Metal powder for 3D-printing
A method of using a metal powder in an additive manufacturing process. The method includes providing the metal powder, and using the metal powder in the additive manufacturing process. The metal powder is a metal which is selected from tantalum and impurities, titanium and impurities, niobium and impurities, an alloy of tantalum, niobium and impurities, an alloy of titanium, niobium and impurities, and an alloy of tantalum, titanium, niobium and impurities. Particles of the metal powder have a dendritic microstructure. Particles of the metal powder have an average aspect ratio ΨA of from 0.7 to 1, where ΨA=X Feret min /X Feret max .
1. A process for producing a three-dimensional article, the process comprising:
providing a metal powder; and
using the metal powder to build up the three-dimensional article layer by layer,
wherein the metal powder consists of:
a metal selected from the group consisting of,
tantalum and impurities,
titanium and impurities,
niobium and impurities,
an alloy consisting of tantalum, niobium and impurities,
an alloy consisting of titanium, niobium and impurities, and
an alloy consisting of tantalum, titanium, niobium and impurities,
wherein,
particles of the metal powder have a dendritic microstructure,
particles of the metal powder comprise an average aspect ratio Ψ A of from 0.7 to 1, where Ψ A =X Feret min /X Feret max .
2. The process as recited in claim 1 , wherein the impurities are <3,440 ppm.
3. The process as recited in claim 2 , wherein the impurities consist of:
oxygen being ≤3000 ppm,
nitrogen being ≤200 ppm,
lithium being ≤80 ppm
sodium being ≤80 ppm, and
potassium being ≤80 ppm.
4. The process as recited in claim 1 , wherein the metal powder consists of the alloy consisting of titanium, niobium and impurities.
5. The process as recited in claim 1 , wherein the metal powder consists of the alloy consisting of tantalum, niobium and impurities.
6. The process as recited in claim 1 , wherein the metal powder consists of the alloy consisting of titanium, niobium, tantalum and impurities.
7. The process as recited in claim 1 , wherein the metal powder has a tap density of 40 to 80% of a theoretical density of the metal powder, each determined according to ASTM B527.
8. The process as recited in claim 1 , wherein the metal powder has a flowability of less than 25 s/50 g, determined according to ASTM B213.
9. The process as recited in claim 1 , wherein the metal powder has,
a particle size distribution D10>2 μm,
a particle size distribution D90<80 μm, and
a particle size distribution D50 of 20 to 50 μm,
each determined according to ASTM B822.
10. The process as recited in claim 1 , wherein the metal powder has,
a particle size distribution D10 of >20 μm,
a particle size distribution D90 of <150 μm, and
a particle size distribution D50 of 40 to 90 μm,
each determined according to ASTM B822.
11. The process as recited in claim 1 , wherein the metal powder has,
a powder distribution D10 of >50 μm,
a powder distribution D90 of <240 μm, and
a powder distribution D50 of 60 to 150 μm,
each determined according to ASTM B822.
12. The process as recited in claim 1 , wherein the process is selected from the group consisting of a selective laser melting (SLM, LBM), an electron beam melting (EBM), and a laser cladding (CL).
13. A method of using a metal powder in an additive manufacturing process, the method comprising:
providing the metal powder; and
successively adding the metal powder layer by layer as the additive manufacturing process so as to provide a three-dimensional object,
wherein the metal powder consists of:
a metal selected from the group consisting of,
tantalum and impurities,
titanium and impurities,
niobium and impurities,
an alloy consisting of tantalum, niobium and impurities,
an alloy consisting of titanium, niobium and impurities, and
an alloy consisting of tantalum, titanium, niobium and impurities,
wherein,
particles of the metal powder have a dendritic microstructure,
particles of the metal powder comprise an average aspect ratio Ψ A of from 0.7 to 1, where Ψ A =X Feret min /X Feret max .
14. The method as recited in claim 13 , wherein the impurities are <3,440 ppm.
15. The method as recited in claim 14 , wherein the impurities consist of:
oxygen being ≤3000 ppm,
nitrogen being ≤200 ppm,
lithium being <80 ppm
sodium being ≤80 ppm, and
potassium being ≤80 ppm.
16. The method as recited in claim 13 , wherein the metal powder consists of the alloy consisting of tantalum, niobium and impurities.
17. The method as recited in claim 13 , wherein the metal powder consists of the alloy consisting of titanium, niobium and impurities.
18. The method as recited in claim 13 , wherein the metal powder consists of the alloy consisting of titanium, niobium, tantalum and impurities.
19. The method as recited in claim 13 , wherein the metal powder has a tap density of 40 to 80% of a theoretical density of the metal powder, each determined according to ASTM B527.
20. The method as recited in claim 13 , wherein the metal powder has a flowability of less than 25 s/50 g, determined according to ASTM B213.
21. The method as recited in claim 13 , wherein the metal powder has,
a particle size distribution D10>2 μm,
a particle size distribution D90<80 μm, and
a particle size distribution D50 of 20 to 50 μm,
each determined according to ASTM B822.
22. The method as recited in claim 13 , wherein the metal powder has,
a particle size distribution D10 of >20 μm,
a particle size distribution D90 of <150 μm, and
a particle size distribution D50 of 40 to 90 μm,
each determined according to ASTM B 822 .
23. The method as recited in claim 13 , wherein the metal powder has,
a powder distribution D10 of >50 μm,
a powder distribution D90 of <240 μm, and
a powder distribution D50 of 60 to 150 μm,
each determined according to ASTM B822.