individually here. It is also envisaged that the data from the above Powder mixture formed powder components is pre-alloyed in a separate process step.
  • the powder mixture consists of water or gas atomized powders, carbonyl powders, ground powders or a combination of these.
  • the powder particles of the powder mixture have a size of ⁇ 50 ⁇ m, preferably between 20-30 ⁇ m.
  • the powder particle size can be between 50 and max. 100 ⁇ m. This particle size is particularly advantageous when the components are to be manufactured quickly, ie when the powder layers are laser sintered. ne layer thickness of max. 100 ⁇ m, at which layer thickness the process can be rotated relatively quickly.
  • the main constituent of the powder mixture the iron powder
  • the iron powder has a proportion between 5 and 20% of particles of the 'size ⁇ 10 ⁇ m and the remaining amount of the powder particles has a size between 50 and 60 ⁇ m.
  • the density of the components after laser sintering can be adjusted so that either short construction times with lower component density or high property requirements (high densities with longer construction times) are taken into account.
  • the technical fields of application of the invention consist in the production of metallic prototypes (rapid prototyping), of individual parts (direct parts) or tools (e.g. mold inserts for plastic injection molding or metal die casting - rapid tooling) with the generative method direct metal laser sintering. Due to the very good mechanical properties, such parts can be used in mold and tool construction as well as in machine, plant and vehicle construction.
  • the role of the additives consists in the setting of certain mechanical, physical and chemical properties of the finished component. Furthermore, the role of the additives in increasing the absorption capacity of the iron powder by laser beams, reducing the melting point of the powder system, using low-melting elements / alloys, reduction in surface tension and viscosity as well as deoxidation to improve sintering activity to achieve high densities.
  • carbon as a fine elemental graphite increases the absorption capacity of iron / steel powder and reduces the melting point of the powder mixture through eutectic reaction and deoxidation.
  • Copper or bronze powder with a powder size of less than 45 ⁇ m acts as a low-melting element or a low-melting compound and improves the sintering activity.
  • Phosphorus and boron reduce the surface tension and the viscosity of the melt, which arises during the laser sintering process, in order to achieve a good surface quality by avoiding the formation of spheres.
  • the role of the other powder alloy elements can lie both in the setting of the desired mechanical properties and in the reaction with other elements for increased melt formation (Fe-C-Mo).
  • the powder elements carbon, molybdenum, chromium, manganese, nickel bring about the high mechanical properties of the finished component.
  • Phosphorus, boron, copper and tin have a high sintering activity.
  • the density can be varied between 70 and 95% of the theoretical density.
  • a powder mixture consisting of iron, 0.8 mass% C, 0.3 mass% B is made with the laser sintering parameters 215 W CO 2 laser, 100 mm / s laser scanning speed, 0.3 mm laser track width with a layer height of 100 ⁇ m laser sintered to a density of 80 - 85% of the theoretical density.
  • the component hardness after laser sintering is approx. 200 HV30.
  • a powder mixture consisting of iron, 0.7 - 1 M. -% C, 2 - 4 M .-% Cu, 1.5 M .-% Mo, 0.15 M .-% B is with the laser sintering parameters 215 W C0 2 lasers, 100 mm / s laser scanning speed, 0.3 mm laser track width at a layer height of 50 ⁇ m to a density of 92 +/- 1% of the theoretical density.
  • the component hardness after laser sintering is approx. 370 HV30.
  • a powder mixture consisting of iron, 1 - 1.2 M .-% C, 2 - 4 M .-% Cu, 0.4 M .-% P is with the laser sintering parameters 215 W CO 2 laser, 100 mm / s laser scanning speed , 0.3 mm laser track width with a, compared to the first example, reduced layer height of 50 ⁇ m to a density of 90 +/- 1% of the theoretical density.
  • An iron powder mixture with 0.8 mass% carbon results in roughness values of R z 150 ⁇ m and R a 29 ⁇ m after laser sintering. If the carbon content is increased to 1.6% by mass, the roughness values improve to R z 60 ⁇ m and R a 19 ⁇ m. Powder mixtures with very good mechanical properties after laser sintering have roughness values of R z 75 ⁇ m and R a 11 ⁇ m.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Automation & Control Theory (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Powder Metallurgy (AREA)

Abstract

The invention relates to a method for producing exact parts by laser a sintering powder material consisting of a mixture of at least two powder elements. The inventive method is characterized in that the powder mixture is formed by the main constituent iron powder and by other power alloy elements, which exist in elementary, prealloyed or partially prealloyed form, and in that over the course of the laser sintering process, a powder alloy is formed from these powder elements. The following powder alloy elements are added to the iron powder separately or combined in any manner: carbon, silicon, copper, tin, nickel, molybdenum, manganese, chromium, tungsten, vanadium, titanium, phosphorous and boron.

