Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C21/00—Alloys based on aluminium
• • 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
  • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• • 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
  • B22F10/60—Treatment of workpieces or articles after build-up
  • B22F10/64—Treatment of workpieces or articles after build-up by thermal means
• • 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
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/12—Both compacting and sintering
  • B22F3/14—Both compacting and sintering simultaneously
  • B22F3/15—Hot isostatic pressing
• • 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
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/24—After-treatment of workpieces or articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y10/00—Processes of additive manufacturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
  • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y70/00—Materials specially adapted for additive manufacturing
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C1/00—Making non-ferrous alloys
  • C22C1/04—Making non-ferrous alloys by powder metallurgy
  • C22C1/0408—Light metal alloys
  • C22C1/0416—Aluminium-based alloys
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C21/00—Alloys based on aluminium
  • C22C21/12—Alloys based on aluminium with copper as the next major constituent
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C21/00—Alloys based on aluminium
  • C22C21/12—Alloys based on aluminium with copper as the next major constituent
  • C22C21/14—Alloys based on aluminium with copper as the next major constituent with silicon
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
  • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
  • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
• • 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
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/24—After-treatment of workpieces or articles
  • B22F2003/248—Thermal after-treatment
• • 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
  • B22F2301/00—Metallic composition of the powder or its coating
  • B22F2301/05—Light metals
  • B22F2301/052—Aluminium
• • 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
  • B22F2998/10—Processes characterised by the sequence of their steps
• • 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

• additive manufacturing is defined, according to the French standard XP E67-001, as a “set of methods for manufacturing, layer by layer, by adding material, a physical object from a digital object. ". ASTM F2792 (January 2012) also defines additive manufacturing. Different additive manufacturing modalities are also defined and described in ISO / ASTM 17296-1. The use of additive manufacturing to produce an aluminum part, with low porosity, has been described in WO2015 / 006447. The application of successive layers is generally carried out by applying a so-called filler material, then melting or sintering the filler material using a laser beam type energy source, electron beam, plasma torch or electric arc.
• each added layer is of the order of a few tens or hundreds of microns.
• An additive manufacturing means is the melting or sintering of a filler material in the form of a powder. It can be fusion or sintering by a beam of energy.
• selective laser sintering techniques selective laser sintering, SLS or direct metal laser sintering, DMLS
• a layer of metal powder or metal alloy is applied to the part to be manufactured and is selectively sintered according to the model
• SLM selective laser melting
• EBM electron beam melting
• Laser melting deposition is also known (laser melting
• LMD liquid crystal deposition
• manufacturing a high strength aluminum comprising: preparing an atomized aluminum powder having one or more desired approximate powder sizes and approximate morphology; sintering the powder to form a product by additive manufacturing; dissolution in solution; quenching; and the income from aluminum made additively.
• Patent Application EP2796229 discloses a method of forming a dispersion strengthened aluminum alloy comprising the steps of: obtaining, in a powder form, an aluminum alloy composition which is capable of acquire a dispersion enhanced microstructure; directing a low energy laser beam onto a portion of the powder having the composition of the alloy; removing the laser beam from the portion of the powdered alloy composition; and cooling the portion of the powdered alloy composition to a higher speed or equal to about 10 6 ° C per second, to thereby form the dispersion strengthened aluminum alloy metal.
• the method is particularly suitable for an alloy having a composition according to the following formula: AlcompFeaSibXc, wherein X represents at least one member selected from the group consisting of Mn, V, Cr, Mo, W, Nb and Ta; "A” ranges from 2.0 to 7.5 atomic percent; “B” ranges from 0.5 to 3.0 atomic%; “C” ranges from 0.05 to 3.5 atomic%; and the balance is aluminum and accidental impurities, provided that the [Fe + Si] / Si ratio is in the range of about 2.0: 1 to 5.0: 1.
• a light and resistant alloy performing at high temperature, comprising aluminum, silicon, and iron and / or nickel.
• Patent Application EP3026135 discloses a casting alloy
• This molding alloy is adapted to be sprayed with an inert gas to form a powder, the powder being used to form an object by additive laser manufacturing, the object then undergoing a treatment of income.
