WO2025149583A1 - Élimination d'oxygène dans des processus de fabrication additive à base de poudre - Google Patents

Élimination d'oxygène dans des processus de fabrication additive à base de poudre

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Publication number
WO2025149583A1
WO2025149583A1 PCT/EP2025/050464 EP2025050464W WO2025149583A1 WO 2025149583 A1 WO2025149583 A1 WO 2025149583A1 EP 2025050464 W EP2025050464 W EP 2025050464W WO 2025149583 A1 WO2025149583 A1 WO 2025149583A1
Authority
WO
WIPO (PCT)
Prior art keywords
powder
plasma
layer
delivery
plasma generator
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.)
Pending
Application number
PCT/EP2025/050464
Other languages
English (en)
Inventor
Ulf Ackelid
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Freemelt AB
Original Assignee
Freemelt AB
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Freemelt AB filed Critical Freemelt AB
Publication of WO2025149583A1 publication Critical patent/WO2025149583A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/14—Treatment of metallic powder
    • B22F1/145—Chemical treatment, e.g. passivation or decarburisation
    • 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
    • B22F10/34—Process control of powder characteristics, e.g. density, oxidation or flowability
    • 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
    • B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
    • 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
    • B22F12/10—Auxiliary heating means
    • B22F12/13—Auxiliary heating means to preheat the material
    • 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
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D 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 [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/10—Pre-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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/70—Recycling
    • B22F10/73—Recycling of powder
    • 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
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/58—Means for feeding of material, e.g. heads for changing the material composition, e.g. by mixing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • 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
    • C22C1/0425—Copper-based alloys
    • 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
    • C22C1/045—Alloys based on refractory metals