Description

Verfahren zur Herstellung präziser Bauteile mittels LasersinternProcess for the production of precise components using laser sintering

Beschreibungdescription

Die Erfindung betrifft ein Verfahren zur Herstellung präziser Bauteile gemäß dem Oberbegriff des Hauptanspruchs.The invention relates to a method for producing precise components according to the preamble of the main claim.

Ein derartiges Verfahren ist aus der EP 0 782 487 bekannt. Danach wird ein Bauteil nach dem Verfahren des Lasersinterns durch Sintern von Metallpulvermischungen mit drei Kompomenten hergestellt. Dabei ist das wichtigste Ziel der Erfindung die Erhöhung der Schmelztemperatur des fertigen Bauteiles.Such a method is known from EP 0 782 487. A component is then produced using the laser sintering method by sintering metal powder mixtures with three components. The most important aim of the invention is to increase the melting temperature of the finished component.

Bei der Herstellung von metallischen Bauteilen aus konventionellen Pulvermischungen besteht das Problem, dass die Porosität der hergestellten Bauteile relativ hoch ist und dass die Erhöhung der Dichte der fertigen Bauteile mit dem Nachteil einer niedrigen Einsatztemperatur dieser Bauteile verbunden ist.The problem with the production of metallic components from conventional powder mixtures is that the porosity of the components produced is relatively high and that the increase in the density of the finished components is associated with the disadvantage of a low operating temperature of these components.

Der Erfindung liegt die Aufgabe zugrunde, metallische Bauteile im Verfahren des Lasersinterns kostengünstig mit sehr guten mechanischen Eigenschaften und in hoher Qualität herzustellen.The invention has for its object to produce metallic components in the laser sintering process inexpensively with very good mechanical properties and in high quality.

Diese Aufgabe wird durch ein Verfahren mit den Merkmalen des Anspruchs 1 gelöst. Die Unteransprüche stellen vorteilhafte Weiterbildungen dar.This object is achieved by a method with the features of claim 1. The subclaims represent advantageous developments.

Danach besteht die Pulvermischung mit der im Verfahren des Lasersinterns Bauteile hergestellt werden sollen, aus dem Hauptbestandteil Eisen und weiteren Pulverbestandteilen, die in elementarer, vorlegierter oder in teilweise vorlegierter Form vorliegen können. Aus diesen Pulverlegierungselementen ent- steht im Verlaufe des Lasersinterprozesses eine Pulverlegierung.Thereafter, the powder mixture with which components are to be produced in the laser sintering process consists of the main component iron and further powder components, which can be in elementary, pre-alloyed or partially pre-alloyed form. From these powder alloy elements there is a powder alloy in the course of the laser sintering process.

Dem Hauptbestandteil Eisen der Pulvermischung werden je nach Anforderungen an das Fertigbauteil oder das Herstellungsverfahren folgende weitere Pulverelemente einzeln oder in beliebiger Kombination zugegeben: Kohlenstoff C, Silizium Si, Kupfer Cu, Zinn Sn, Nickel Ni, Molybdän Mo, Mangan Mn, Chrom Cr, Kobalt Co, Wolfram W, Vanadium V, Titan Ti, Phosphor P, Bor B.Depending on the requirements of the finished component or the manufacturing process, the following additional powder elements are added individually or in any combination to the main component iron of the powder mixture: carbon C, silicon Si, copper Cu, tin Sn, nickel Ni, molybdenum Mo, manganese Mn, chromium Cr, cobalt Co, Tungsten W, Vanadium V, Titanium Ti, Phosphorus P, Boron B.