• OSiMg, AI7SiMg and AU 2Si are the most mature aluminum alloys for the SLM application. These alloys offer a very good aptitude for the SLM process but suffer from limited mechanical properties.
• the Scalmalloy® (DE102007018123A1) developed by APWorks offers (with a post-manufacturing heat treatment of 4 hours at 325 ° C) good mechanical properties at room temperature.
• this solution suffers from a high cost in powder form related to its high scandium content ( ⁇ 0.7% Sc) and the need for a specific atomization process.
• This solution also suffers from poor mechanical properties at high temperature, for example greater than 150 ° C.
• additive manufacturing depend on the alloy forming the filler metal, and more precisely on its composition, the parameters of the additive manufacturing process as well as the heat treatments applied.
• the inventors have determined an alloy composition which, used in an additive manufacturing process, makes it possible to obtain pieces having remarkable characteristics.
• the parts obtained according to the present invention have improved characteristics compared with the prior art (in particular alloy 8009), in particular in terms of hardness under heat (for example after 1 hour at 400 ° C.).
• a first object of the invention is a method for manufacturing a part comprising a formation of successive solid metal layers superimposed on each other, each layer describing a pattern defined from a numerical model, each layer being formed by the deposition of a metal, said filler metal, the filler metal being subjected to a supply of energy so as to melt and form, by solidifying, said layer, in which the metal in the form of a powder, whose exposure to an energy beam results in a melting followed by solidification so as to form a solid layer, the process being characterized in that the filler metal is a aluminum alloy comprising at least the following alloying elements:
• Ni in a mass fraction of 1 to 6%, preferably 1 to 5%, more preferably from 2 to 4%;
• Mn in a mass fraction of 1 to 7%, preferably 1 to 6%, more preferably 2 to 5%;
• Fe in a mass fraction of less than or equal to 1%, preferably from 0.05 to 0.5%, more preferably from 0.1 to 0.3%;
• alloy according to the present invention may also comprise:
• impurities with a mass fraction of less than 0.05% each (ie 500 ppm) and less than 0.15% in total;
• the alloy according to the present invention comprises a
• part of the Zr can be kept in solid solution during the SLM process and can thus allow additional hardening during post-production heat treatment, for example at 400 ° C., by formation of dispersoids nanometric type AI3Zr for example.
• the melting of the powder may be partial or total. Preferably, from 50 to 100% of the exposed powder will melt, more preferably from 80 to 100%.
• the alloy may also comprise Cu in a mass fraction of 0 to 8%, preferably 0 to 6%, more
• the alloy may also comprise at least one element chosen from: Ti, W, Nb, Ta, Y, Yb, Nd, Er, Cr, Hf, Ce, Sc, La, V, Co and / or mischmetal, in a mass fraction of less than or equal to 5%, preferably less than or equal to 3% each, and less than or equal to 15%, preferably less than or equal to 12%, and even more
• the addition of Sc is avoided, the preferred mass fraction of Sc then being less than 0.05%, and preferably less than 0.01%.
• the amount of La is less than or equal to 3% by mass fraction.
• the addition of La is avoided, the preferred mass fraction of La then being less than 0.05%, and preferably less than 0.01% by mass fraction.
• the alloy may also comprise at least one element chosen from: Sr, Ba, Sb, Bi, Ca, P, B, In and / or Sn, with a mass fraction of less than or equal to 1%, of preferably less than or equal to 0.1%, even more preferably less than or equal to 700 ppm each, and less than or equal to 2%, preferably less than or equal to 1% in total.
• the addition of Bi is avoided, the preferred mass fraction of Bi then being less than 0.05%, and preferably less than 0.01%.
• the alloy may also comprise at least one element chosen from: Ag according to a mass fraction of 0.06 to 1%, Li according to a mass fraction of 0.06 to 1%, and / or Zn according to a mass fraction of 0.06 to 1%. These elements may act on the resistance of the material by hardening precipitation or by their effect on the properties of the solid solution.
