WO2024203945A1 - Metal powder for molding, and molded article - Google Patents
Metal powder for molding, and molded article Download PDFInfo
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- WO2024203945A1 WO2024203945A1 PCT/JP2024/011470 JP2024011470W WO2024203945A1 WO 2024203945 A1 WO2024203945 A1 WO 2024203945A1 JP 2024011470 W JP2024011470 W JP 2024011470W WO 2024203945 A1 WO2024203945 A1 WO 2024203945A1
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- 239000000843 powder Substances 0.000 title claims abstract description 49
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 46
- 239000002184 metal Substances 0.000 title claims abstract description 46
- 238000000465 moulding Methods 0.000 title claims abstract description 15
- 239000012535 impurity Substances 0.000 claims abstract description 6
- 229910052748 manganese Inorganic materials 0.000 claims description 7
- 229910052759 nickel Inorganic materials 0.000 claims description 7
- 229910052804 chromium Inorganic materials 0.000 claims description 6
- 229910052750 molybdenum Inorganic materials 0.000 claims description 6
- 229910052717 sulfur Inorganic materials 0.000 claims description 6
- 229910052720 vanadium Inorganic materials 0.000 claims description 6
- 229910052802 copper Inorganic materials 0.000 claims description 5
- 229910052799 carbon Inorganic materials 0.000 abstract description 7
- 230000032683 aging Effects 0.000 description 21
- 238000000034 method Methods 0.000 description 18
- 229910000831 Steel Inorganic materials 0.000 description 15
- 150000001247 metal acetylides Chemical class 0.000 description 15
- 239000010959 steel Substances 0.000 description 15
- 239000002245 particle Substances 0.000 description 13
- 239000000463 material Substances 0.000 description 10
- 239000000047 product Substances 0.000 description 10
- 229910001315 Tool steel Inorganic materials 0.000 description 9
- 229910000765 intermetallic Inorganic materials 0.000 description 8
- 230000015572 biosynthetic process Effects 0.000 description 7
- 230000000052 comparative effect Effects 0.000 description 7
- 230000000694 effects Effects 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 6
- 238000005204 segregation Methods 0.000 description 6
- 238000007493 shaping process Methods 0.000 description 6
- 238000005245 sintering Methods 0.000 description 6
- 238000009826 distribution Methods 0.000 description 5
- 238000013507 mapping Methods 0.000 description 5
- 238000002844 melting Methods 0.000 description 5
- 230000008018 melting Effects 0.000 description 5
- 238000000889 atomisation Methods 0.000 description 4
- 229910001566 austenite Inorganic materials 0.000 description 4
- 238000005266 casting Methods 0.000 description 4
- 239000013078 crystal Substances 0.000 description 4
- 230000007423 decrease Effects 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- 239000000523 sample Substances 0.000 description 4
- 229910000859 α-Fe Inorganic materials 0.000 description 4
- 239000000654 additive Substances 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 3
- 230000001186 cumulative effect Effects 0.000 description 3
- 238000007711 solidification Methods 0.000 description 3
- 230000008023 solidification Effects 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 238000009689 gas atomisation Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 238000000879 optical micrograph Methods 0.000 description 2
- 238000007500 overflow downdraw method Methods 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000007670 refining Methods 0.000 description 2
- 238000007873 sieving Methods 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 238000003723 Smelting Methods 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 238000003483 aging Methods 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 230000001376 precipitating effect Effects 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000000790 scattering method Methods 0.000 description 1
- 239000003923 scrap metal Substances 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 238000005211 surface analysis Methods 0.000 description 1
- 150000003568 thioethers Chemical class 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- 238000009692 water atomization Methods 0.000 description 1
Images
Classifications
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- 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
-
- 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
- B22F10/36—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
- 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
- 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
-
- 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
- B33Y80/00—Products made by additive manufacturing
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/60—Ferrous alloys, e.g. steel alloys containing lead, selenium, tellurium, or antimony, or more than 0.04% by weight of sulfur
Definitions
- the present invention relates to metal powder for molding and molded objects using the same.
- Age-hardened austenitic tool steels are non-magnetic and highly hard, and are therefore used in plastic molds and jigs that require non-magnetic properties.
- Patent Document 1 proposes an age-hardened austenitic tool steel.
- Age-hardened austenitic tool steels are also required to be machinable, and Patent Document 1 optimizes high strength and machinability through component design.
- Such age-hardened austenitic tool steels are manufactured by the so-called smelting process, in which steel material is obtained by hot plastic processing of steel ingots obtained by an ingot-making process such as normal casting or remelting casting.
- the age-hardened austenitic tool steel of Patent Document 1 has a composition that allows the formation of carbides and MnS in order to obtain high strength and machinability.
- carbides and MnS that crystallize from the molten metal during normal casting or remelt casting are deformed by hot plastic processing to form the steel into its final shape.
- These carbides and MnS remain in the subsequent heat treatment process, making it difficult to refine them while still in the steel state.
- the object of the present invention is to provide a metal powder for molding capable of producing objects that have both high strength and machinability, and objects made using the same.
- the inventors investigated methods for controlling the structure of age-hardened austenitic tool steel, and discovered that by adopting a process for solidifying and molding metal powder for molding, it is possible to obtain molded products that combine high strength and machinability by refining the structure, thus arriving at the present invention.
- the present invention provides a useful technology for manufacturing objects that combine high strength and machinability by refining the microstructural morphology of age-hardened austenitic tool steel.
- FIG. 2 is an elemental mapping image of S obtained by analyzing a cross section of a metal powder for molding according to an embodiment of the present invention using an electron probe microanalyzer (EPMA).
- FIG. 13 is a diagram showing an element mapping image of S obtained by analyzing a cross section parallel to the layering direction of a shaped object according to an example of the present invention by EPMA.
- FIG. 2 is a diagram showing an element mapping image of S when a cross section of a steel material serving as a comparative example is analyzed by EPMA. 13 is an optical microscope photograph of a molded object according to an embodiment of the present invention after solution treatment. 4 is an optical microscope photograph of a comparative steel material after solution treatment.
- C is an austenite-forming element together with Mn and Ni, and is an element necessary for maintaining the structure of the shaped article of the present invention as austenite.
- C forms carbides together with Cr, Mo, and V.
- C is an element necessary for improving hardness and wear resistance.
- the C content is set to 0.40 mass % or more.
- the C content is preferably 0.45 mass % or more, and more preferably 0.50 mass % or more.
- the C content is set to 0.70 mass% or less.
- the C content is preferably 0.65 mass % or less, and more preferably 0.60 mass % or less.
- Si 1.40% by mass or less
- Si is an element necessary for improving oxidation resistance. However, if there is too much Si, segregation may occur inside the shaped object, which may reduce the strength. For this reason, the Si content is set to 1.40% by mass or less.
- the Si content is preferably set to 1.00% by mass or less, and more preferably 0.60% by mass or less.
- the Si content is preferably 0.1 ppm by mass or more, and more preferably 0.5 ppm by mass or more.
- Mn 5.00-15.00% by mass Mn, together with C and Ni, is an austenite-forming element and is necessary for maintaining the structure of the shaped article of the present invention as austenite. If the Mn content is too low, ferrite will be generated, and the aging treatment will cause the formation of ferrite. There is a risk of lowering the maximum hardness. For this reason, the Mn content is set to 5.00 mass% or more. In the present invention, for the same reason as above, the Mn content is set to 5.50 mass% or more. It is preferable that the content of the Cr content is 6.00 mass % or more, and more preferable that the content of the Cr content is 6.00 mass % or more.
- the Mn content is set to 15.00 mass% or less.
- the Mn content is preferably 10.00 mass % or less.
- Ni 2.00 to 10.00% by mass Ni, together with C and Mn, is an element necessary for maintaining the structure of the shaped article of the present invention as austenite.
- Ni forms fine intermetallic particles with Al during aging treatment after solution treatment.
- Ni is an element necessary for forming a compound and obtaining the hardness required for an age-hardened austenitic tool steel. Therefore, the Ni content is set to 2.00 mass % or more.
- the Ni content is preferably 3.00 mass % or more, and more preferably 5.00 mass % or more.
- the Ni content is set to 10.00 mass% or less.
- the Ni content is preferably 9.00 mass % or less, and more preferably 8.00 mass % or less.
- the Cr content is preferably 8.00 mass% or more, and more preferably 9.00 mass% or more.
- the Cr content is set to 14.00 mass% or less.
- the Cr content is preferably set to 13.00 mass% or less, and 12. 00% by mass or less is more preferable.
- the Mo content is preferably 1.30 mass% or more, and more preferably 1.80 mass% or more. is more preferred.
- the Mo content is set to 5.00 mass% or less.
- the Mo content is preferably 4.00 mass % or less, and more preferably 3.00 mass % or less.
- V 1.00-2.50% by mass
- Vanadium (V) is an element necessary for forming carbides and suppressing the coarsening of crystal grains during solution treatment.
- V precipitates fine carbides during aging treatment, and is particularly effective in preventing coarsening of grains during high aging.
- V is an element necessary for obtaining hardness. Therefore, the V content is set to 1.00 mass % or more. In the present invention, for the same reason as above, the V content is set to 1.20 mass %. % is preferable.
- the V content is set to 2.50 mass% or less.
- the V content is preferably 2.00 mass % or less, and more preferably 1.50 mass % or less.
- Cu 0.60-4.00% by mass
- Cu is an element necessary for forming fine intermetallic compounds with Fe during aging treatment after solution treatment, and for obtaining the hardness required for age-hardening austenitic tool steel.
- Cu is an element that has the effect of enhancing corrosion resistance. Therefore, the Cu content is set to 0.60 mass % or more. In the present invention, for the same reason as above, the Cu content is set to 0.80 mass %. % or more, and more preferably 1.00% by mass or more. On the other hand, if the Cu content is too high, there is a concern that the hardness may decrease. For this reason, the Cu content is set to 4.00 mass% or less. The content is preferably 3.50% by mass or less, and more preferably 3.00% by mass or less.
- Al 0.60-4.00% by mass
- Al is an element necessary for forming fine intermetallic compounds with Ni during aging treatment after solution treatment, and for obtaining the hardness required for age-hardenable austenitic tool steel.
- the Al content is set to 0.60 mass % or more. In the present invention, for the same reason as above, the Al content is preferably set to 0.90 mass % or more. On the other hand, if the Al content is too high, it will lead to the formation of ferrite. Therefore, the Al content is set to 4.00 mass% or less. For the same reason as above, in the present invention, the Al content is set to 4.00 mass% or less. It is preferably 3.00% by mass or less, and more preferably 2.00% by mass or less.
- S 0.0500 to 0.1500% by mass
- S (sulfur) is an element necessary for forming sulfides together with Mn and improving machinability. If the S content is too high, the toughness of the obtained shaped article is reduced. For this reason, the S content is set to 0.0500 to 0.1500 mass%. In the present invention, for the same reason as above, the S content is set to 0.0500 to 0.1000 mass%. preferable.
- the metal powder of the present invention can be produced by, for example, gas atomization, water atomization, disk atomization, plasma atomization, rotating electrode atomization, or the like.