Diese Pulverbestandteile können einzeln oder in beliebiger Kombination, je nach Anforderungen an die Eigenschaften des Fertigbauteils oder des Herstellungsverfahrens, in folgenden Mengen zugegeben werden: Kohlenstoff C: 0,01-2 M.-%, Silizium Si: bis zu 1 M.-%, Kupfer Cu:bis zu 10 M.-%, Zinn Sn: bis zu 2 M.-%, Nickel Ni: bis zu 10 M.-%, Molybdän Mo: bis zu 6 M.-%, Mangan Mn: bis zu 2 M.-% oder 10 - 13 M.-%, Chrom Cr: bis zu 5 M.-% oder 12 - 18 M.-%, Kobalt Co: bis zu 2 M.-%, Wolfram W bis zu 5 M.-%, Vanadium V: bis zu 1 M.-%, Titan Ti: bis zu 0,5 M.-%, Phosphor P: bis zu 1 M.-%, Bor B: bis zu 1 M.-%.These powder components can be added individually or in any combination, depending on the requirements for the properties of the prefabricated component or the manufacturing process, in the following quantities: carbon C: 0.01-2% by mass, silicon Si: up to 1% by mass , Copper Cu: up to 10% by mass, tin Sn: up to 2% by mass, nickel Ni: up to 10% by mass, molybdenum Mo: up to 6% by mass, manganese Mn: up to 2% by mass or 10-13% by mass, chromium Cr: up to 5% by mass or 12-18% by mass, cobalt Co: up to 2% by mass, tungsten W up to 5% .-%, vanadium V: up to 1% by mass, titanium Ti: up to 0.5% by mass, phosphorus P: up to 1% by mass, boron B: up to 1% by mass.

Die Erfindung sieht vor, dass die einzelnen Pulverbestandteile in elementarer, legierter oder teilweise legierter Form vorliegen. Dabei kann es sich um Pulverteilchen handeln, die mit dem Hauptbestandteil Eisen legiert sind. In diesem Fall liegen sie als z.B. Ferrobor, Ferrochrom, Ferrophosphor oder Eisensi- lizid vor. Es können auch weitere Pulverelemente in legierter oder vorlegierter Form zugegeben werden, wie z.B. Kupferphos- phid, die aber im übrigen hier nicht einizeln aufgezählt werden. Es ist auch vorgesehen, dass die aus den o.g. Pulverbestandteilen gebildete Pulvermischung in einem separaten Verfahrensschritt vorlegiert wird.The invention provides that the individual powder components are in elementary, alloyed or partially alloyed form. These can be powder particles that are alloyed with the main component iron. In this case they are e.g. Ferrobor, ferrochrome, ferrophosphorus or iron silicide. Further powder elements in alloyed or pre-alloyed form can also be added, e.g. Copper phosphide, which, however, are not listed individually here. It is also envisaged that the data from the above Powder mixture formed powder components is pre-alloyed in a separate process step.

Gemäß einer vorteilhaften Ausgestaltung der Erfindung besteht die Pulvermischung aus wasser - oder gasverdüsten Pulvern, Karbonylpulvern, gemahlenen Pulvern oder einer Kombination aus diesen.According to an advantageous embodiment of the invention, the powder mixture consists of water or gas atomized powders, carbonyl powders, ground powders or a combination of these.

Es ist vorgesehen, dass die Pulverpartikel der Pulvermischung eine Größe <50 um, bevorzugt zwischen 20-30 um aufweisen.It is envisaged that the powder particles of the powder mixture have a size of <50 μm, preferably between 20-30 μm.

In einer vorteilhaften Ausgestaltung der Erfindung ist auch vorgesehen, dass die Pulverpartikelgröße zwischen 50 und max.lOO um liegen kann. Diese Partikelgröße ist dann besonderes vorteilhaft, wenn die Bauteile schnell hergestellt werden sollen, d.h. wenn die Pulverschichten im Lasersinterverfahren ei- ne Schichtdicke von max. lOOμm aufweisen, bei welcher Schichtdicke das Verfahren relativ schnell drehgeführt werden kann.In an advantageous embodiment of the invention it is also provided that the powder particle size can be between 50 and max. 100 μm. This particle size is particularly advantageous when the components are to be manufactured quickly, ie when the powder layers are laser sintered. ne layer thickness of max. 100 μm, at which layer thickness the process can be rotated relatively quickly.

Es hat sich herausgestellt, dass eine Partikelverteilung von 30% <20 um und einer Restmenge aus Partikeln der Größe zwischen 20 und βOμ zu besonderes guten Verfahrensergebnissen' führt, da dadurch hohe 'Schüttdichte bei gleichzeitig guter Fließfähigkeit erreicht wird.It has been found that a particle distribution of 30% <20 microns and a residual amount of particles of size between 20 and βOμ 'leads, as this high' to special good method results Bulk density is achieved with good flowability.