• the alloy may also comprise Mg in a mass fraction of at least 0.06% and at most 0.5%.
• Mg is not recommended and the Mg content is
• the alloy may also comprise at least one element for refining the grains and to avoid a coarse columnar microstructure, for example AITiC or AITiB2 (for example in AT5B or AT3B form), in an amount of less than or equal to 50 kg. / tonne, preferably less than or equal to 20 kg / tonne, more preferably less than or equal to 12 kg / tonne each, and less than or equal to 50 kg / tonne, preferably less than or equal to 20 kg / tonne in total.
• AITiC or AITiB2 for example in AT5B or AT3B form
• the method may comprise, following the formation of the layers:
• a heat treatment typically at a temperature of at least 100 ° C and at most 550 ° C,
• CIC hot isostatic compression
• the heat treatment may in particular allow a
• the CIC treatment can in particular make it possible to improve the elongation properties and the fatigue properties.
• Hot isostatic compression can be performed before, after or instead of heat treatment.
• the hot isostatic compression is carried out at a temperature of 250 ° C to 550 ° C and preferably 300 ° C to 450 ° C at a pressure of 500 to 3000 bar and for a period of 0, 5 to 10 hours.
• Hot isostatic compression can in this case
• the process according to the invention is advantageous because it preferably does not require solution treatment followed by quenching. Solution may have a detrimental effect on mechanical strength in some cases by participating in a magnification of dispersoids or fine intermetallic phases.
• the method according to the present invention further optionally comprises a machining treatment, and / or a chemical, electrochemical or mechanical surface treatment, and / or tribofinishing. These treatments can be carried out in particular to reduce the roughness and / or improve the corrosion resistance and / or improve the resistance to the initiation of fatigue cracks.
• a second object of the invention is a metal part, obtained by a method according to the first subject of the invention.
• a third object of the invention is a powder comprising
• an aluminum alloy comprising at least the following alloying elements:
• Ni in a mass fraction of 1 to 6%, preferably 1 to 5%, more preferably 2 to 4%;
• Mn in a mass fraction of 1 to 7%, preferably 1 to 6%, more preferably 2 to 5%;
• Fe in a mass fraction of less than or equal to 1%, preferably from 0.05 to 0.5%, more preferably from 0.1 to 0.3%;
• alloy according to the present invention can comprise
• impurities with a mass fraction of less than 0.05% each (ie 500 ppm) and less than 0.15% in total;
• the aluminum alloy of the powder according to the present invention may also comprise:
• the addition of Sc is avoided, the preferred mass fraction of Sc then being less than 0.05%, and preferably less than 0.01%.
• the amount of La is less than or equal to 3% by mass fraction.
• the addition of La is avoided, the preferred mass fraction of La being then less than
• P, B, In, and / or Sn in a mass fraction of less than or equal to 1%, preferably less than or equal to 0.1%, even more preferably less than or equal to 700 ppm each, and less than or equal to 2 %, preferably less than or equal to 1% in total.
• the addition of Bi is avoided, the preferred mass fraction of Bi then being less than 0.05%, and preferably less than 0.01%. ; and or
• Mg according to a mass fraction of at least
• the Mg content is preferably kept below an impurity value of 0.05% by mass; and or Optionally at least one element chosen for refining the grains and avoiding a coarse columnar microstructure, for example AITiC or AITiB2 (for example in AT5B or AT3B form), in an amount of less than or equal to 50 kg / tonne, preferably less than or equal to 20 kg / ton, even more preferably less than or equal to 12 kg / ton each, and less than or equal to 50 kg / ton, preferably less than or equal to 20 kg / tonne in total.
• AITiC or AITiB2 for example in AT5B or AT3B form
• FIG. 1 is a diagram illustrating an additive manufacturing process of SLM type, or EBM.
• FIGs. 2 shows a micrograph of a cross section of a
• FIG. 1 generally describes an embodiment, in which
• the filler material is in the form of an alloy powder according to the invention.
• a source of energy for example a laser source or an electron source 31, emits a beam of energy, for example a laser beam or an electron beam 32.