- the gas atomization method can use scrap metal, raw metal materials, etc. as the melting raw material, and can be manufactured at a lower cost than the plasma atomization method, the rotating electrode method, etc., which require the preparation of a raw material with a desired composition and shape in advance, and is therefore preferable as a manufacturing method for obtaining the metal powder of the present invention.
- the metal powder of the present invention preferably has a 50% particle size (hereinafter referred to as "D50") of a cumulative particle size distribution based on volume of 10 to 250 ⁇ m.
- D50 50% particle size
- the cumulative particle size distribution of the metal powder of the present invention is represented by a cumulative volumetric particle size distribution, and its D50 is represented by a value measured by the laser diffraction scattering method defined in JIS Z 8825.
- the particle size of the metal powder of the present invention is preferably adjusted by sieving classification using a mesh or air current classification in accordance with the molding method.
- the metal powder is melted by the laser beam as a heat source, while coarse powder that is difficult to melt must be removed in order to minimize the range of the thermal effect.
- fine powder with high adhesion must be removed. Therefore, when the metal powder of the present invention is applied to the powder bed fusion method, it is preferable to adjust D50 to the range of 10 to 53 ⁇ m.
- the maximum length of MnS included in the observation field in a cross section parallel to the stacking direction is less than 1 ⁇ m.
- the cross section parallel to the stacking direction refers to, for example, a cross section parallel to the filling direction of the metal powder in the case of a shaped product obtained by a pressure sintering method, or a cross section parallel to the direction in which multiple laminar solidified layers are formed in the case of a shaped product obtained by an additive manufacturing method.
- An example of an elemental mapping image of S when MnS confirmed in a cross section parallel to the layering direction of a molded object was analyzed by EPMA is shown in Figure 2.
- the dot-like inclusions shown in gray in the base material shown in black are MnS.
- the maximum length of MnS less than 1 ⁇ m, internal defects such as cracks can be reduced, and deterioration of mechanical properties such as ductility and toughness can be suppressed.
- EPMA for example, can be used to perform surface analysis of the S concentration distribution in a cross section parallel to the stacking direction. First, a cross section parallel to the stacking direction of the molded object is taken from an arbitrary position on the molded object. Then, an arbitrary area can be analyzed with EPMA at, for example, 5000x magnification to obtain the S distribution.
- the shaped object of the present invention has an S content of 0.0500 to 0.1500 mass%. And, in the present invention, for the same reasons as above, it is preferable that the S content be 0.0500 to 0.1000 mass%.
- the shaped object of the present invention can be obtained, for example, by a powder sintering method.
- the shaped object can be obtained by pressure sintering the above-mentioned metal powder.
- pressure sintering for example, a HIP method, a hot pressing method, an electric current sintering method, etc. can be applied.
- the object of the present invention can also be applied to an additive manufacturing method in which a step of spreading metal powder in layers and a step of forming solidified layers by successively melting and solidifying the spread metal powder with a scanning heat source to form a solidified layer are repeated to form a plurality of solidified layers.
- a laser or an electron beam can be used as the scanning heat source.
- the laser output is too high, the molten part of the metal during laser irradiation will become deeper, making it easier for strong segregation to form during solidification.
- the laser output is too low, the metal powder will not melt sufficiently, and many voids resulting from gaps in the metal powder will form in the molded object after solidification. For this reason, it is preferable to set the laser output to 50 to 350 W.
- the metal powder will not receive enough heat, making it difficult to melt the powder as needed for shaping, and many voids will likely form in the solidified component.
- the laser scanning speed is too slow, the molten part of the metal will become deep during laser irradiation, making it more likely for segregation to form.
- excess heat will be applied to the metal powder, causing the molten part to flow vigorously, which will entrain gas and make it more likely for air bubbles to become mixed into the solidified component. For this reason, it is preferable to set the scanning speed to 200 to 2000 mm/sec.
- the scanning pitch is the distance between the scanning beams. If the scanning pitch becomes too small, the molten part of the metal becomes deep during laser irradiation, making it easier for segregation to form. For this reason, it is preferable to set the scanning pitch to 0.02 to 0.20 mm.
- the “layer thickness per scan” refers to the "thickness of each metal powder layer” that is laid out when shaping each layer. If the layer thickness per scan is too small, the number of layers required to reach the desired size of the object will increase, and the time required for shaping will increase. For this reason, it is preferable to set the layer thickness per scan to 10 to 200 ⁇ m.
- the molded product of the present invention is preferably further subjected to a heat treatment process including a solution treatment and an aging treatment.
- the age-hardened austenitic tool steel is used as a product after the component is subjected to a solution treatment and an aging treatment.
- a solution treatment By performing a solution treatment, the intermetallic compounds precipitated by the heat during molding are put into solution, and further, by recrystallizing the anisotropic structure formed by the pressure sintering method or the molten pool or solidified structure formed by the additive manufacturing method, a structure with equiaxed crystal grains is obtained, and the anisotropy of the mechanical properties can be suppressed.
- the solution treatment temperature is preferably 1100°C or higher, and more preferably 1150°C or higher. Increasing the solution treatment temperature improves the effect of eliminating segregation formed during shaping. However, if the solution treatment temperature is too high, the main body of the shaped object melts, and the strength and toughness of the shaped object decrease. For this reason, the solution treatment temperature is preferably 1250°C or lower, and more preferably 1200°C or lower.
- the solution treatment time (maintenance time at the solution treatment temperature) is preferably 10 minutes or more, and more preferably 15 minutes or more. By increasing the solution treatment time, the effect of eliminating segregation formed during shaping is improved. However, if the solution treatment time is too long, the prior austenite grain size becomes coarse. For this reason, the solution treatment time is preferably 120 minutes or less, and more preferably 90 minutes or less.
- the aging temperature is preferably 400°C or higher, more preferably 450°C or higher, and even more preferably 500°C or higher.
- the aging temperature is particularly preferably 550°C or higher. Increasing the aging temperature further improves the effect of improving strength. However, if the aging temperature is too high, the intermetallic compounds become coarse, and sufficient strength commensurate with the amount of precipitation of the intermetallic compounds cannot be obtained. For this reason, the aging temperature is preferably 900°C or lower, and more preferably 800°C or lower.
- the aging treatment time (maintenance time at the aging treatment temperature) is preferably 30 minutes or more, and more preferably 60 minutes or more.
- the aging treatment time is preferably 600 minutes or less, and more preferably 400 minutes or less.
- each metal raw material so as to have the composition of Sample No. 1-1 in Table 1
- the raw materials were charged into a high-frequency induction melting furnace and melted, and the molten metal was pulverized with argon gas to obtain an atomized powder.
- the resulting atomized powder was subjected to sieving classification using a mesh and air flow classification to adjust the powder particle size, thereby obtaining a metal powder of the present invention having a D50 of 28.8 ⁇ m.
- a molded object was produced using this metal powder.
- an EOS-M290 manufactured by EOS was used to produce the molded object under the molding conditions shown in Table 2.
- Figure 1 shows elemental mapping images of S when a cross section of a metal powder according to an example of the present invention, a shaped product according to an example of the present invention, and a steel material according to a comparative example were analyzed by EPMA.
- a large number of MnS particles having a maximum length exceeding 10 ⁇ m were confirmed, as shown in the gray areas in FIG.
- the maximum length of all MnS particles was less than 1 ⁇ m, and it was confirmed that the MnS particles were finely dispersed.
- Fig. 4 shows the optical micrographs of the shaped article according to the present invention
- Fig. 5 shows the optical micrographs of the steel material according to the comparative example.
- the steel material of the comparative example a large number of MnS particles with a maximum length exceeding 10 ⁇ m were confirmed.
- the maximum length of all MnS particles was less than 1 ⁇ m, and it was confirmed that the MnS particles were finely dispersed.
- Such fine dispersion of MnS and carbides is expected to have a favorable effect on the mechanical properties and machinability required for a tool steel.
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Abstract
Provided are: a metal powder for molding from which a molded article having both high strength and machinability can be produced; and a molded article molded by using the same. Provided are: a metal powder for molding which contains 0.40-0.70 mass% of C, at most 1.40 mass% of Si, 5.00-15.00 mass% of Mn, 2.00-10.00 mass% of Ni, 7.00-14.00 mass% of Cr, 0.80-5.00 mass% of Mo, 1.00-2.50 mass% of V, 0.60-4.00 mass% of Cu, 0.60-4.00 mass% of Al, and 0.0500-0.1500 mass% of S, with the balance being Fe and inevitable impurities; and a molded article molded by using the same.
Description
本発明は、造形用金属粉末およびこれを用いた造形物に関する。
The present invention relates to metal powder for molding and molded objects using the same.
時効硬化型オーステナイト系工具鋼は、非磁性かつ高硬度であるという特徴から、プラマグ成形型や非磁性が求められる治具などに活用されている。時効硬化型オーステナイト系工具鋼として、例えば特許文献１が提案されている。時効硬化型オーステナイト系工具鋼には、被削性も要求されており、特許文献１では成分設計によって高強度および被削性の最適化がなされている。このような時効硬化型オーステナイト系工具鋼は、普通鋳造または再溶解鋳造といった造塊プロセスで得た鋼塊を熱間で塑性加工して鋼材を得る、所謂溶製法で製造されている。
Age-hardened austenitic tool steels are non-magnetic and highly hard, and are therefore used in plastic molds and jigs that require non-magnetic properties. For example, Patent Document 1 proposes an age-hardened austenitic tool steel. Age-hardened austenitic tool steels are also required to be machinable, and Patent Document 1 optimizes high strength and machinability through component design. Such age-hardened austenitic tool steels are manufactured by the so-called smelting process, in which steel material is obtained by hot plastic processing of steel ingots obtained by an ingot-making process such as normal casting or remelting casting.
特許文献１の時効硬化型オーステナイト系工具鋼は、高強度および被削性を得るために、炭化物やＭｎＳが形成される成分組成となっている。これを溶製法で製造する場合は、普通鋳造または再溶解鋳造中に溶湯から晶出した炭化物やＭｎＳを、熱間での塑性加工によって変形させ、最終形状の鋼材に成形する。これら炭化物やＭｎＳは、その後の熱処理工程においても残存し、鋼材の状態で微細化させることが困難であった。
The age-hardened austenitic tool steel of Patent Document 1 has a composition that allows the formation of carbides and MnS in order to obtain high strength and machinability. When this is manufactured by the ingot process, the carbides and MnS that crystallize from the molten metal during normal casting or remelt casting are deformed by hot plastic processing to form the steel into its final shape. These carbides and MnS remain in the subsequent heat treatment process, making it difficult to refine them while still in the steel state.
本発明の目的は、高強度および被削性を兼ね備えた造形物を製造可能な造形用金属粉末およびこれを用いた造形物を提供することである。
The object of the present invention is to provide a metal powder for molding capable of producing objects that have both high strength and machinability, and objects made using the same.
本発明者は、時効硬化型オーステナイト系工具鋼の組織制御手法を検討し、造形用金属粉末を固化成形するプロセスを採用することで、組織形態の微細化により、高強度および被削性を兼ね備えた造形物を得ることができることを見い出し、本発明に到達した。
The inventors investigated methods for controlling the structure of age-hardened austenitic tool steel, and discovered that by adopting a process for solidifying and molding metal powder for molding, it is possible to obtain molded products that combine high strength and machinability by refining the structure, thus arriving at the present invention.