Definitions

  • the present disclosure relates generally to arrangements and methods for oxygen removal or oxide reduction in powders used in additive manufacturing such as metallic materials including metal powders.
  • oxygen bound to the powder may be disadvantageous for the additive manufacturing process in several ways.
  • Oxygen can bind either to the surface of the powder particles, for example in the form of surface oxides, or oxygen can be incorporated inside the powder particles, for example as dissolved oxygen or bulk oxides.
  • Surface oxides can affect the sintering and melting behavior of the powder, they can lead to a need for a high process temperature, and they can affect the material properties of the built material.
  • Oxides can also affect the recyclability of the powder.
  • Oxygen in the bulk of the powder can also affect the material properties of the built material as well as the recyclability of the powder.
  • a reactive gas can be fed into an apparatus for producing a three- dimensional object from a metal powder, in order to remove oxygen from the powder and/or to add carbon and/or nitrogen to the powder.
  • Oxygen is often considered as an undesired contamination in powder-based additive manufacturing technologies. Oxygen can affect the behavior of the powder in the additive manufacturing machine before the powder is consolidated into solid parts, such as recoating behavior or pre-sintering behavior. Oxygen can also affect the behavior of the powder during the consolidation by the energy beam, for example spattering behavior. Oxygen can also affect the material properties of the built parts, for example brittleness, cracking propensity, thermal conductivity or electrical conductivity. Oxygen can also affect the lifetime of the powder, that is how many times the powder can be reused before it must be scrapped.
  • oxygen could be removed in a more efficient way, it could lead to several benefits.
  • a method for oxygen removal could give benefits such as lower build temperature, reduced heat load on the E-PBF machine, increased build area, increased build speed, better material properties in built material, and better recyclability of powder.
  • a method for oxygen removal could enable successful E-PBF processing of powder materials that have been considered difficult or impossible in the past.
  • the arrangement preferably comprises an additive manufacturing apparatus for additive manufacturing by selective fusion of a three-dimensional product from a powder bed containing a powder which is exposed to an energy beam such as a laser beam or an electron beam, and a plasma generator, wherein the powder is exposed to plasma generated by the plasma generator only after being exposed to the energy beam and before a new powder layer has been supplied, and the hydrogen plasma thereby removes oxygen from the powder and/or the fused material after the fusion process.
  • an energy beam such as a laser beam or an electron beam
  • a method for oxygen removal from a powder of an electrically conductive material used in an additive manufacturing apparatus for additive manufacturing by selective fusion of a three-dimensional product build up by consecutively laid powder layers by directing an energy beam to a powder bed with the powder comprising controlling at least one plasma generator to deliver plasma and expose the powder bed to plasma only after selective melting and resolidification of a top powder layer and before distribution of a new powder layer.
  • the plasma generator is in preferred embodiments a hydrogen plasma generator but may also be a plasma generator using mixtures of hydrogen and argon or any other inert gas.
  • the powder bed is not exposed to the plasma during the powder distribution phase, the preheating phase and the melting phase, but only after melting the powder layer has finished, and before a new powder layer is distributed over the powder bed.
  • a postheating or a postcooling process to maintain thermal balance of the build.
  • process monitoring tools such as optical photography or backscatter electron imaging during this late part of the layer cycle.
  • the step of controlling comprises delivering plasma for exposure to the top powder layer synchronized with melting and distribution of a new powder layer; and exposing the top powder layer including the freshly melted and resolidified powder to plasma generated by the at least one plasma generator only after the melting and before distribution of a new powder layer.
  • the step of controlling further comprises shielding the at least one plasma generator from the powder bed during powder distribution, preheating and melting.
  • the controlling comprises generating the plasma by at least one plasma generator synchronized with melting and distribution of a new powder layer.
  • the controlling comprises the step of generating the plasma by at least one plasma generator continuously.
  • the step of controlling further comprises opening a shielding mechanism for the at least one plasma generator synchronized with the selective melting and resolidification of a top powder layer and before distribution of a new powder layer and closing the shielding mechanism after delivery of plasma.
  • the controlling further comprises moving the at least one plasma generator to an exposure position during generation and delivery of plasma and to a shielded position after delivery of plasma.
  • the controlling comprises controlling a shutter mechanism to open during delivery of plasma and to close after delivery of plasma.
  • the powder is shuffled sequentially in synchronism with delivery or exposure to plasma such that powder is distributed after the delivery of plasma to obtain a layer-by-layer exposure of the powder to plasma.
  • the powder bed is formed by distributing the powder from a powder container using a recoater mechanism, wherein the recoater mechanism is operated synchronized with the controlling of the at least one plasma generator.
  • the powder is exposed to the plasma in synchronism with distribution of the powder from the powder container to the powder bed by the recoater mechanism such that the powder is exposed to the plasma before distribution of a new powder layer.
  • hydrogen plasma is to be understood as hydrogen gas which has been excited to the level of splitting the hydrogen molecules, H2, into hydrogen free radicals with unpaired electrons, H, which are much more reactive than hydrogen molecules.
  • Plasma is generally recognized as the fourth state of matter and is fundamentally different from the three well-known states: solids, liquids and gases.
  • hydrophilicity and "plasma” are also to be understood as plasma being made from hydrogen gas only, or plasma being made from hydrogen gas mixed with at least one inert gas, such as argon or helium. Such a gas mixture may be easier to use in an additive manufacturing machine from a safety perspective, and while excited as a plasma, it still contains hydrogen free radicals capable of removing oxygen from metals.