Gemäß einer vorteilhaften Ausgestaltung nach Anspruch 9 ist vorgesehen, dass der Hauptbestandteil der Pulvermischung, das Eisenpulver, einen Anteil zwischen 5 und 20% von Partikeln der' Größe <10μm aufweist und die Restmenge der Pulverpartikel eine Größe zwischen 50 und 60 μm aufweist.According to an advantageous embodiment according to claim 9, it is provided that the main constituent of the powder mixture, the iron powder, has a proportion between 5 and 20% of particles of the 'size <10 μm and the remaining amount of the powder particles has a size between 50 and 60 μm.

Durch die optimierte Wahl der Belichtungsparameter kann die Dichte der Bauteile nach dem Lasersintern so eingestellt werden, dass entweder kurze Bauzeiten mit niedrigerer Bauteildichte oder hohe Eigenschaftsanforderungen (hohe Dichten bei längeren Bauzeiten) berücksichtigt werden.Through the optimized choice of exposure parameters, the density of the components after laser sintering can be adjusted so that either short construction times with lower component density or high property requirements (high densities with longer construction times) are taken into account.

Die technischen Anwendungsgebiete der Erfindung bestehen in der Herstellung metallischer Prototypen (Rapid Prototyping) , von Einzelteilen (Direct Parts) oder Werkzeugen (z.B. Formeinsätze für den Kunstoffspritzguss oder Metalldruckguss - Rapid Tooling) mi*t dem generativen Verfahren Direktes Metall Lasersintern. Aufgrund der sehr guten mechanischen Eigenschaften können solche Teile im Formen- und Werkzeugbau sowie im Maschinen-, Anlagen- und Fahrzeugbau verwendet werden.The technical fields of application of the invention consist in the production of metallic prototypes (rapid prototyping), of individual parts (direct parts) or tools (e.g. mold inserts for plastic injection molding or metal die casting - rapid tooling) with the generative method direct metal laser sintering. Due to the very good mechanical properties, such parts can be used in mold and tool construction as well as in machine, plant and vehicle construction.

Das erfindungsgemäße Verfahren wird im Folgenden anhand einiger Ausführungsbeispie näher beschrieben:The method according to the invention is described in more detail below on the basis of some exemplary embodiments:

Beispiel 1:Example 1:

Konventionelle Pulver werden in der gewünschten Legierungszusammensetzung miteinander gemischt, wobei die Pulvereigenschaften dabei so eingestellt werden, dass sie den Anforderungen an das Fertigbauteil oder das Verfahren entsprechen. Es ist wesentlich, dass ein gutes Fliessverhalten bei gleichzeitig hoher Schüttdichte erreicht wird. Die Rolle der Zusatzstoffe besteht in der Einstellung bestimmter mechanischer, physikalischer und chemischer Eigenschaften des fertigen Bauteils. Weiterhin kann die Rolle der Zusatzstoffe in der Erhöhung des Absorptionsvermögens des Eisenpulvers von Laserstrahlen, der Verringerung des Schmelzpunktes des Pulversystems, dem Einsatz niedrigschmelzender Elemente/Legierungen, der Ver- ringerung der Oberflächenspannung und Viskosität sowie der De- soxidation zur Verbesserung der Sinteraktivität zum Erzielen hoher Dichten bestehen. Z. B. bewirkt Kohlenstoff als feiner elementarer Graphit (Pulvergröße 1 - 2 μm) die Erhöhung des Absorptionsvermögens von Eisen-/Stahlpulver und die Verringerung des Schmelzpunktes der Pulvermischung durch eutektische Reaktion und Desoxidation. Kupfer- oder Bronzepulver mit einer Pulvergröße von kleiner 45 μm fungiert als ein niedrigschmelzendes Element bzw. eine niedrigschmelzende Verbindung und verbessert die Sinteraktivität. Phosphor und Bor verringern die Oberflächenspannung und die Viskosität der Schmelze, die während des Lasersinterprozesses entsteht, um durch das Vermeiden der Kugelbildung eine gute Oberflächenqualität zu erzielen. Die Rolle der weiteren Pulver-Legierungselemente kann sowohl in der Einstellung gewünschter mechanischer Eigenschaften als auch in der Reaktion mit anderen Elementen zur verstärkten Schmelzebildung (Fe-C-Mo) liegen. Die Pulverelemente Kohlenstoff, Molybdän, Chrom, Mangan, Nickel bewirken die hohen mechanischen Eigenschaften des fertigen Bauteils. Phosphor, Bor, Kupfer und Zinn bewirken eine hohe Sinteraktivität. Durch die Wahl geeigneter Lasersinterparameter kann die Dichte zwischen 70 und 95 % der theoretischen Dichte variiert werden.Conventional powders are mixed with one another in the desired alloy composition, the powder properties being adjusted so that they meet the requirements for the finished component or the process. It is essential that good flow behavior is achieved with a high bulk density. The role of the additives consists in the setting of certain mechanical, physical and chemical properties of the finished component. Furthermore, the role of the additives in increasing the absorption capacity of the iron powder by laser beams, reducing the melting point of the powder system, using low-melting elements / alloys, reduction in surface tension and viscosity as well as deoxidation to improve sintering activity to achieve high densities. For example, carbon as a fine elemental graphite (powder size 1 - 2 μm) increases the absorption capacity of iron / steel powder and reduces the melting point of the powder mixture through eutectic reaction and deoxidation. Copper or bronze powder with a powder size of less than 45 μm acts as a low-melting element or a low-melting compound and improves the sintering activity. Phosphorus and boron reduce the surface tension and the viscosity of the melt, which arises during the laser sintering process, in order to achieve a good surface quality by avoiding the formation of spheres. The role of the other powder alloy elements can lie both in the setting of the desired mechanical properties and in the reaction with other elements for increased melt formation (Fe-C-Mo). The powder elements carbon, molybdenum, chromium, manganese, nickel bring about the high mechanical properties of the finished component. Phosphorus, boron, copper and tin have a high sintering activity. By choosing suitable laser sintering parameters, the density can be varied between 70 and 95% of the theoretical density.