本発明は、質量％で、Ｃ＝０．４０～０．７０％、Ｓｉ＝１．４０％以下、Ｍｎ＝５．００～１５．００％、Ｎｉ＝２．００～１０．００％、Ｃｒ＝７．００～１４．００％、Ｍｏ＝０．８０～５．００％、Ｖ＝１．００～２．５０％、Ｃｕ＝０．６０～４．００％、Ａｌ＝０．６０～４．００％、Ｓ＝０．０５００～０．１５００％含有し、残部がＦｅおよび不可避的不純物からなる造形用金属粉末である。
The present invention is a metal powder for molding that contains, by mass%, C = 0.40-0.70%, Si = 1.40% or less, Mn = 5.00-15.00%, Ni = 2.00-10.00%, Cr = 7.00-14.00%, Mo = 0.80-5.00%, V = 1.00-2.50%, Cu = 0.60-4.00%, Al = 0.60-4.00%, S = 0.0500-0.1500%, and the balance being Fe and unavoidable impurities.
そして、本発明は、質量％で、Ｃ＝０．４０～０．７０％、Ｓｉ＝１．４０％以下、Ｍｎ＝５．００～１５．００％、Ｎｉ＝２．００～１０．００％、Ｃｒ＝７．００～１４．００％、Ｍｏ＝０．８０～５．００％、Ｖ＝１．００～２．５０％、Ｃｕ＝０．６０～４．００％、Ａｌ＝０．６０～４．００％、Ｓ＝０．０５００～０．１５００％含有し、残部がＦｅおよび不可避的不純物からなり、積層方向と平行な断面において、ＭｎＳの最大長さが１μｍ未満の造形物である。
The present invention is a shaped object containing, by mass%, C = 0.40-0.70%, Si = 1.40% or less, Mn = 5.00-15.00%, Ni = 2.00-10.00%, Cr = 7.00-14.00%, Mo = 0.80-5.00%, V = 1.00-2.50%, Cu = 0.60-4.00%, Al = 0.60-4.00%, S = 0.0500-0.1500%, with the remainder being Fe and unavoidable impurities, and in which the maximum length of MnS in a cross section parallel to the lamination direction is less than 1 μm.
本発明は、時効硬化型オーステナイト系工具鋼の組織形態の微細化により、高強度および被削性を兼ね備えた造形物の製造に有用な技術となる。
The present invention provides a useful technology for manufacturing objects that combine high strength and machinability by refining the microstructural morphology of age-hardened austenitic tool steel.
本発明の造形用金属粉末（以下、単に「金属粉末」ともいう。）および造形物は、質量％で、Ｃ＝０．４０～０．７０％、Ｓｉ＝１．４０％以下、Ｍｎ＝５．００～１５．００％、Ｎｉ＝２．００～１０．００％、Ｃｒ＝７．００～１４．００％、Ｍｏ＝０．８０～５．００％、Ｖ＝１．００～２．５０％、Ｃｕ＝０．６０～４．００％、Ａｌ＝０．６０～４．００％、Ｓ＝０．０５００～０．１５００％含有し、残部がＦｅおよび不可避的不純物からなる。
The metal powder for molding (hereinafter also simply referred to as "metal powder") and molded object of the present invention contain, by mass%, C = 0.40-0.70%, Si = 1.40% or less, Mn = 5.00-15.00%, Ni = 2.00-10.00%, Cr = 7.00-14.00%, Mo = 0.80-5.00%, V = 1.00-2.50%, Cu = 0.60-4.00%, Al = 0.60-4.00%, S = 0.0500-0.1500%, with the remainder being Fe and unavoidable impurities.
Ｃ＝０．４０～０．７０質量％
Ｃ（炭素）は、Ｍｎ、Ｎｉとともにオーステナイト形成元素として、本発明の造形物の組織をオーステナイトとして保つために必要な元素である。また、Ｃは、Ｃｒ、Ｍｏ、Ｖとともに炭化物を形成することで、硬さの向上や、耐摩耗性を向上させるためにも必要な元素である。Ｃの含有量は、造形物の硬さを得る観点から、０．４０質量％以上とする。本発明では、上記と同様の理由から、Ｃの含有量を０．４５質量％以上にすることが好ましく、０．５０質量％以上がより好ましい。
一方、Ｃの含有量が高すぎると、粗大な炭化物が形成されてしまい、靭性の低下を招く虞がある。このため、Ｃの含有量は、０．７０質量％以下とする。本発明では、上記と同様の理由から、Ｃの含有量を０．６５質量％以下にすることが好ましく、０．６０質量％以下がより好ましい。 C=0.40-0.70% by mass
Carbon (C) is an austenite-forming element together with Mn and Ni, and is an element necessary for maintaining the structure of the shaped article of the present invention as austenite. In addition, C forms carbides together with Cr, Mo, and V. C is an element necessary for improving hardness and wear resistance. From the viewpoint of obtaining hardness of the shaped product, the C content is set to 0.40 mass % or more. For the same reasons as above, the C content is preferably 0.45 mass % or more, and more preferably 0.50 mass % or more.
On the other hand, if the C content is too high, coarse carbides are formed, which may lead to a decrease in toughness. For this reason, the C content is set to 0.70 mass% or less. For the same reasons as above, the C content is preferably 0.65 mass % or less, and more preferably 0.60 mass % or less.
Ｃ（炭素）は、Ｍｎ、Ｎｉとともにオーステナイト形成元素として、本発明の造形物の組織をオーステナイトとして保つために必要な元素である。また、Ｃは、Ｃｒ、Ｍｏ、Ｖとともに炭化物を形成することで、硬さの向上や、耐摩耗性を向上させるためにも必要な元素である。Ｃの含有量は、造形物の硬さを得る観点から、０．４０質量％以上とする。本発明では、上記と同様の理由から、Ｃの含有量を０．４５質量％以上にすることが好ましく、０．５０質量％以上がより好ましい。
一方、Ｃの含有量が高すぎると、粗大な炭化物が形成されてしまい、靭性の低下を招く虞がある。このため、Ｃの含有量は、０．７０質量％以下とする。本発明では、上記と同様の理由から、Ｃの含有量を０．６５質量％以下にすることが好ましく、０．６０質量％以下がより好ましい。 C=0.40-0.70% by mass
Carbon (C) is an austenite-forming element together with Mn and Ni, and is an element necessary for maintaining the structure of the shaped article of the present invention as austenite. In addition, C forms carbides together with Cr, Mo, and V. C is an element necessary for improving hardness and wear resistance. From the viewpoint of obtaining hardness of the shaped product, the C content is set to 0.40 mass % or more. For the same reasons as above, the C content is preferably 0.45 mass % or more, and more preferably 0.50 mass % or more.
On the other hand, if the C content is too high, coarse carbides are formed, which may lead to a decrease in toughness. For this reason, the C content is set to 0.70 mass% or less. For the same reasons as above, the C content is preferably 0.65 mass % or less, and more preferably 0.60 mass % or less.
Ｓｉ＝１．４０質量％以下
Ｓｉは、耐酸化性を高めるために必要な元素である。ただし、Ｓｉが多すぎると、造形物の内部に偏析が生じてしまい、強度が低下する虞がある。このため、Ｓｉの含有量は、１．４０質量％以下とする。本発明では、上記と同様の理由から、Ｓｉの含有量を１．００質量％以下にすることが好ましく、０．６０質量％以下がより好ましい。
なお、Ｓｉは、工業的量産性を考慮して、０．１質量ｐｐｍ以上にすることが好ましく、０．５質量ｐｐｍ以上にすることがより好ましい。 Si = 1.40% by mass or less Si is an element necessary for improving oxidation resistance. However, if there is too much Si, segregation may occur inside the shaped object, which may reduce the strength. For this reason, the Si content is set to 1.40% by mass or less. In the present invention, for the same reasons as above, the Si content is preferably set to 1.00% by mass or less, and more preferably 0.60% by mass or less.
In addition, taking into consideration industrial mass productivity, the Si content is preferably 0.1 ppm by mass or more, and more preferably 0.5 ppm by mass or more.
Ｓｉは、耐酸化性を高めるために必要な元素である。ただし、Ｓｉが多すぎると、造形物の内部に偏析が生じてしまい、強度が低下する虞がある。このため、Ｓｉの含有量は、１．４０質量％以下とする。本発明では、上記と同様の理由から、Ｓｉの含有量を１．００質量％以下にすることが好ましく、０．６０質量％以下がより好ましい。
なお、Ｓｉは、工業的量産性を考慮して、０．１質量ｐｐｍ以上にすることが好ましく、０．５質量ｐｐｍ以上にすることがより好ましい。 Si = 1.40% by mass or less Si is an element necessary for improving oxidation resistance. However, if there is too much Si, segregation may occur inside the shaped object, which may reduce the strength. For this reason, the Si content is set to 1.40% by mass or less. In the present invention, for the same reasons as above, the Si content is preferably set to 1.00% by mass or less, and more preferably 0.60% by mass or less.
In addition, taking into consideration industrial mass productivity, the Si content is preferably 0.1 ppm by mass or more, and more preferably 0.5 ppm by mass or more.
Ｍｎ＝５．００～１５．００質量％
Ｍｎは、Ｃ、Ｎｉとともにオーステナイト形成元素として、本発明の造形物の組織をオーステナイトとして保つために必要な元素である。Ｍｎの含有量は、低すぎるとフェライトが生成されてしまい、時効処理における最高硬さを低下させる虞がある。このため、Ｍｎの含有量は、５．００質量％以上とする。本発明では、上記と同様の理由から、Ｍｎの含有量を５．５０質量％以上にすることが好ましく、６．００質量％以上がより好ましい。
一方、Ｍｎの含有量が高すぎると、被削性を低下させる虞がある。このため、Ｍｎの含有量は、１５．００質量％以下とする。本発明では、上記と同様の理由から、Ｍｎの含有量を１０．００質量％以下にすることが好ましい。 Mn=5.00-15.00% by mass
Mn, together with C and Ni, is an austenite-forming element and is necessary for maintaining the structure of the shaped article of the present invention as austenite. If the Mn content is too low, ferrite will be generated, and the aging treatment will cause the formation of ferrite. There is a risk of lowering the maximum hardness. For this reason, the Mn content is set to 5.00 mass% or more. In the present invention, for the same reason as above, the Mn content is set to 5.50 mass% or more. It is preferable that the content of the Cr content is 6.00 mass % or more, and more preferable that the content of the Cr content is 6.00 mass % or more.
On the other hand, if the Mn content is too high, there is a risk of reducing machinability. Therefore, the Mn content is set to 15.00 mass% or less. For the same reason as above, in the present invention, The Mn content is preferably 10.00 mass % or less.