  • oxygen is to be understood as any oxygen-containing chemical species, not only metal oxide, but also for example hydroxide, or oxygen atoms dissolved into metal.
  • Fig. 3 schematically illustrates arrangements for oxygen removal from a metal powder used in additive manufacturing, in accordance with one or more embodiments described herein.
  • Fig. 4 schematically illustrates arrangements for oxygen removal from a metal powder used in additive manufacturing, in accordance with one or more embodiments described herein.
  • Fig. 5 schematically illustrates a method for oxygen removal from a metal powder used in an additive manufacturing apparatus for additive manufacturing by selective fusion of a three-dimensional product by exposing a powder bed to an energy beam, in accordance with one or more embodiments described herein.
  • oxygen bound to the powder may constitute a problem.
  • Oxygen can be present in the powder particles in different chemical forms, for example as metal oxides on the particle surfaces, or as oxygen-rich inclusions inside the particles, or as atomic oxygen dissolved into the bulk of the particles.
  • Such bound oxygen regardless of its chemical form and location in the powder particles, may create process stability issues as well as problems with material properties in the built parts.
  • Surface oxides on the powder may reduce the electrical conductivity between powder particles which increases the risk of so-called "smoke events” and eventually a build failure of the E-PBF process.
  • Surface oxides can affect the interparticle friction in the recoating process, leading to poor packing density and/or layer thickness variation.
  • Surface oxides on the powder can also contribute to increased spatter formation in the melting process, both for L-PBF and E-PBF. Spatter is undesired since it means that material is removed from the melt pool.
  • Surface oxides can also affect the melting behavior of a powder and reduce the wettability of the melt pool, leading to so-called "balling effects”.
  • Too high oxygen content in the built parts is also a potential problem, both for E-PBF and L-PBF.
  • Unalloyed copper for example, must maintain a very low oxygen content to preserve its high electrical conductivity necessary for many industrial applications.
  • Refractory metals such as tungsten and molybdenum are other examples. Oxygen contamination is known to embrittle tungsten and molybdenum and increase the risk of cracking.
  • Oxide reduction, especially surface oxide reduction, in a metal powder may improve the electrical conductivity and/or the sinterability of the metal powder. This may enable a lower process temperature in E- PBF, which would lower the heat load on the additive manufacturing apparatus, and allow for a faster build process. This opens the possibility to build over a larger powder bed for a given beam power. There may also be less spatter from the melt pool, as well as a better cracking resistance in built material, thanks to a lower amount of oxygen in the builds. In conclusion, there are numerous cases where oxygen content is considered detrimental for additive manufacturing processes. There is thus a great need for arrangements and methods for oxygen removal, both from metal powder used in additive manufacturing and from material built in the additive manufacturing process. The present disclosure relates generally to arrangements and methods for oxygen removal in powder-based additive manufacturing processes. Embodiments of the disclosed solution are presented in more detail in connection with the figures.
  • Figs. 1a-e schematically illustrate arrangements 100 for oxygen removal in powder-based additive manufacturing processes.
  • the schematically illustrated arrangement 100 comprises an additive manufacturing apparatus 200, for additive manufacturing by selective fusion of a three-dimensional product.
  • the schematically illustrated additive manufacturing apparatus 200 comprises an energy beam source 210 and a powder bed 240, arranged in a build chamber 280.
  • the build chamber can be a vacuum chamber, typical of E-PBF, or a chamber containing inert gas, typical of L-PBF.
  • the powder bed 240 may e.g. be formed by metal powder being distributed from a powder container 230 using a recoater mechanism 290.
  • the powder bed 240 may comprise metal-based powder of any kind, such as e.g.
  • the metal powder composed of pure metal, metal alloys, intermetallics, metal matrix composite, or any powder mixture thereof.
  • the powder can also be a mixture of metal-based powder and insulating or semiconducting powder,
  • the metal powder may e.g. comprise tungsten or copper.
  • the metal powder in the powder bed 240 is exposed to a energy beam 220 from the beam source 210. During the exposure to the energy beam 220, the metal powder is melted to form a melt pool.
  • the build chamber 280 and the powder container 230 are separated with a partitioning wall 235.
  • the partitioning wall 235 is provided with a shutter mechanism 238 arranged to swiftly open and close , for example, when the recoater mechanism 290 moves back and forth to deliver metal powder into the built chamber 280.
  • a shutter mechanism 238 arranged to swiftly open and close , for example, when the recoater mechanism 290 moves back and forth to deliver metal powder into the built chamber 280.
  • the schematically illustrated arrangement 100 further comprises at least one hydrogen plasma generator 150.
  • the metal powder is exposed to hydrogen plasma generated by the hydrogen plasma generator 150 before being exposed to the energy beam 220, and/or during the exposure to the energy beam 220 (see Fig. 1d or 1 e), which allows the hydrogen plasma to remove oxygen from the metal powder (or melt pool) before (or during) the selective fusion process.
  • the hydrogen plasma generator 150 is arranged to generate and deliver hydrogen plasma into the powder container 230.
  • the hydrogen plasma generator may be arranged to generate and deliver hydrogen plasma into build chamber 280.
  • a further embodiment shown in Fig. 1d comprises one hydrogen plasma generator 150 arranged to generate and deliver hydrogen plasma into the powder container 230 and one hydrogen plasma generator 150 arranged to generate and deliver hydrogen plasma into the build chamber 280.
  • the hydrogen plasma generator 150 is therefore preferably arranged close to the metal powder, to make sure that the hydrogen plasma does not lose its reactivity before reaching the metal powder.
  • the exposing of the metal powder to hydrogen plasma takes place while the metal powder is contained in a container, which may be a separate container or the powder container 230.
  • a pump 260 is arranged for pumping or removing any gases in the powder container 260 and/or the build chamber 280, respectively.
  • the pump 260 is however only used in case an E-PBF equipment is used.
  • a L-PBF equipment may be used and in which case the pump can be omitted and a gas outflow can be used instead.