• the energy source is coupled to the input material by an optical system or electromagnetic lenses 33, the movement of the beam can thus be determined according to a digital model M.
• the energy beam 32 follows a movement along the longitudinal plane XY, describing a pattern dependent on the numerical model M.
• the powder 25 is deposited on a support 10. The interaction of the energy beam 32 with the powder 25 generates a selective fusion of the latter, followed solidification, resulting in the formation of a layer 20i ... 20 n . When a layer has been formed, it is coated with powder of the filler metal and another layer is formed, superimposed on the layer previously made.
• the thickness of the powder forming a layer may for example be 10 to 100 ⁇ m.
• This additive manufacturing method is typically known as selective laser melting (SLM) when the energy beam is a laser beam, the process being in this case
• EBM electron beam melting
• the layer is obtained by selective sintering by laser (selective laser sintering, SLS or direct metal laser sintering, DMLS), the layer of alloy powder according to the invention being sintered selectively according to the numerical model chosen with thermal energy provided by a laser beam.
• laser selective laser sintering, SLS or direct metal laser sintering, DMLS
• the powder is sprayed and melted simultaneously by a generally laser beam. This process is known as laser melting deposition.
• Direct Energy Deposition Direct Energy Deposition, DED
• direct deposit of metal Direct Metal Deposition, DMD
• direct laser deposit Direct Laser Deposition, DLD
• laser deposition technology Laser Deposition Technology, LDT
• Laser Metal Deposition Laser Deposition, LMD
• Laser Engineering Net Shaping LENS
• Electroplating Technology laser Laser Cladding Technology, LCT
• LCT Laser Cladding Technology
• the method according to the invention is used for producing a hybrid part comprising a part 10 obtained by conventional rolling and / or spinning and / or molding and / or forging optionally followed by machining and an integral part 20 obtained by additive manufacturing.
• This embodiment may also be suitable for the repair of parts obtained by conventional methods.
• the metal parts obtained by the process according to the invention are particularly advantageous because they have a hardness in the raw state of manufacture lower than that of a reference in 8009, and at the same time a hardness after a superior heat treatment that of a reference in 8009.
• the hardness of the alloys according to the present invention increases between the raw state of manufacture and the state after a heat treatment .
• the lower crude hardness of manufacturing the alloys according to the present invention with respect to an 8009 alloy is considered advantageous for SLM processability, by inducing a lower stress level during SLM manufacture and thus lower sensitivity to hot cracking.
• the higher hardness after a heat treatment (for example 1 hour at 400 ° C.) of the alloys according to the present invention with respect to an 8009 alloy provides a better thermal stability.
• the heat treatment could be a post-manufacturing SLM hot isostatic pressing (CIC) stage.
• CIC post-manufacturing SLM hot isostatic pressing
• the alloys according to the present invention are softer in the raw state of manufacture but have a better hardness after heat treatment, resulting in better mechanical properties for the parts in use.
• the Knoop hardness HK0,05 in the raw state of manufacture of the metal parts obtained according to the present invention is preferably from 110 to 250 HK, more preferably from 130 to 220 HK.
• the Knoop HK0,05 hardness of the metal parts obtained according to the present invention after a heat treatment of at least 100 ° C. and at most 550 ° C. and / or a hot isostatic compression, for example after 1 h at 400 ° C, is 140 to 300 HK, more preferably 150 to 250 HK.
• the protocol for measuring the Knoop hardness is described in the examples below.
• average particle size of 5 to 100 miti, preferably 5 to 25 miti, or 20 to 60 miti.
• the values given mean that at least 80% of the particles have an average size in the specified range;
• the sphericity of a powder can for example be determined using a morphogranulometer
• the flowability of a powder may for example be determined according to ASTM B213 or ISO 4490: 2018. According to ISO 4490: 2018, the flow time is preferably less than 50 s;
• the porosity preferably from 0 to 5%, more preferably from 0 to 2%, even more preferably from 0 to 1% by volume.