Ｍｎは、Ｃ、Ｎｉとともにオーステナイト形成元素として、本発明の造形物の組織をオーステナイトとして保つために必要な元素である。Ｍｎの含有量は、低すぎるとフェライトが生成されてしまい、時効処理における最高硬さを低下させる虞がある。このため、Ｍｎの含有量は、５．００質量％以上とする。本発明では、上記と同様の理由から、Ｍｎの含有量を５．５０質量％以上にすることが好ましく、６．００質量％以上がより好ましい。
一方、Ｍｎの含有量が高すぎると、被削性を低下させる虞がある。このため、Ｍｎの含有量は、１５．００質量％以下とする。本発明では、上記と同様の理由から、Ｍｎの含有量を１０．００質量％以下にすることが好ましい。 Mn=5.00-15.00% by mass
Mn, together with C and Ni, is an austenite-forming element and is necessary for maintaining the structure of the shaped article of the present invention as austenite. If the Mn content is too low, ferrite will be generated, and the aging treatment will cause the formation of ferrite. There is a risk of lowering the maximum hardness. For this reason, the Mn content is set to 5.00 mass% or more. In the present invention, for the same reason as above, the Mn content is set to 5.50 mass% or more. It is preferable that the content of the Cr content is 6.00 mass % or more, and more preferable that the content of the Cr content is 6.00 mass % or more.
On the other hand, if the Mn content is too high, there is a risk of reducing machinability. Therefore, the Mn content is set to 15.00 mass% or less. For the same reason as above, in the present invention, The Mn content is preferably 10.00 mass % or less.
Ｎｉ＝２．００～１０．００質量％
Ｎｉは、Ｃ、Ｍｎとともに、本発明の造形物の組織をオーステナイトとして保つために必要な元素である。また、Ｎｉは、溶体化処理後の時効処理において、Ａｌとの間に微細な金属間化合物を形成し、時効硬化型オーステナイト系工具鋼として必要な硬度を得るために必要な元素である。このため、Ｎｉの含有量は、２．００質量％以上とする。本発明では、上記と同様の理由から、Ｎｉの含有量を３．００質量％以上にすることが好ましく、５．００質量％以上がより好ましい。
一方、Ｎｉの含有量が高すぎると、造形物の組織に非金属介在物が増加してしまい、靭性が低下する虞がある。このため、Ｎｉの含有量は、１０．００質量％以下とする。本発明では、上記と同様の理由から、Ｎｉの含有量を９．００質量％以下にすることが好ましく、８．００質量％以下がより好ましい。 Ni = 2.00 to 10.00% by mass
Ni, together with C and Mn, is an element necessary for maintaining the structure of the shaped article of the present invention as austenite. In addition, Ni forms fine intermetallic particles with Al during aging treatment after solution treatment. Ni is an element necessary for forming a compound and obtaining the hardness required for an age-hardened austenitic tool steel. Therefore, the Ni content is set to 2.00 mass % or more. For the same reason, the Ni content is preferably 3.00 mass % or more, and more preferably 5.00 mass % or more.
On the other hand, if the Ni content is too high, nonmetallic inclusions will increase in the structure of the molded product, which may reduce toughness. For this reason, the Ni content is set to 10.00 mass% or less. In the present invention, for the same reasons as above, the Ni content is preferably 9.00 mass % or less, and more preferably 8.00 mass % or less.
Ｎｉは、Ｃ、Ｍｎとともに、本発明の造形物の組織をオーステナイトとして保つために必要な元素である。また、Ｎｉは、溶体化処理後の時効処理において、Ａｌとの間に微細な金属間化合物を形成し、時効硬化型オーステナイト系工具鋼として必要な硬度を得るために必要な元素である。このため、Ｎｉの含有量は、２．００質量％以上とする。本発明では、上記と同様の理由から、Ｎｉの含有量を３．００質量％以上にすることが好ましく、５．００質量％以上がより好ましい。
一方、Ｎｉの含有量が高すぎると、造形物の組織に非金属介在物が増加してしまい、靭性が低下する虞がある。このため、Ｎｉの含有量は、１０．００質量％以下とする。本発明では、上記と同様の理由から、Ｎｉの含有量を９．００質量％以下にすることが好ましく、８．００質量％以下がより好ましい。 Ni = 2.00 to 10.00% by mass
Ni, together with C and Mn, is an element necessary for maintaining the structure of the shaped article of the present invention as austenite. In addition, Ni forms fine intermetallic particles with Al during aging treatment after solution treatment. Ni is an element necessary for forming a compound and obtaining the hardness required for an age-hardened austenitic tool steel. Therefore, the Ni content is set to 2.00 mass % or more. For the same reason, the Ni content is preferably 3.00 mass % or more, and more preferably 5.00 mass % or more.
On the other hand, if the Ni content is too high, nonmetallic inclusions will increase in the structure of the molded product, which may reduce toughness. For this reason, the Ni content is set to 10.00 mass% or less. In the present invention, for the same reasons as above, the Ni content is preferably 9.00 mass % or less, and more preferably 8.00 mass % or less.
Ｃｒ＝７．００～１４．００質量％
Ｃｒは、鋼材の耐食性や耐酸化性を高め、また炭化物を形成して溶体化処理時の結晶粒の粗大化を抑制するために必要な元素である。このため、Ｃｒの含有量は、７．００質量％以上とする。本発明では、上記と同様の理由から、Ｃｒの含有量を８．００質量％以上にすることが好ましく、９．００質量％以上がより好ましい。
一方、Ｃｒの含有量が高すぎると、粗大な炭化物の生成を助長してしまい、靭性が低下する虞がある。また、Ｃｒの含有量が高すぎると、高温強度の低下やフェライトの生成を招く。このため、Ｃｒの含有量は、１４．００質量％以下とする。本発明では、上記と同様の理由から、Ｃｒの含有量を１３．００質量％以下にすることが好ましく、１２．００質量％以下がより好ましい。 Cr=7.00-14.00% by mass
Cr is an element necessary for improving the corrosion resistance and oxidation resistance of steel materials, and for suppressing the coarsening of crystal grains during solution treatment by forming carbides. In the present invention, for the same reasons as above, the Cr content is preferably 8.00 mass% or more, and more preferably 9.00 mass% or more.
On the other hand, if the Cr content is too high, it may promote the formation of coarse carbides, which may reduce the toughness. Also, if the Cr content is too high, it may reduce the high-temperature strength and suppress the formation of ferrite. For this reason, the Cr content is set to 14.00 mass% or less. In the present invention, for the same reason as above, the Cr content is preferably set to 13.00 mass% or less, and 12. 00% by mass or less is more preferable.
Ｃｒは、鋼材の耐食性や耐酸化性を高め、また炭化物を形成して溶体化処理時の結晶粒の粗大化を抑制するために必要な元素である。このため、Ｃｒの含有量は、７．００質量％以上とする。本発明では、上記と同様の理由から、Ｃｒの含有量を８．００質量％以上にすることが好ましく、９．００質量％以上がより好ましい。
一方、Ｃｒの含有量が高すぎると、粗大な炭化物の生成を助長してしまい、靭性が低下する虞がある。また、Ｃｒの含有量が高すぎると、高温強度の低下やフェライトの生成を招く。このため、Ｃｒの含有量は、１４．００質量％以下とする。本発明では、上記と同様の理由から、Ｃｒの含有量を１３．００質量％以下にすることが好ましく、１２．００質量％以下がより好ましい。 Cr=7.00-14.00% by mass
Cr is an element necessary for improving the corrosion resistance and oxidation resistance of steel materials, and for suppressing the coarsening of crystal grains during solution treatment by forming carbides. In the present invention, for the same reasons as above, the Cr content is preferably 8.00 mass% or more, and more preferably 9.00 mass% or more.
On the other hand, if the Cr content is too high, it may promote the formation of coarse carbides, which may reduce the toughness. Also, if the Cr content is too high, it may reduce the high-temperature strength and suppress the formation of ferrite. For this reason, the Cr content is set to 14.00 mass% or less. In the present invention, for the same reason as above, the Cr content is preferably set to 13.00 mass% or less, and 12. 00% by mass or less is more preferable.
Ｍｏ＝０．８０～５．００質量％
Ｍｏは、炭化物を形成して溶体化処理時の結晶粒の粗大化を抑制し、時効処理時に微細な炭化物を析出し、高い時効硬さと高温強度を得るために必要な元素である。このため、Ｍｏの含有量は、０．８０質量％以上とする。本発明では、上記と同様の理由から、Ｍｏの含有量を１．３０質量％以上にすることが好ましく、１．８０質量％以上がより好ましい。
一方、Ｍｏの含有量が高すぎると、粗大な炭化物が形成されてしまい、靭性を低下させる懸念がある。このため、Ｍｏの含有量は、５．００質量％以下とする。本発明では、上記と同様の理由から、Ｍｏの含有量を４．００質量％以下にすることが好ましく、３．００質量％以下がより好ましい。 Mo=0.80-5.00% by mass
Mo is an element that is necessary for forming carbides to suppress the coarsening of crystal grains during solution treatment, precipitating fine carbides during aging treatment, and obtaining high aging hardness and high-temperature strength. In the present invention, for the same reasons as above, the Mo content is preferably 1.30 mass% or more, and more preferably 1.80 mass% or more. is more preferred.
On the other hand, if the Mo content is too high, coarse carbides are formed, which may reduce toughness. For this reason, the Mo content is set to 5.00 mass% or less. For the same reasons as above, the Mo content is preferably 4.00 mass % or less, and more preferably 3.00 mass % or less.
Ｍｏは、炭化物を形成して溶体化処理時の結晶粒の粗大化を抑制し、時効処理時に微細な炭化物を析出し、高い時効硬さと高温強度を得るために必要な元素である。このため、Ｍｏの含有量は、０．８０質量％以上とする。本発明では、上記と同様の理由から、Ｍｏの含有量を１．３０質量％以上にすることが好ましく、１．８０質量％以上がより好ましい。
一方、Ｍｏの含有量が高すぎると、粗大な炭化物が形成されてしまい、靭性を低下させる懸念がある。このため、Ｍｏの含有量は、５．００質量％以下とする。本発明では、上記と同様の理由から、Ｍｏの含有量を４．００質量％以下にすることが好ましく、３．００質量％以下がより好ましい。 Mo=0.80-5.00% by mass
Mo is an element that is necessary for forming carbides to suppress the coarsening of crystal grains during solution treatment, precipitating fine carbides during aging treatment, and obtaining high aging hardness and high-temperature strength. In the present invention, for the same reasons as above, the Mo content is preferably 1.30 mass% or more, and more preferably 1.80 mass% or more. is more preferred.
On the other hand, if the Mo content is too high, coarse carbides are formed, which may reduce toughness. For this reason, the Mo content is set to 5.00 mass% or less. For the same reasons as above, the Mo content is preferably 4.00 mass % or less, and more preferably 3.00 mass % or less.
Ｖ＝１．００～２．５０質量％
Ｖ（バナジウム）は、炭化物を形成し、溶体化処理時の結晶粒の粗大化を抑制するために必要な元素である。また、Ｖは、時効処理時に微細な炭化物を析出し、特に高い時効硬さを得るために必要な元素である。このため、Ｖの含有量は、１．００質量％以上とする。本発明では、上記と同様の理由から、Ｖの含有量を１．２０質量％にすることが好ましい。
一方、Ｖの含有量が高すぎると、粗大な炭化物が形成されてしまい、靭性を低下させる懸念がある。このため、Ｖの含有量は、２．５０質量％以下とする。本発明では、上記と同様の理由から、Ｖの含有量を２．００質量％以下にすることが好ましく、１．５０質量％以下がより好ましい。 V=1.00-2.50% by mass
Vanadium (V) is an element necessary for forming carbides and suppressing the coarsening of crystal grains during solution treatment. In addition, V precipitates fine carbides during aging treatment, and is particularly effective in preventing coarsening of grains during high aging. V is an element necessary for obtaining hardness. Therefore, the V content is set to 1.00 mass % or more. In the present invention, for the same reason as above, the V content is set to 1.20 mass %. % is preferable.