  • the exposing of the metal powder to hydrogen plasma takes place while the metal powder is contained in the powder container 230.
  • the oxide reduction may e.g. take place on the top layer of metal powder in the powder container 230, just before the distribution of the metal powder to the powder bed 240 by the recoater mechanism 290.
  • the exposing of the metal powder to the hydrogen plasma may e.g. involve directing low-pressure hydrogen plasma towards the metal powder on top of the powder container 230.
  • the hydrogen plasma generator 150 is preferably arranged in a position from where hydrogen free radicals can reach the powder container 230 with few or no intermediate collisions with other surfaces.
  • the oxide removal may be speeded up by the use of a heating device, e.g. an IR heater 270, arranged inside the additive manufacturing apparatus 200.
  • the exposure of the metal powder to the hydrogen plasma takes place before connecting the powder container 230a to the additive manufacturing apparatus 200 as shown in Fig. 1b.
  • the hydrogen plasma generator 150 is preferably connected to the tank containing the metal powder, so that the container may be filled with hydrogen plasma.
  • a higher pressure e.g. up to near atmospheric pressure.
  • Heating and/or stirring of the powder is preferably used to speed up the oxide reduction, because hydrogen plasma is not likely to penetrate into a stationary and densely packed powder volume.
  • heating can be made using an IR heating device 270 and stirring can be achieved using a mixing device or an agitator 275.
  • the metal powder is not exposed to air before being transferred to the additive manufacturing apparatus 200, to prevent re-oxidation of the metal powder.
  • this may e.g. be achieved by transferring the powder container 230 to the additive manufacturing apparatus 200 through a load-lock.
  • the powder bed 240 may comprise metal-based powder of any kind, such as e.g. metal powder composed of pure metal, metal alloys, i ntermetallics, metal matrix composite, or any powder mixture thereof.
  • the powder can also be a mixture of metal-based powder and insulating or semiconducting powder,
  • the metal powder may e.g. comprise tungsten or copper.
  • the metal powder in the powder bed 240 is exposed to an energy beam 220 from the beam source 210. During the exposure to the energy beam 220, the metal powder is melted to form a melt pool.
  • an IR heating device 270 may be arranged to heating of the powder to speed up the oxide reduction.
  • the hydrogen free radicals (H) are very reactive, they will easily recombine or react upon collision with surfaces or gaseous species. Hydrogen free radicals are therefore short lived, and energy must be continuously added to the hydrogen plasma generator 150 to maintain an active hydrogen plasma.
  • the first and second hydrogen plasma generator 150a and 150b are therefore preferably arranged close to the metal powder, to make sure that the hydrogen plasma does not lose its reactivity before reaching the metal powder.
  • a pump 260 is arranged for pumping or removing any gases in the powder container 260 and/or the build chamber 280, respectively.
  • the arrangement 104 for oxygen removal in powder-based additive manufacturing processes comprises an additive manufacturing apparatus 200, for additive manufacturing by selective fusion of a three-dimensional product comprising a hydrogen plasma generator 150 arranged in the build chamber 280.
  • the exposing of the metal powder to hydrogen plasma takes place in the powder bed 240.
  • the exposing of the metal powder to hydrogen plasma may e.g. involve directing a low-pressure hydrogen plasma towards the metal powder on top of the powder bed 240.
  • the schematically illustrated additive manufacturing apparatus 200 comprises an energy beam source 210 and a powder bed 240, arranged in a build chamber 280.
  • the build chamber can be a vacuum chamber, typical of E-PBF, or a chamber containing inert gas, typical of L- PBF.
  • the powder bed 240 may e.g. be formed by metal powder being distributed from a powder container 230 using a recoater mechanism 290.
  • the powder bed 240 may comprise metal-based powder of any kind, such as e.g. metal powder composed of pure metal, metal alloys, I ntermetall ics, metal matrix composite, or any powder mixture thereof.
  • the powder can also be a mixture of metal-based powder and insulating or semiconducting powder,
  • the metal powder may e.g. comprise tungsten or copper.
  • the metal powder in the powder bed 240 is exposed to an energy beam 220 from the beam source 210. During the exposure to the energy beam 220, the metal powder is melted to form a melt pool.
  • pump 260 is arranged for pumping or removing any gases in the powder container 260 and/or the build chamber 280, respectively.
  • the build chamber 280 is a L-PBF vacuum chamber the pump can be omitted, and a gas outflow can be arranged to remove gases.
  • Fig. 2 schematically illustrates a method 300 for oxygen removal from a metal powder, or from the melt pool, or from the fused material.
  • the method is preferable used in an additive manufacturing apparatus 200 for additive manufacturing by selective fusion of a three-dimensional from a powder bed containing a metal powder which is exposed to an energy beam such as a laser beam or an electron beam, and a hydrogen plasma generator, wherein the metal powder is exposed to hydrogen plasma generated by the hydrogen plasma generator before being exposed to the energy beam, and/or during the exposure to the energy beam, and the hydrogen plasma thereby removes oxygen from the metal powder or melt pool before or during the selective fusion process.
  • an energy beam such as a laser beam or an electron beam
  • the method 300 preferably comprises, before exposing the metal powder in the powder bed 240 to the energy beam 220, and/or during the exposure of the metal powder to the energy beam 220: Step 320: generating hydrogen plasma by at least one hydrogen plasma generator 150.
  • Step 330 delivering hydrogen plasma for exposure to the metal powder.
  • Step 340 optionally handling the metal power in the powder container such that the metal powder is exposed to the hydrogen plasma in a batch fashion, so that essentially all powder particles in the powder container become exposed to the hydrogen plasma.
  • the metal powder may be stirred in the powder container, wherein the stirring occurs in synchronism with delivery or exposure to hydrogen plasma, continuously and/or in intervals during delivery or exposure to hydrogen plasma.
  • the metal powder may be shuffled sequentially in synchronism with delivery or exposure to hydrogen plasma, continuously and/or in intervals during delivery or exposure to hydrogen plasma to obtain a layer-by-layer exposure of the metal powder to hydrogen plasma.
  • Step 540 delivering hydrogen plasma for exposure to the top powder layer.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Plasma & Fusion (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Powder Metallurgy (AREA)