• the porosity can in particular be determined by scanning electron microscopy or by helium pycnometry (see ASTM B923);
• the powder according to the present invention can be obtained by means of
• the powder can be obtained by mixing primary powders before exposure to the energy beam, different compositions of the primary powders having an average composition corresponding to the composition of the alloy according to the invention.
• infusible, non-soluble particles for example oxides or particles T1B2 or carbon particles
• these particles can be used to refine the microstructure. They can also be used to harden the alloy if they are nanoscale. These particles may be present in a volume fraction of less than 30%, preferably less than 20%, more preferably less than 10%.
• the powder according to the present invention can be obtained for example by gas jet atomization, plasma atomization, water jet atomization, ultrasonic atomization, centrifugal atomization, electrolysis and spheronization, or grinding and spheronization.
• the powder according to the present invention is obtained by gas jet atomization.
• the gas jet atomization method has the advantage of producing a powder having a spherical shape, in contrast to the water jet atomization which produces a powder having an irregular shape.
• Another advantage of gas jet atomization is a good powder density, in particular due to the spherical shape and the particle size distribution. Yet another advantage of this method is good reproducibility of the particle size distribution.
• the powder according to the present invention may be steamed, in particular to reduce its moisture.
• the powder can also be packaged and stored between its manufacture and its use.
• the powder according to the present invention may especially be used in the following applications:
• selective laser sintering Selective Laser Sintering or SLS
• direct sintering of metal by laser Direct Metal Laser Sintering or DMLS in English
• SLM Selective Laser Melting
• EBM Electron Beam Melting
• Laser melting deposition Laser Melting Deposition
• direct deposit by contribution of energy Direct Energy Deposition or DED in English
• direct deposit of metal Direct Metal Deposition or DMD in English
• direct laser deposit Direct Laser Deposition or DLD in English
• Laser Deposition Technology Laser Deposition Technology or LDT
• LCD laser cladding technology
• LFMT laser freeform manufacturing technology
• laser melting deposit Laser Metal Deposition or LMD in English
• cold spraying Cold Spray Consolidation or CSC
• friction additive manufacturing Additional Friction Stir or AFS
• Alloys according to the present invention called Innovl, Innnov2 and Innnov3, and an alloy 8009 of the prior art were cast in a copper mold using an Induthem VC 650V machine to obtain ingots of 130 mm in height. , 95 mm wide and 5 mm thick.
• the composition of the alloys, obtained by ICP, is given as a percentage of mass fraction in the following Table 1.
• the alloys as described in Table 1 above were tested by a rapid prototyping method. Samples were machined for scanning the surface with a laser, in the form of platelets of dimensions 60 ⁇ 22 ⁇ 3 mm, from the ingots obtained above. The wafers were placed in an SLM machine and surface sweeps were performed with a laser using the same scanning strategy and process conditions representative of those used for the SLM process. It has indeed been found that it is possible in this way to evaluate the suitability of the alloys for the SLM process and in particular the surface quality, the sensitivity to hot cracking, the hardness in the raw state and the hardness. after heat treatment. Under the laser beam, the metal melts in a bath 10 to 350 pm thick. After passing the laser, the metal cools rapidly as in the SLM process. After laser scanning, a thin surface layer 10 to 350 ⁇ m thick was melted and then solidified. The properties of the metal in this layer are close to the properties of the metal at the core of a part manufactured by SLM because the scanning parameters are
• the laser scanning of the surface of the various samples was carried out using a 3DSystems ProX300 selective laser melting machine.
• the laser source had a power of 250 W, the vector deviation was 60 ⁇ m, the scanning speed was 300 mm / s and the beam diameter was 80 ⁇ m.
• Hardness is an important property for alloys. Indeed, if the hardness in the recoat layer by scanning the surface with a laser is high, a part made with the same alloy will potentially have a high breaking strength.
• the hardness was measured at room temperature according to the Knoop scale with a load of 50 g after laser treatment (in the raw state) and after additional heat treatment at 400 ° C. for different durations (1 h, 4 hours). h and 10 h), in particular to evaluate the suitability of the alloy for hardening during a heat treatment and the effect of a possible CIC treatment on the mechanical properties.