On the other hand, if the V content is too high, coarse carbides are formed, which may reduce the toughness. For this reason, the V content is set to 2.50 mass% or less. For the same reasons as above, the V content is preferably 2.00 mass % or less, and more preferably 1.50 mass % or less.
Ｖ（バナジウム）は、炭化物を形成し、溶体化処理時の結晶粒の粗大化を抑制するために必要な元素である。また、Ｖは、時効処理時に微細な炭化物を析出し、特に高い時効硬さを得るために必要な元素である。このため、Ｖの含有量は、１．００質量％以上とする。本発明では、上記と同様の理由から、Ｖの含有量を１．２０質量％にすることが好ましい。
一方、Ｖの含有量が高すぎると、粗大な炭化物が形成されてしまい、靭性を低下させる懸念がある。このため、Ｖの含有量は、２．５０質量％以下とする。本発明では、上記と同様の理由から、Ｖの含有量を２．００質量％以下にすることが好ましく、１．５０質量％以下がより好ましい。 V=1.00-2.50% by mass
Vanadium (V) is an element necessary for forming carbides and suppressing the coarsening of crystal grains during solution treatment. In addition, V precipitates fine carbides during aging treatment, and is particularly effective in preventing coarsening of grains during high aging. V is an element necessary for obtaining hardness. Therefore, the V content is set to 1.00 mass % or more. In the present invention, for the same reason as above, the V content is set to 1.20 mass %. % is preferable.
On the other hand, if the V content is too high, coarse carbides are formed, which may reduce the toughness. For this reason, the V content is set to 2.50 mass% or less. For the same reasons as above, the V content is preferably 2.00 mass % or less, and more preferably 1.50 mass % or less.
Ｃｕ＝０．６０～４．００質量％
Ｃｕは、溶体化処理後の時効処理において、Ｆｅとの間に微細な金属間化合物を形成し、時効硬化型オーステナイト系工具鋼として必要な硬度を得るために必要な元素である。また、Ｃｕは、耐食性を高める効果がある元素である。このため、Ｃｕの含有量は、０．６０質量％以上とする。本発明では、上記と同様の理由から、Ｃｕの含有量を０．８０質量％以上にすることが好ましく、１．００質量％以上がより好ましい。
一方、Ｃｕの含有量が高すぎると、硬度を低下させる懸念がある。このため、Ｃｕの含有量は、４．００質量％以下とする。本発明では、上記と同様の理由から、Ｃｕの含有量を３．５０質量％以下にすることが好ましく、３．００質量％以下がより好ましい。 Cu=0.60-4.00% by mass
Cu is an element necessary for forming fine intermetallic compounds with Fe during aging treatment after solution treatment, and for obtaining the hardness required for age-hardening austenitic tool steel. Cu is an element that has the effect of enhancing corrosion resistance. Therefore, the Cu content is set to 0.60 mass % or more. In the present invention, for the same reason as above, the Cu content is set to 0.80 mass %. % or more, and more preferably 1.00% by mass or more.
On the other hand, if the Cu content is too high, there is a concern that the hardness may decrease. For this reason, the Cu content is set to 4.00 mass% or less. The content is preferably 3.50% by mass or less, and more preferably 3.00% by mass or less.
Ｃｕは、溶体化処理後の時効処理において、Ｆｅとの間に微細な金属間化合物を形成し、時効硬化型オーステナイト系工具鋼として必要な硬度を得るために必要な元素である。また、Ｃｕは、耐食性を高める効果がある元素である。このため、Ｃｕの含有量は、０．６０質量％以上とする。本発明では、上記と同様の理由から、Ｃｕの含有量を０．８０質量％以上にすることが好ましく、１．００質量％以上がより好ましい。
一方、Ｃｕの含有量が高すぎると、硬度を低下させる懸念がある。このため、Ｃｕの含有量は、４．００質量％以下とする。本発明では、上記と同様の理由から、Ｃｕの含有量を３．５０質量％以下にすることが好ましく、３．００質量％以下がより好ましい。 Cu=0.60-4.00% by mass
Cu is an element necessary for forming fine intermetallic compounds with Fe during aging treatment after solution treatment, and for obtaining the hardness required for age-hardening austenitic tool steel. Cu is an element that has the effect of enhancing corrosion resistance. Therefore, the Cu content is set to 0.60 mass % or more. In the present invention, for the same reason as above, the Cu content is set to 0.80 mass %. % or more, and more preferably 1.00% by mass or more.
On the other hand, if the Cu content is too high, there is a concern that the hardness may decrease. For this reason, the Cu content is set to 4.00 mass% or less. The content is preferably 3.50% by mass or less, and more preferably 3.00% by mass or less.
Ａｌ＝０．６０～４．００質量％
Ａｌは、溶体化処理後の時効処理において、Ｎｉとの間に微細な金属間化合物を形成し、時効硬化型オーステナイト系工具鋼として必要な硬度を得るために必要な元素である。このため、Ａｌの含有量は、０．６０質量％以上とする。本発明では、上記と同様の理由から、Ａｌの含有量を０．９０質量％以上にすることが好ましい。
一方、Ａｌの含有量が高すぎると、フェライトの生成を招く。このため、Ａｌ含有量は、４．００質量％以下とする。本発明では、上記と同様の理由から、Ａｌの含有量を３．００質量％以下にすることが好ましく、２．００質量％以下がより好ましい。 Al=0.60-4.00% by mass
Al is an element necessary for forming fine intermetallic compounds with Ni during aging treatment after solution treatment, and for obtaining the hardness required for age-hardenable austenitic tool steel. The Al content is set to 0.60 mass % or more. In the present invention, for the same reason as above, the Al content is preferably set to 0.90 mass % or more.
On the other hand, if the Al content is too high, it will lead to the formation of ferrite. Therefore, the Al content is set to 4.00 mass% or less. For the same reason as above, in the present invention, the Al content is set to 4.00 mass% or less. It is preferably 3.00% by mass or less, and more preferably 2.00% by mass or less.
Ａｌは、溶体化処理後の時効処理において、Ｎｉとの間に微細な金属間化合物を形成し、時効硬化型オーステナイト系工具鋼として必要な硬度を得るために必要な元素である。このため、Ａｌの含有量は、０．６０質量％以上とする。本発明では、上記と同様の理由から、Ａｌの含有量を０．９０質量％以上にすることが好ましい。
一方、Ａｌの含有量が高すぎると、フェライトの生成を招く。このため、Ａｌ含有量は、４．００質量％以下とする。本発明では、上記と同様の理由から、Ａｌの含有量を３．００質量％以下にすることが好ましく、２．００質量％以下がより好ましい。 Al=0.60-4.00% by mass
Al is an element necessary for forming fine intermetallic compounds with Ni during aging treatment after solution treatment, and for obtaining the hardness required for age-hardenable austenitic tool steel. The Al content is set to 0.60 mass % or more. In the present invention, for the same reason as above, the Al content is preferably set to 0.90 mass % or more.
On the other hand, if the Al content is too high, it will lead to the formation of ferrite. Therefore, the Al content is set to 4.00 mass% or less. For the same reason as above, in the present invention, the Al content is set to 4.00 mass% or less. It is preferably 3.00% by mass or less, and more preferably 2.00% by mass or less.
Ｓ＝０．０５００～０．１５００質量％
Ｓ（硫黄）は、Ｍｎとの間に硫化物を形成し、被削性を向上させるために必要な元素である。Ｓの含有量が高すぎると、得られる造形物の靭性を低下させる。このため、Ｓの含有量は、０．０５００～０．１５００質量％とする。本発明では、上記と同様の理由から、Ｓの含有量を０．０５００～０．１０００質量％にすることが好ましい。 S=0.0500 to 0.1500% by mass
S (sulfur) is an element necessary for forming sulfides together with Mn and improving machinability. If the S content is too high, the toughness of the obtained shaped article is reduced. For this reason, the S content is set to 0.0500 to 0.1500 mass%. In the present invention, for the same reason as above, the S content is set to 0.0500 to 0.1000 mass%. preferable.
Ｓ（硫黄）は、Ｍｎとの間に硫化物を形成し、被削性を向上させるために必要な元素である。Ｓの含有量が高すぎると、得られる造形物の靭性を低下させる。このため、Ｓの含有量は、０．０５００～０．１５００質量％とする。本発明では、上記と同様の理由から、Ｓの含有量を０．０５００～０．１０００質量％にすることが好ましい。 S=0.0500 to 0.1500% by mass
S (sulfur) is an element necessary for forming sulfides together with Mn and improving machinability. If the S content is too high, the toughness of the obtained shaped article is reduced. For this reason, the S content is set to 0.0500 to 0.1500 mass%. In the present invention, for the same reason as above, the S content is set to 0.0500 to 0.1000 mass%. preferable.
本発明の金属粉末は、例えば、ガスアトマイズ法や水アトマイズ法、ディスクアトマイズ法、プラズマアトマイズ法、回転電極法等によって製造することができる。
これらの製造方法の中でも、ガスアトマイズ法は、スクラップ金属や金属粗原料等を溶解原料に使用することが可能であり、予め所望の組成および形状の原料を準備する必要があるプラズマアトマイズ法や回転電極法等と比較して、安価なコストで製造することが可能となる。このため、本発明の金属粉末を得る製法として好ましい。 The metal powder of the present invention can be produced by, for example, gas atomization, water atomization, disk atomization, plasma atomization, rotating electrode atomization, or the like.
Among these manufacturing methods, the gas atomization method can use scrap metal, raw metal materials, etc. as the melting raw material, and can be manufactured at a lower cost than the plasma atomization method, the rotating electrode method, etc., which require the preparation of a raw material with a desired composition and shape in advance, and is therefore preferable as a manufacturing method for obtaining the metal powder of the present invention.
これらの製造方法の中でも、ガスアトマイズ法は、スクラップ金属や金属粗原料等を溶解原料に使用することが可能であり、予め所望の組成および形状の原料を準備する必要があるプラズマアトマイズ法や回転電極法等と比較して、安価なコストで製造することが可能となる。このため、本発明の金属粉末を得る製法として好ましい。 The metal powder of the present invention can be produced by, for example, gas atomization, water atomization, disk atomization, plasma atomization, rotating electrode atomization, or the like.
Among these manufacturing methods, the gas atomization method can use scrap metal, raw metal materials, etc. as the melting raw material, and can be manufactured at a lower cost than the plasma atomization method, the rotating electrode method, etc., which require the preparation of a raw material with a desired composition and shape in advance, and is therefore preferable as a manufacturing method for obtaining the metal powder of the present invention.