Beim direkten Lasersintern der beschriebenen Pulvermischung werden Dichten von 70 - 95 % der theoretischen Dichte erzielt. Die maximale Dichte hängt von der Belichtungsstrategie und der chemischen Zusammensetzung, der Legierungsweise sowie den Eigenschaften (Pulverform, Partikelverteilung, Pulvergröße) der verwendeten Pulvermischung ab: z.B. kann mit den Lasersinterparametern 215 W cw C02-Laser mit der Baugeschwindigkeit vonWith direct laser sintering of the powder mixture described, densities of 70-95% of the theoretical density are achieved. The maximum density depends on the exposure strategy and the chemical composition, the type of alloy and the properties (powder form, particle distribution, powder size) of the powder mixture used: e.g. with the laser sintering parameters, 215 W cw C0 2 lasers with the construction speed of

5.4 cm3 /h eine Dichte von 92 ± 1 % der theoretischen Dichte für Pulver, bestehend aus (in M.-%): 0,7 - I C, 2 - 4 Cu, bis zu5.4 cm 3 / h a density of 92 ± 1% of the theoretical density for powder, consisting of (in mass%): 0.7 - IC, 2 - 4 Cu, up to

1.5 Mo, bis zu 2 Ni, bis zu 0,4 Sn, 0,15 B, erreicht werden.1.5 Mo, up to 2 Ni, up to 0.4 Sn, 0.15 B can be achieved.

Beispiel 2:Example 2:

Eine Pulvermischung bestehend aus Eisen, 0,8 M.-% C, 0,3 M.-% B wird mit den Lasersinterparametern 215 W C02-Laser, 100 mm/s Laserscangeschwindigkeit, 0,3 mm Laserspurbreite bei einer Schichthöhe von 100 μm zu einer Dichte von 80 - 85 % der theoretischen Dichte lasergesintert. Die Bauteilhärte nach dem Lasersintern beträgt ca. 200 HV30. Beispiel 3:A powder mixture consisting of iron, 0.8 mass% C, 0.3 mass% B is made with the laser sintering parameters 215 W CO 2 laser, 100 mm / s laser scanning speed, 0.3 mm laser track width with a layer height of 100 μm laser sintered to a density of 80 - 85% of the theoretical density. The component hardness after laser sintering is approx. 200 HV30. Example 3:

Eine Pulvermischung bestehend aus Eisen, 0, 7 - 1 M. -% C, 2 - 4 M.-% Cu, 1,5 M.-% Mo, 0,15 M.-% B wird mit den Lasersinterparametern 215 W C02-Laser, 100 mm/s Laserscangeschwindigkeit, 0,3 mm Laserspurbreite bei einer Schichthöhe von 50 μm zu einer Dichte von 92 +/- 1 % der theoretischen Dichte lasergesintert. Die Bauteilhärte nach dem Lasersintern beträgt ca. 370 HV30.A powder mixture consisting of iron, 0.7 - 1 M. -% C, 2 - 4 M .-% Cu, 1.5 M .-% Mo, 0.15 M .-% B is with the laser sintering parameters 215 W C0 2 lasers, 100 mm / s laser scanning speed, 0.3 mm laser track width at a layer height of 50 μm to a density of 92 +/- 1% of the theoretical density. The component hardness after laser sintering is approx. 370 HV30.