• the alloys according to the present invention showed a Knoop hardness HK0.05 in the raw state lower than that of the reference alloy 8009, but after a heat treatment at 400 ° C. , higher than that of the reference alloy 8009.
• the Knoop HK0,05 hardness of the alloys according to the present invention was increased by the heat treatment of 1 hour and 4 hours. This increase would be related to the formation during heat treatment of Zr based hardening dispersoids.
• the Knoop hardness HK0.05 of the 8009 reference was greatly reduced by the heat treatment. The response of the alloy according to the present invention to a heat treatment is thus improved compared to that of a reference alloy in 8009.
• Table 2 above shows the best thermal stability of the alloys according to the present invention relative to the reference alloy 8009. Indeed, the hardness of alloy 8009 dropped sharply from the beginning of the heat treatment, then reached a plateau. On the contrary, the hardness of the alloys according to the present invention first increased and then decreased gradually. Finally, the addition of Cu in the alloy according to the present invention has further increased the hardness HK0,05 while maintaining good thermal stability.
• the ingots of each alloy were then converted into powder by atomization using a VIGA atomizer (Vacuum Inert Gas Atomization).
• the particle size of the powder of each alloy was measured by laser diffraction with a Malvern 2000 instrument and is given in Table 4 below.
• the Invention 3 alloy seems particularly advantageous, as shown in the tables below.
• the powder of the Invention 3 alloy has been used successfully for SLM testing using an EOS M290 laser selective melting machine. The tests were carried out with the following parameters: layer thickness: 60 miti, 370-390 W laser power, plateau heating at around 200 ° C, vector deviation 0.11-0.13 mm, laser speed 1000-1400 mm / s.
• test pieces Two types were printed:
• the cracking specimens of the alloy Invention 3 showed a very low sensitivity to cracking.
• cylinders of the alloy Invention 3 underwent a relaxation heat treatment of 2 hours at 300 ° C. Some test pieces were used in the raw state of relaxation and others were further treated for 1 hour or 4 hours at 400 ° C (hardening annealing).
• the alloys according to the present invention therefore make it possible to dispense with a conventional thermal treatment of the solution / quench / tempering type.
• the 1 hour heat treatment at 400 ° C can simulate a hot isostatic pressing stage and / or a long aging (> 1000h) at the test temperature (service temperature).
• the invention Invention 3 thus combines a very good processability in SLM (very low sensitivity to cracking), very good mechanical properties at room temperature, at 200 ° C and 250 ° C.
• the powder of the alloys 1, 4 and 5 has been used successfully for SLM tests using a selective laser melting machine.
• FormUp 350 marketed by the company AddUp.
• the tests were carried out with the following parameters: layer thickness: 60pm, power of the 370W-390W laser, plateau heating at around 200 ° C, vector deviation 0.11-0.13 mm, laser speed 1000-1400 mm / s.
• Cylindrical specimens (45 mm in height and 11 mm in diameter) for tensile tests in the direction of construction Z (most critical direction) were printed.
• the cylinders of the alloys 1, 4 and 5 have undergone a flash heat treatment of 2 hours at 300 ° C. Some test pieces were used in the raw state of relaxation and others were further treated for 1 hour at 400 ° C (hardening annealing).
• the alloys tested have a yield strength in the raw state greater than 250 MPa and exceeding 400 MPa for the alloys of invention 1 and invention 4.
• the heat treatment of 1 hour at 400 ° C. can simulate a step of
• the alloys tested thus combine a very good processability in SLM (very low sensitivity to cracking), very good mechanical properties at room temperature, at 200 ° C and 250 ° C.

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• 2018
  • 2018-07-09 FR FR1870820A patent/FR3083479B1/fr active Active
• 2019
  • 2019-04-05 JP JP2020570514A patent/JP7314184B2/ja active Active
  • 2019-04-05 KR KR1020217002276A patent/KR20210030939A/ko not_active Application Discontinuation
  • 2019-04-05 DE DE19720977.8T patent/DE19720977T1/de active Pending
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