本発明の金属粉末は、体積基準の累積粒度分布の５０％粒径（以下、「Ｄ５０」という。）が１０～２５０μｍであることが好ましい。本発明の金属粉末は、そのＤ５０を２５０μｍ以下とすることにより、粉末の溶融が容易になり、造形物中に欠陥が形成されることを抑制できる。
また、本発明の金属粉末は、そのＤ５０を１０μｍ以上とすることにより、雰囲気中の湿気等の影響を受けにくくなり、良好な流動性を確保することができる。
尚、本発明の金属粉末おける累積粒度分布は、累積体積粒度分布で表わされ、そのＤ５０は、ＪＩＳ Ｚ ８８２５で規定される、レーザー回折散乱法による測定値で表わされる。 The metal powder of the present invention preferably has a 50% particle size (hereinafter referred to as "D50") of a cumulative particle size distribution based on volume of 10 to 250 μm. By making the metal powder of the present invention have a D50 of 250 μm or less, the powder can be easily melted and the formation of defects in the molded product can be suppressed.
Furthermore, by making the metal powder of the present invention have a D50 of 10 μm or more, it becomes less susceptible to the effects of moisture in the atmosphere, etc., and good fluidity can be ensured.
The cumulative particle size distribution of the metal powder of the present invention is represented by a cumulative volumetric particle size distribution, and its D50 is represented by a value measured by the laser diffraction scattering method defined in JIS Z 8825.
また、本発明の金属粉末は、そのＤ５０を１０μｍ以上とすることにより、雰囲気中の湿気等の影響を受けにくくなり、良好な流動性を確保することができる。
尚、本発明の金属粉末おける累積粒度分布は、累積体積粒度分布で表わされ、そのＤ５０は、ＪＩＳ Ｚ ８８２５で規定される、レーザー回折散乱法による測定値で表わされる。 The metal powder of the present invention preferably has a 50% particle size (hereinafter referred to as "D50") of a cumulative particle size distribution based on volume of 10 to 250 μm. By making the metal powder of the present invention have a D50 of 250 μm or less, the powder can be easily melted and the formation of defects in the molded product can be suppressed.
Furthermore, by making the metal powder of the present invention have a D50 of 10 μm or more, it becomes less susceptible to the effects of moisture in the atmosphere, etc., and good fluidity can be ensured.
The cumulative particle size distribution of the metal powder of the present invention is represented by a cumulative volumetric particle size distribution, and its D50 is represented by a value measured by the laser diffraction scattering method defined in JIS Z 8825.
本発明の金属粉末は、造形方法に合わせて、メッシュを用いた篩別分級や気流分級等により粉末粒径を調整することが好ましい。
例えば、レーザービームを用いた粉末床溶融結合法に使用される金属粉末は、熱源となるレーザービームにより金属粉末を溶融させる一方で、熱影響の範囲を極力狭めるために溶融しづらい粗大な粉末を除去する必要がある。また、金属粉末の敷設性を確保するための最適な流動性を得るために、付着性の高い微細な粉末も除去する必要がある。このため、本発明の金属粉末を粉末床溶融結合法に適用する場合は、Ｄ５０を１０～５３μｍの範囲に調整することが好ましい。 The particle size of the metal powder of the present invention is preferably adjusted by sieving classification using a mesh or air current classification in accordance with the molding method.
For example, in the case of metal powder used in the powder bed fusion method using a laser beam, the metal powder is melted by the laser beam as a heat source, while coarse powder that is difficult to melt must be removed in order to minimize the range of the thermal effect. Also, in order to obtain optimal fluidity to ensure the laying of the metal powder, fine powder with high adhesion must be removed. Therefore, when the metal powder of the present invention is applied to the powder bed fusion method, it is preferable to adjust D50 to the range of 10 to 53 μm.
例えば、レーザービームを用いた粉末床溶融結合法に使用される金属粉末は、熱源となるレーザービームにより金属粉末を溶融させる一方で、熱影響の範囲を極力狭めるために溶融しづらい粗大な粉末を除去する必要がある。また、金属粉末の敷設性を確保するための最適な流動性を得るために、付着性の高い微細な粉末も除去する必要がある。このため、本発明の金属粉末を粉末床溶融結合法に適用する場合は、Ｄ５０を１０～５３μｍの範囲に調整することが好ましい。 The particle size of the metal powder of the present invention is preferably adjusted by sieving classification using a mesh or air current classification in accordance with the molding method.
For example, in the case of metal powder used in the powder bed fusion method using a laser beam, the metal powder is melted by the laser beam as a heat source, while coarse powder that is difficult to melt must be removed in order to minimize the range of the thermal effect. Also, in order to obtain optimal fluidity to ensure the laying of the metal powder, fine powder with high adhesion must be removed. Therefore, when the metal powder of the present invention is applied to the powder bed fusion method, it is preferable to adjust D50 to the range of 10 to 53 μm.
本発明の造形物は、積層方向と平行な断面において、観察視野中に含まれるＭｎＳの最大長さが１μｍ未満である。ここで、積層方向と平行な断面とは、例えば、加圧焼結法により得た造形物であれば金属粉末の充填方向と平行な断面のことをいい、積層造形法により得た造形物であれば複数の層状の凝固層が形成される方向と平行な断面のことをいう。
造形物の積層方向と平行な断面に確認されるＭｎＳをＥＰＭＡで分析したときの、Ｓの元素マッピング画像の一例を図２に示す。図２中で、黒色部で示される素地中に灰色部で示される点状の介在物がＭｎＳである。
本発明の造形物は、ＭｎＳの最大長さを１μｍ未満とすることで、割れなどの内部欠陥を減少させることができ、延性や靭性などの機械的特性の低下を抑制できる。 In the shaped product of the present invention, the maximum length of MnS included in the observation field in a cross section parallel to the stacking direction is less than 1 μm. Here, the cross section parallel to the stacking direction refers to, for example, a cross section parallel to the filling direction of the metal powder in the case of a shaped product obtained by a pressure sintering method, or a cross section parallel to the direction in which multiple laminar solidified layers are formed in the case of a shaped product obtained by an additive manufacturing method.
An example of an elemental mapping image of S when MnS confirmed in a cross section parallel to the layering direction of a molded object was analyzed by EPMA is shown in Figure 2. In Figure 2, the dot-like inclusions shown in gray in the base material shown in black are MnS.
In the shaped article of the present invention, by making the maximum length of MnS less than 1 μm, internal defects such as cracks can be reduced, and deterioration of mechanical properties such as ductility and toughness can be suppressed.
造形物の積層方向と平行な断面に確認されるＭｎＳをＥＰＭＡで分析したときの、Ｓの元素マッピング画像の一例を図２に示す。図２中で、黒色部で示される素地中に灰色部で示される点状の介在物がＭｎＳである。
本発明の造形物は、ＭｎＳの最大長さを１μｍ未満とすることで、割れなどの内部欠陥を減少させることができ、延性や靭性などの機械的特性の低下を抑制できる。 In the shaped product of the present invention, the maximum length of MnS included in the observation field in a cross section parallel to the stacking direction is less than 1 μm. Here, the cross section parallel to the stacking direction refers to, for example, a cross section parallel to the filling direction of the metal powder in the case of a shaped product obtained by a pressure sintering method, or a cross section parallel to the direction in which multiple laminar solidified layers are formed in the case of a shaped product obtained by an additive manufacturing method.
An example of an elemental mapping image of S when MnS confirmed in a cross section parallel to the layering direction of a molded object was analyzed by EPMA is shown in Figure 2. In Figure 2, the dot-like inclusions shown in gray in the base material shown in black are MnS.
In the shaped article of the present invention, by making the maximum length of MnS less than 1 μm, internal defects such as cracks can be reduced, and deterioration of mechanical properties such as ductility and toughness can be suppressed.
ＭｎＳの最大長さが１μｍ未満であることを測定するための、積層方向と平行な断面におけるＳの濃度分布を面分析するには、例えば、ＥＰＭＡを利用することができる。まず、造形物の任意の位置から、造形物の積層方向と平行する断面を採取する。そして、任意の領域、例えば５０００倍で、ＥＰＭＡ分析することで、Ｓの分布を得ることができる。
To measure whether the maximum length of MnS is less than 1 μm, EPMA, for example, can be used to perform surface analysis of the S concentration distribution in a cross section parallel to the stacking direction. First, a cross section parallel to the stacking direction of the molded object is taken from an arbitrary position on the molded object. Then, an arbitrary area can be analyzed with EPMA at, for example, 5000x magnification to obtain the S distribution.
また、本発明の造形物は、被削性を向上させる観点から、Ｓの含有量を、０．０５００～０．１５００質量％にする。そして、本発明では、上記と同様の理由から、Ｓの含有量を０．０５００～０．１０００質量％にすることが好ましい。
Furthermore, from the viewpoint of improving machinability, the shaped object of the present invention has an S content of 0.0500 to 0.1500 mass%. And, in the present invention, for the same reasons as above, it is preferable that the S content be 0.0500 to 0.1000 mass%.
本発明の造形物は、例えば、粉末焼結法で得ることができる。具体的には、上述した金属粉末を加圧焼結することにより得ることができる。そして、加圧焼結としては、例えば、ＨＩＰ法、ホットプレス法、通電焼結法等を適用することができる。
また、本発明の造形物は、金属粉末を層状に敷き詰める工程と、この敷き詰められた金属粉末を走査熱源によって逐次溶融し凝固させることで凝固層を形成する工程とを繰り返して、複数の層状の凝固層を形成する積層造形法も適用することができる。ここで、走査熱源には、例えば、レーザーや電子ビームを利用できる。そして、この走査熱源の直径を、金属粉末の平均直径よりも大きくすることで、金属粉末の集合を均等に溶融できる点で好ましい。 The shaped object of the present invention can be obtained, for example, by a powder sintering method. Specifically, the shaped object can be obtained by pressure sintering the above-mentioned metal powder. For pressure sintering, for example, a HIP method, a hot pressing method, an electric current sintering method, etc. can be applied.
The object of the present invention can also be applied to an additive manufacturing method in which a step of spreading metal powder in layers and a step of forming solidified layers by successively melting and solidifying the spread metal powder with a scanning heat source to form a solidified layer are repeated to form a plurality of solidified layers. Here, for example, a laser or an electron beam can be used as the scanning heat source. In addition, it is preferable to make the diameter of the scanning heat source larger than the average diameter of the metal powder, in order to melt the collection of metal powder evenly.
また、本発明の造形物は、金属粉末を層状に敷き詰める工程と、この敷き詰められた金属粉末を走査熱源によって逐次溶融し凝固させることで凝固層を形成する工程とを繰り返して、複数の層状の凝固層を形成する積層造形法も適用することができる。ここで、走査熱源には、例えば、レーザーや電子ビームを利用できる。そして、この走査熱源の直径を、金属粉末の平均直径よりも大きくすることで、金属粉末の集合を均等に溶融できる点で好ましい。 The shaped object of the present invention can be obtained, for example, by a powder sintering method. Specifically, the shaped object can be obtained by pressure sintering the above-mentioned metal powder. For pressure sintering, for example, a HIP method, a hot pressing method, an electric current sintering method, etc. can be applied.
The object of the present invention can also be applied to an additive manufacturing method in which a step of spreading metal powder in layers and a step of forming solidified layers by successively melting and solidifying the spread metal powder with a scanning heat source to form a solidified layer are repeated to form a plurality of solidified layers. Here, for example, a laser or an electron beam can be used as the scanning heat source. In addition, it is preferable to make the diameter of the scanning heat source larger than the average diameter of the metal powder, in order to melt the collection of metal powder evenly.