Beispiel 4:Example 4:

Eine Pulvermischung bestehend aus Eisen, 1 - 1,2 M.-% C, 2 - 4 M.-% Cu, 0,4 M.-% P wird mit den Lasersinterparametern 215 W C02-Laser, 100 mm/s Laserscangeschwindigkeit, 0,3 mm Laserspurbreite bei einer, im Vergleich zum ersten Beispiel, verringerten Schichthöhe von 50 μm zu einer Dichte von 90 +/-1 % der theoretischen Dichte lasergesintert.A powder mixture consisting of iron, 1 - 1.2 M .-% C, 2 - 4 M .-% Cu, 0.4 M .-% P is with the laser sintering parameters 215 W CO 2 laser, 100 mm / s laser scanning speed , 0.3 mm laser track width with a, compared to the first example, reduced layer height of 50 μm to a density of 90 +/- 1% of the theoretical density.

Beispiel 5:Example 5:

Eine Eisenpulvermischung mit 0,8 M.-% Kohlenstoff ergibt nach dem Lasersintern Rauheitswerte von Rz 150 μm und Ra 29 μm. Wird der Kohlenstoffanteil auf 1,6 M.-% erhöht, verbessern sich die Rauheitswerte auf Rz 60 μm und Ra 19 μm. Pulvermischungen mit sehr guten mechanischen Eigenschaften nach dem Lasersintern weisen Rauheitswerte von Rz 75 μm und Ra 11 μm auf. An iron powder mixture with 0.8 mass% carbon results in roughness values of R z 150 μm and R a 29 μm after laser sintering. If the carbon content is increased to 1.6% by mass, the roughness values improve to R z 60 μm and R a 19 μm. Powder mixtures with very good mechanical properties after laser sintering have roughness values of R z 75 μm and R a 11 μm.