Abstract

Selon un ou plusieurs modes de réalisation, l'invention concerne un agencement (100) pour éliminer de l'oxygène de matériaux métalliques utilisés dans la fabrication additive. L'agencement (100) comprend un appareil de fabrication additive (200) par fusion sélective d'un produit tridimensionnel à partir d'un lit de poudre (240) contenant une poudre métallique qui est exposée à un faisceau d'énergie (220), et un générateur de plasma d'hydrogène (150), la poudre métallique étant exposée à un plasma d'hydrogène généré par le générateur de plasma d'hydrogène (150) uniquement après fusion sélective et resolidification d'une couche de poudre supérieure et avant la distribution d'une nouvelle couche de poudre.
PCT/EP2025/050464 2024-01-09 2025-01-09 Élimination d'oxygène dans des processus de fabrication additive à base de poudre Pending WO2025149583A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE2450013 2024-01-09
SE2450013-4 2024-01-09

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WO2025149583A1 true WO2025149583A1 (fr) 2025-07-17

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3165304A1 (fr) * 2015-11-04 2017-05-10 Ricoh Company, Ltd. Appareil de fabrication d'objet tridimensionnel
US20170165791A1 (en) * 2015-12-10 2017-06-15 Canon Kabushiki Kaisha Method for treating raw-material powder, apparatus for treating raw-material powder, and method for producing object
FR3105037A1 (fr) * 2019-12-19 2021-06-25 Addup Traitement in situ de poudre pour fabrication additive en vue d’améliorer sa conductivité thermique et/OU électrique
EP3570973B1 (fr) * 2017-01-17 2021-10-06 Universität Innsbruck Procédé de fabrication additive
US20220011252A1 (en) * 2020-06-15 2022-01-13 Thermo Electron Scientific Instruments Llc Shutter Assembly for X-Ray Detection
GB2602458A (en) * 2020-12-22 2022-07-06 Wayland Additive Ltd Additive manufacturing using powder bed fusion

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US20170165791A1 (en) * 2015-12-10 2017-06-15 Canon Kabushiki Kaisha Method for treating raw-material powder, apparatus for treating raw-material powder, and method for producing object
EP3570973B1 (fr) * 2017-01-17 2021-10-06 Universität Innsbruck Procédé de fabrication additive
FR3105037A1 (fr) * 2019-12-19 2021-06-25 Addup Traitement in situ de poudre pour fabrication additive en vue d’améliorer sa conductivité thermique et/OU électrique
US20220011252A1 (en) * 2020-06-15 2022-01-13 Thermo Electron Scientific Instruments Llc Shutter Assembly for X-Ray Detection
GB2602458A (en) * 2020-12-22 2022-07-06 Wayland Additive Ltd Additive manufacturing using powder bed fusion

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