レーザー出力が高すぎると、レーザー照射中の金属の溶融部が深くなって、凝固時に強い偏析が形成されやすくなる。しかし、レーザー出力が低すぎると、金属粉末を十分に溶融できなくなり、凝固後の造形物中には、金属粉末の隙間に由来する空孔が多く形成されてしまう。このため、レーザー出力は５０～３５０Ｗとすることが好ましい。
If the laser output is too high, the molten part of the metal during laser irradiation will become deeper, making it easier for strong segregation to form during solidification. However, if the laser output is too low, the metal powder will not melt sufficiently, and many voids resulting from gaps in the metal powder will form in the molded object after solidification. For this reason, it is preferable to set the laser output to 50 to 350 W.
レーザーの走査速度が速すぎると、金属粉末が十分な熱を得られないことで、造形に必要な溶融が困難になってしまい、凝固後の部材中に空孔が多く形成されやすくなる。一方、レーザーの走査速度が遅すぎると、レーザー照射中の金属の溶融部が深くなって偏析が形成されやすくなる。また、レーザーの走査速度が遅すぎると、金属粉末に過剰な熱が与えられて溶融部の流動が盛んになることでガスを巻き込んでしまい、凝固後の部材に気泡が混入しやすい。このため、走査速度は２００～２０００ｍｍ／秒とすることが好ましい。
If the laser scanning speed is too fast, the metal powder will not receive enough heat, making it difficult to melt the powder as needed for shaping, and many voids will likely form in the solidified component. On the other hand, if the laser scanning speed is too slow, the molten part of the metal will become deep during laser irradiation, making it more likely for segregation to form. Also, if the laser scanning speed is too slow, excess heat will be applied to the metal powder, causing the molten part to flow vigorously, which will entrain gas and make it more likely for air bubbles to become mixed into the solidified component. For this reason, it is preferable to set the scanning speed to 200 to 2000 mm/sec.
走査ピッチが大きくなりすぎると、レーザー照射時に、敷き詰められた金属粉末を全面で溶融することが難しくなってしまい、凝固後の部材の内部に空孔が形成される要因となり得る。なお、走査ピッチとは、走査するビーム間の距離のことである。そして、走査ピッチが小さくなりすぎると、レーザー照射中の金属の溶融部が深くなって偏析が形成されやすくなる。このため、走査ピッチは０．０２～０．２０ｍｍとすることが好ましい。
If the scanning pitch becomes too large, it becomes difficult to melt the entire surface of the spread metal powder when the laser is irradiated, which can lead to the formation of voids inside the component after solidification. The scanning pitch is the distance between the scanning beams. If the scanning pitch becomes too small, the molten part of the metal becomes deep during laser irradiation, making it easier for segregation to form. For this reason, it is preferable to set the scanning pitch to 0.02 to 0.20 mm.
なお、一走査あたりの積層厚さが大きすぎると、レーザー照射時に、敷き詰められた金属粉末の全体に熱が伝わり難くなって、造形に必要な溶融が困難になる。「一走査あたりの積層厚さ」とは、一層々々を造形するときに敷き詰めた「一層毎の金属粉末層の厚さ」のことである。そして、一走査あたりの積層厚さが小さすぎると、所定の造形物の大きさにするまでの積層数が多くなって、造形に要する時間が長くなる。このため、一走査あたりの積層厚さは１０～２００μｍとすることが好ましい。
If the layer thickness per scan is too large, heat will not be easily transferred to the entire metal powder when the laser is irradiated, making it difficult to achieve the melting required for shaping. The "layer thickness per scan" refers to the "thickness of each metal powder layer" that is laid out when shaping each layer. If the layer thickness per scan is too small, the number of layers required to reach the desired size of the object will increase, and the time required for shaping will increase. For this reason, it is preferable to set the layer thickness per scan to 10 to 200 μm.
本発明の造形物は、さらに、溶体化処理および時効処理を含む熱処理工程を行なうことが好ましい。時効硬化型オーステナイト系工具鋼は、部材に溶体化処理および時効処理を施してから製品として使用される。溶体化処理を行なうことで、造形中の熱で析出した金属間化合物を溶体化させ、さらに、加圧焼結法によって形成される異方性または積層造形法で形成される溶融池や凝固組織によって形成される異方性を有した組織形態を再結晶させることで、等軸状の結晶粒を有した組織とし、機械的特性の異方性を抑制することができる。
The molded product of the present invention is preferably further subjected to a heat treatment process including a solution treatment and an aging treatment. The age-hardened austenitic tool steel is used as a product after the component is subjected to a solution treatment and an aging treatment. By performing a solution treatment, the intermetallic compounds precipitated by the heat during molding are put into solution, and further, by recrystallizing the anisotropic structure formed by the pressure sintering method or the molten pool or solidified structure formed by the additive manufacturing method, a structure with equiaxed crystal grains is obtained, and the anisotropy of the mechanical properties can be suppressed.
溶体化処理温度は、１１００℃以上とすることが好ましく、１１５０℃以上とすることがより好ましい。溶体化処理温度を高くすることで、造形時に形成される偏析の解消効果が向上する。但し、溶体化処理温度が高くなりすぎると、造形物本体が溶融してしまうために、造形物の強度および靭性が低下する。このため、溶体化処理温度は１２５０℃以下とすることが好ましく、１２００℃以下にすることがより好ましい。
そして、溶体化処理時間（溶体化処理温度での維持時間）は、１０分以上とすることが好ましく、１５分以上にすることがより好ましい。溶体化処理時間を長くすることで、造形時に形成される偏析の解消効果が向上する。但し、溶体化処理時間が長くなりすぎると、旧オーステナイト粒径が粗大化する。このため、溶体化処理時間は１２０分以下とすることが好ましく、９０分以下にすることがより好ましい。 The solution treatment temperature is preferably 1100°C or higher, and more preferably 1150°C or higher. Increasing the solution treatment temperature improves the effect of eliminating segregation formed during shaping. However, if the solution treatment temperature is too high, the main body of the shaped object melts, and the strength and toughness of the shaped object decrease. For this reason, the solution treatment temperature is preferably 1250°C or lower, and more preferably 1200°C or lower.
The solution treatment time (maintenance time at the solution treatment temperature) is preferably 10 minutes or more, and more preferably 15 minutes or more. By increasing the solution treatment time, the effect of eliminating segregation formed during shaping is improved. However, if the solution treatment time is too long, the prior austenite grain size becomes coarse. For this reason, the solution treatment time is preferably 120 minutes or less, and more preferably 90 minutes or less.
そして、溶体化処理時間（溶体化処理温度での維持時間）は、１０分以上とすることが好ましく、１５分以上にすることがより好ましい。溶体化処理時間を長くすることで、造形時に形成される偏析の解消効果が向上する。但し、溶体化処理時間が長くなりすぎると、旧オーステナイト粒径が粗大化する。このため、溶体化処理時間は１２０分以下とすることが好ましく、９０分以下にすることがより好ましい。 The solution treatment temperature is preferably 1100°C or higher, and more preferably 1150°C or higher. Increasing the solution treatment temperature improves the effect of eliminating segregation formed during shaping. However, if the solution treatment temperature is too high, the main body of the shaped object melts, and the strength and toughness of the shaped object decrease. For this reason, the solution treatment temperature is preferably 1250°C or lower, and more preferably 1200°C or lower.
The solution treatment time (maintenance time at the solution treatment temperature) is preferably 10 minutes or more, and more preferably 15 minutes or more. By increasing the solution treatment time, the effect of eliminating segregation formed during shaping is improved. However, if the solution treatment time is too long, the prior austenite grain size becomes coarse. For this reason, the solution treatment time is preferably 120 minutes or less, and more preferably 90 minutes or less.
そして、この部材に時効処理を行なうことで、各種の金属間化合物を組織中に析出させて、例えば、硬さを２０～５０ＨＲＣに調整して、より優れた高強度と高靭性とを得ることができる。
時効処理温度は、４００℃以上とすることが好ましく、４５０℃以上がより好ましく、５００℃以上がさらに好ましい。時効処理温度は、５５０℃以上にすることが特に好ましい。時効処理温度を高くすることで、より強度向上の効果が向上する。但し、時効処理温度が高くなりすぎると、金属間化合物が粗大化して、金属間化合物の析出量に見合った強度が十分に得られなくなる。このため、時効処理温度は９００℃以下とすることが好ましく、８００℃以下にすることがより好ましい。
そして、時効処理時間（時効処理温度での維持時間）は、３０分以上とすることが好ましく、６０分以上にすることがより好ましい。時効処理時間を長くすることで、形成される金属間化合物量が増加する。但し、時効処理時間が長くなりすぎると、金属間化合物が粗大化し、強度が低下する。このため、時効処理時間は６００分以下とすることが好ましく、４００分以下にすることがより好ましい。 Then, by subjecting this member to aging treatment, various intermetallic compounds are precipitated in the structure, and, for example, the hardness can be adjusted to 20 to 50 HRC, thereby obtaining superior high strength and high toughness.
The aging temperature is preferably 400°C or higher, more preferably 450°C or higher, and even more preferably 500°C or higher. The aging temperature is particularly preferably 550°C or higher. Increasing the aging temperature further improves the effect of improving strength. However, if the aging temperature is too high, the intermetallic compounds become coarse, and sufficient strength commensurate with the amount of precipitation of the intermetallic compounds cannot be obtained. For this reason, the aging temperature is preferably 900°C or lower, and more preferably 800°C or lower.
The aging treatment time (maintenance time at the aging treatment temperature) is preferably 30 minutes or more, and more preferably 60 minutes or more. By increasing the aging treatment time, the amount of intermetallic compounds formed increases. However, if the aging treatment time is too long, the intermetallic compounds become coarse and the strength decreases. For this reason, the aging treatment time is preferably 600 minutes or less, and more preferably 400 minutes or less.
時効処理温度は、４００℃以上とすることが好ましく、４５０℃以上がより好ましく、５００℃以上がさらに好ましい。時効処理温度は、５５０℃以上にすることが特に好ましい。時効処理温度を高くすることで、より強度向上の効果が向上する。但し、時効処理温度が高くなりすぎると、金属間化合物が粗大化して、金属間化合物の析出量に見合った強度が十分に得られなくなる。このため、時効処理温度は９００℃以下とすることが好ましく、８００℃以下にすることがより好ましい。
そして、時効処理時間（時効処理温度での維持時間）は、３０分以上とすることが好ましく、６０分以上にすることがより好ましい。時効処理時間を長くすることで、形成される金属間化合物量が増加する。但し、時効処理時間が長くなりすぎると、金属間化合物が粗大化し、強度が低下する。このため、時効処理時間は６００分以下とすることが好ましく、４００分以下にすることがより好ましい。 Then, by subjecting this member to aging treatment, various intermetallic compounds are precipitated in the structure, and, for example, the hardness can be adjusted to 20 to 50 HRC, thereby obtaining superior high strength and high toughness.
The aging temperature is preferably 400°C or higher, more preferably 450°C or higher, and even more preferably 500°C or higher. The aging temperature is particularly preferably 550°C or higher. Increasing the aging temperature further improves the effect of improving strength. However, if the aging temperature is too high, the intermetallic compounds become coarse, and sufficient strength commensurate with the amount of precipitation of the intermetallic compounds cannot be obtained. For this reason, the aging temperature is preferably 900°C or lower, and more preferably 800°C or lower.