Claims

Patentansprüche claims 1. Verfahren zur Herstellung präziser Bauteile durch Lasersintern eines Pulvermaterials, das aus einer Mischung von mindestens zwei Pulverelementen besteht dadurch gekennzeichnet, dass die Pulvermischung durch den Hauptbestandteil Eisenpulver und weitere Pulverlegierungselemente gebildet ist, die in elementarer, vorlegierter oder teilweise vorlegierter Form vorliegen, wobei im Verlaufe des Lasersinterprozesses aus diesen Pulverelementen eine Pulverlegierung entsteht.1. A method for producing precise components by laser sintering a powder material consisting of a mixture of at least two powder elements, characterized in that the powder mixture is formed by the main constituent iron powder and further powder alloy elements, which are present in elementary, pre-alloyed or partially pre-alloyed form, in which During the laser sintering process, a powder alloy is created from these powder elements. 2. Verfahren nach Anspruch 1 dadurch gekennzeichnet, dass folgende, in elementarer, legierter oder vorlegierter Form vorliegende, Pulverelemente jedes für sich oder in beliebiger Kombination dem Eisenpulver zugegeben werden: Kohlenstoff, Silizium, Kupfer, Zinn, Nickel, Molybdän, Mangan, Chrom, Kobalt, Wolfram, Vanadium, Titan, Phosphor, Bor.2. The method according to claim 1, characterized in that the following, in elemental, alloyed or pre-alloyed form, powder elements are added to the iron powder, either individually or in any combination: carbon, silicon, copper, tin, nickel, molybdenum, manganese, chromium, Cobalt, tungsten, vanadium, titanium, phosphorus, boron. 3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, dass die Pulverelemente jedes für sich oder in beliebiger Kombination in folgenden Mengen zugegeben werden: Kohlenstoff: 0,01-2 M.- %, Silizium: bis zu 1 M.-%, Kupfer:bis zu 10 M.-%, Zinn: bis zu 2 M.-%, Nickel: bis zu 10 M.-%, Molybdän: bis zu 6 M.-%, Mangan: bis zu 2 M.-% oder 10 - 13 M.-%, Chrom: bis zu 5 M.-% oder 12 - 18 M.-%, Kobalt: bis zu 2 M.-%, Wolfram bis zu 5 M.- %, Vanadium: bis zu 1 M.-%, Titan: bis zu 0,5 M.-%, Phosphor: bis zu 1 M.-%, Bor: bis zu 1 M.-%.3. The method according to claim 2, characterized in that the powder elements are added individually or in any combination in the following amounts: carbon: 0.01-2% by mass, silicon: up to 1% by mass, copper: up to 10% by mass, tin: up to 2% by mass, nickel: up to 10% by mass, molybdenum: up to 6% by mass, manganese: up to 2% by mass or 10 - 13 mass%, chromium: up to 5 mass% or 12 - 18 mass%, cobalt: up to 2 mass%, tungsten up to 5 mass%, vanadium: up to 1 mass -%, titanium: up to 0.5% by mass, phosphorus: up to 1% by mass, boron: up to 1% by mass. 4. Verfahren nach einem der vorangegangenen Ansprüche dadurch gekennzeichnet, dass die Pulverelemente in legierter oder vorlegierter Form als Ferrochrom, Ferrobor, Ferrophosphor, Kup- ' ferphosphid oder Eisensilizid vorliegen.4. The method according to any one of the preceding claims, characterized in that the powder elements are present in alloyed or pre-alloyed form as ferrochrome, ferroboron, ferrophosphorus, copper ' ferphosphide or iron silicide. 5. Verfahren nach einem der vorangegangenen Ansprüche dadurch gekennzeichnet, dass die Pulvermischung aus gasverdüsten Pulvern, Karbonylpulvern, gemalenen Pulvern oder einer Kombination davon besteht.5. The method according to any one of the preceding claims, characterized in that the powder mixture consists of gas-atomized powders, carbonyl powders, painted powders or a combination thereof. 6. Verfahren nach einem der vorangegangenen Ansprüche dadurch gekennzeichnet, dass die Pulvermischung aus einer Menge von Pulverpartikeln mit einer Größe kleiner 50μm, bevorzugt zwischen 20 - 30μm besteht. 6. The method according to any one of the preceding claims, characterized in that the powder mixture consists of an amount of powder particles with a size smaller than 50 microns, preferably between 20-30 microns. 7. Verfahren nach einem der vorangegangenen Ansprüche 1 bis 5 dadurch gekennzeichnet, dass die Pulvermischung aus Partikeln mit einer Größe 50 - ax.lOOμm besteht.7. The method according to any one of the preceding claims 1 to 5, characterized in that the powder mixture consists of particles with a size 50 - ax.lOOμm. 8. Verfahren nach einem der vorangegangenen Ansprüche dadurch gekennzeichnet, dass die Pulvermischung zu 30% aus Partikeln besteht, die kleiner sind als 20um und dass die Restmenge aus Partikeln mit der Größe zwischen 20 und 60 μm besteht.8. The method according to any one of the preceding claims, characterized in that the powder mixture consists of 30% of particles that are smaller than 20 microns and that the remaining amount consists of particles with the size between 20 and 60 microns. 9. Verfahren nach einem der vorangegangenen Ansprüche dadurch gekennzeichnet, dass der Hauptbestandteil der Pulvermischung, das Eisenpulver zwischen 5 und 20% der Partikel der Größe kleiner 10 μm aufweist und dass die Restmenge aus Partikeln der Größe 50 - 60 μm besteht.9. The method according to any one of the preceding claims, characterized in that the main component of the powder mixture, the iron powder has between 5 and 20% of the particles smaller than 10 microns and that the remaining amount consists of particles of size 50 - 60 microns. 10. Verfahren nach einem der vorangegangenen Ansprüche dadurch gekennzeichnet, dass die Parameter des Lasersintervorganges wie Laserenergie, Lasergeschwindigkeit, Spurbreite und Belichtung, in Abhängigkeit von den gewünschten Eigenschaften des Fertigteiles eingestellt werden. 10. The method according to any one of the preceding claims, characterized in that the parameters of the laser sintering process such as laser energy, laser speed, track width and exposure are set as a function of the desired properties of the finished part.
PCT/DE2001/002887 2000-08-07 2001-07-27 Method for producing exact parts by means of laser sintering Ceased WO2002011929A1 (en)

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