The aging treatment time (maintenance time at the aging treatment temperature) is preferably 30 minutes or more, and more preferably 60 minutes or more. By increasing the aging treatment time, the amount of intermetallic compounds formed increases. However, if the aging treatment time is too long, the intermetallic compounds become coarse and the strength decreases. For this reason, the aging treatment time is preferably 600 minutes or less, and more preferably 400 minutes or less.
表１の試料Ｎｏ．１－１の組成となるように、各金属粗原料を準備した後、高周波誘導溶解炉に装入して溶融させ、この溶融金属をアルゴンガスによって粉砕することでアトマイズ粉末を得た。
得られたアトマイズ粉末に対して、メッシュを用いた篩別分級および気流分級を行なうことで粉末粒径を調整して、Ｄ５０が２８．８μｍである本発明例となる金属粉末を得た。
次いで、この金属粉末を用いて造形物を製作した。造形には、ＥＯＳ製のＥＯＳ－Ｍ２９０を用いて、表２に示す造形条件で造形物を作製した。得られた本発明例となる造形物の成分分析結果を表１に試料Ｎｏ．１－２として示す。
また、比較例として、表１の試料Ｎｏ．２の成分組成となる溶湯から造塊プロセスを経て、熱間で塑性加工して得た鋼材を準備した。 After preparing each metal raw material so as to have the composition of Sample No. 1-1 in Table 1, the raw materials were charged into a high-frequency induction melting furnace and melted, and the molten metal was pulverized with argon gas to obtain an atomized powder.
The resulting atomized powder was subjected to sieving classification using a mesh and air flow classification to adjust the powder particle size, thereby obtaining a metal powder of the present invention having a D50 of 28.8 μm.
Next, a molded object was produced using this metal powder. For molding, an EOS-M290 manufactured by EOS was used to produce the molded object under the molding conditions shown in Table 2. The results of component analysis of the obtained molded object, which is an example of the present invention, are shown in Table 1 as Sample No. 1-2.
Also, as a comparative example, a steel material was prepared by subjecting a molten metal having the composition of sample No. 2 in Table 1 to an ingot-making process and then to hot plastic working.
得られたアトマイズ粉末に対して、メッシュを用いた篩別分級および気流分級を行なうことで粉末粒径を調整して、Ｄ５０が２８．８μｍである本発明例となる金属粉末を得た。
次いで、この金属粉末を用いて造形物を製作した。造形には、ＥＯＳ製のＥＯＳ－Ｍ２９０を用いて、表２に示す造形条件で造形物を作製した。得られた本発明例となる造形物の成分分析結果を表１に試料Ｎｏ．１－２として示す。
また、比較例として、表１の試料Ｎｏ．２の成分組成となる溶湯から造塊プロセスを経て、熱間で塑性加工して得た鋼材を準備した。 After preparing each metal raw material so as to have the composition of Sample No. 1-1 in Table 1, the raw materials were charged into a high-frequency induction melting furnace and melted, and the molten metal was pulverized with argon gas to obtain an atomized powder.
The resulting atomized powder was subjected to sieving classification using a mesh and air flow classification to adjust the powder particle size, thereby obtaining a metal powder of the present invention having a D50 of 28.8 μm.
Next, a molded object was produced using this metal powder. For molding, an EOS-M290 manufactured by EOS was used to produce the molded object under the molding conditions shown in Table 2. The results of component analysis of the obtained molded object, which is an example of the present invention, are shown in Table 1 as Sample No. 1-2.
Also, as a comparative example, a steel material was prepared by subjecting a molten metal having the composition of sample No. 2 in Table 1 to an ingot-making process and then to hot plastic working.
炭化物およびＭｎＳの存在状態の確認をした。図１に本発明例となる金属粉末、図２に本発明例となる造形物、図３に比較例となる鋼材の断面をそれぞれＥＰＭＡで分析したときの、Ｓの元素マッピング画像をそれぞれ示す。
比較例となる所謂溶製法で得られた鋼材においては、図３の灰色部で示されるように、最大長さが１０μｍを超えるＭｎＳが多数確認された。
これに対して、本発明例となる金属粉末およびそれを用いて造形した造形物においては、図１および図２の灰色部で示されるように、いずれのＭｎＳも最大長さが１μｍ未満であり、微細に分散していることが確認できた。 The state of existence of carbides and MnS was confirmed. Figure 1 shows elemental mapping images of S when a cross section of a metal powder according to an example of the present invention, a shaped product according to an example of the present invention, and a steel material according to a comparative example were analyzed by EPMA.
In the comparative steel material obtained by the so-called melting method, a large number of MnS particles having a maximum length exceeding 10 μm were confirmed, as shown in the gray areas in FIG.
In contrast, in the metal powders of the present invention and the objects produced using the same, as shown in the gray areas in Figures 1 and 2, the maximum length of all MnS particles was less than 1 µm, and it was confirmed that the MnS particles were finely dispersed.
比較例となる所謂溶製法で得られた鋼材においては、図３の灰色部で示されるように、最大長さが１０μｍを超えるＭｎＳが多数確認された。
これに対して、本発明例となる金属粉末およびそれを用いて造形した造形物においては、図１および図２の灰色部で示されるように、いずれのＭｎＳも最大長さが１μｍ未満であり、微細に分散していることが確認できた。 The state of existence of carbides and MnS was confirmed. Figure 1 shows elemental mapping images of S when a cross section of a metal powder according to an example of the present invention, a shaped product according to an example of the present invention, and a steel material according to a comparative example were analyzed by EPMA.
In the comparative steel material obtained by the so-called melting method, a large number of MnS particles having a maximum length exceeding 10 μm were confirmed, as shown in the gray areas in FIG.
In contrast, in the metal powders of the present invention and the objects produced using the same, as shown in the gray areas in Figures 1 and 2, the maximum length of all MnS particles was less than 1 µm, and it was confirmed that the MnS particles were finely dispersed.
上記で得た造形物に１１８０℃で１時間の溶体化処理を実施し、組織形態を確認した。図４に本発明例となる造形物、図５に比較例となる鋼材の光学顕微鏡組織をそれぞれ示す。
比較例の鋼材においては、最大長さが１０μｍを超えるＭｎＳが多数確認された。
これに対して、本発明例となる造形物においては、いずれのＭｎＳも最大長さが１μｍ未満であり、微細に分散していることが確認できた。
このようなＭｎＳや炭化物の微細分散は、工具鋼として必要な機械的特性や被削性に良好な効果を与えることが期待できる。 The shaped article obtained above was subjected to solution treatment at 1180° C. for 1 hour, and the microstructure was confirmed. Fig. 4 shows the optical micrographs of the shaped article according to the present invention, and Fig. 5 shows the optical micrographs of the steel material according to the comparative example.
In the steel material of the comparative example, a large number of MnS particles with a maximum length exceeding 10 μm were confirmed.
In contrast, in the shaped objects according to the present invention, the maximum length of all MnS particles was less than 1 μm, and it was confirmed that the MnS particles were finely dispersed.
Such fine dispersion of MnS and carbides is expected to have a favorable effect on the mechanical properties and machinability required for a tool steel.
比較例の鋼材においては、最大長さが１０μｍを超えるＭｎＳが多数確認された。
これに対して、本発明例となる造形物においては、いずれのＭｎＳも最大長さが１μｍ未満であり、微細に分散していることが確認できた。
このようなＭｎＳや炭化物の微細分散は、工具鋼として必要な機械的特性や被削性に良好な効果を与えることが期待できる。 The shaped article obtained above was subjected to solution treatment at 1180° C. for 1 hour, and the microstructure was confirmed. Fig. 4 shows the optical micrographs of the shaped article according to the present invention, and Fig. 5 shows the optical micrographs of the steel material according to the comparative example.
In the steel material of the comparative example, a large number of MnS particles with a maximum length exceeding 10 μm were confirmed.
In contrast, in the shaped objects according to the present invention, the maximum length of all MnS particles was less than 1 μm, and it was confirmed that the MnS particles were finely dispersed.
Such fine dispersion of MnS and carbides is expected to have a favorable effect on the mechanical properties and machinability required for a tool steel.
Claims (2)
- 質量％で、Ｃ＝０．４０～０．７０％、Ｓｉ＝１．４０％以下、Ｍｎ＝５．００～１５．００％、Ｎｉ＝２．００～１０．００％、Ｃｒ＝７．００～１４．００％、Ｍｏ＝０．８０～５．００％、Ｖ＝１．００～２．５０％、Ｃｕ＝０．６０～４．００％、Ａｌ＝０．６０～４．００％、Ｓ＝０．０５００～０．１５００％含有し、残部がＦｅおよび不可避的不純物からなる造形用金属粉末。 A metal powder for molding containing, by mass, C = 0.40-0.70%, Si = 1.40% or less, Mn = 5.00-15.00%, Ni = 2.00-10.00%, Cr = 7.00-14.00%, Mo = 0.80-5.00%, V = 1.00-2.50%, Cu = 0.60-4.00%, Al = 0.60-4.00%, S = 0.0500-0.1500%, with the remainder being Fe and unavoidable impurities.
- 質量％で、Ｃ＝０．４０～０．７０％、Ｓｉ＝１．４０％以下、Ｍｎ＝５．００～１５．００％、Ｎｉ＝２．００～１０．００％、Ｃｒ＝７．００～１４．００％、Ｍｏ＝０．８０～５．００％、Ｖ＝１．００～２．５０％、Ｃｕ＝０．６０～４．００％、Ａｌ＝０．６０～４．００％、Ｓ＝０．０５００～０．１５００％含有し、残部がＦｅおよび不可避的不純物からなり、積層方向と平行な断面において、ＭｎＳの最大長さが１μｍ未満である造形物。
A shaped object containing, by mass, C = 0.40 to 0.70%, Si = 1.40% or less, Mn = 5.00 to 15.00%, Ni = 2.00 to 10.00%, Cr = 7.00 to 14.00%, Mo = 0.80 to 5.00%, V = 1.00 to 2.50%, Cu = 0.60 to 4.00%, Al = 0.60 to 4.00%, S = 0.0500 to 0.1500%, with the balance being Fe and unavoidable impurities, and in a cross section parallel to the stacking direction, the maximum length of MnS is less than 1 μm.
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Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05302149A (en) * | 1992-02-25 | 1993-11-16 | Hitachi Metals Ltd | Age hardening type austenitic tool steel |
| JP2010222661A (en) * | 2009-03-24 | 2010-10-07 | Seiko Epson Corp | Metal powder and sintered compact |
| JP2020172674A (en) * | 2019-04-09 | 2020-10-22 | セイコーエプソン株式会社 | Powder for lamination molding, lamination molded object and manufacturing method of lamination molded object |
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- 2024-03-22 WO PCT/JP2024/011470 patent/WO2024203945A1/en unknown
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05302149A (en) * | 1992-02-25 | 1993-11-16 | Hitachi Metals Ltd | Age hardening type austenitic tool steel |
| JP2010222661A (en) * | 2009-03-24 | 2010-10-07 | Seiko Epson Corp | Metal powder and sintered compact |
| JP2020172674A (en) * | 2019-04-09 | 2020-10-22 | セイコーエプソン株式会社 | Powder for lamination molding, lamination molded object and manufacturing method of lamination molded object |
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