# US 12,000,006 B2 · 3D printable hard ferrous metallic alloys for powder bed fusion

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- Number: US 12,000,006 B2
- Document ID: US12000006B2
- Status: Granted
- Kind: B2
- Application number: 17/248,953
- Filed: 2021-02-15
- Published: 2021-09-30
- Granted: 2024-06-04
- Earliest claimed: 2016-11-01
- Assignees: MacLean-Fogg Company
- Applicants: Maclean-Fogg Company
- Inventors: Charles D. Tuffile; Harald Lemke
- Web page: https://patentgrep.com/patent/US12000006B2

## CPC

- C21D 1/18: Hardening (C21D1/02 takes precedence); Quenching with or without subsequent tempering (quenching devices C21D1/62)
- B22F 10/00: Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00)
- B22F 10/20: Direct sintering or melting
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 10/32: of the atmosphere, e.g. composition or pressure in a building chamber
- B22F 10/36: of energy beam parameters
- B22F 12/17: to heat the build chamber or platform
- B23K 15/0086: {welding for purposes other than joining, e.g. build-up welding}
- B23K 26/0006: {taking account of the properties of the material involved (B23K26/32, B23K26/40 take precedence)}
- B23K 26/342: Build-up welding
- B33Y 10/00: Processes of additive manufacturing
- B33Y 40/00: Auxiliary operations or equipment, e.g. for material handling
- B33Y 70/00: Materials specially adapted for additive manufacturing
- C21D 1/613: Gases; Liquefied or solidified normally gaseous material
- C21D 6/002: {containing Cr (C21D6/004 takes precedence)}
- C21D 6/004: {containing Cr and Ni}
- C21D 6/005: {containing Mn}
- C21D 6/008: {containing Si}
- C21D 8/0257: {with diffusion of elements, e.g. decarburising, nitriding}
- C22C 38/001: {containing N}
- C22C 38/02: containing silicon
- C22C 38/04: containing manganese
- C22C 38/20: with copper
- C22C 38/22: with molybdenum or tungsten
- C22C 38/26: with niobium or tantalum
- C22C 38/40: with nickel
- C22C 38/42: with copper
- C22C 38/44: with molybdenum or tungsten
- C22C 38/48: with niobium or tantalum
- C23C 8/22: of ferrous surfaces
- C23C 8/54: Carbo-nitriding
- B22F 1/05: Metallic powder characterised by the size or surface area of the particles
- B22F 9/082: {atomising using a fluid (using centrifugal force B22F9/10)}
- B22F 2003/241: {Chemical after-treatment on the surface}
- B22F 2003/248: {Thermal after-treatment}
- B22F 2201/02: Nitrogen
- B22F 2201/30: Carburising atmosphere
- B22F 2998/10: Processes characterised by the sequence of their steps
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- C22C 33/0278: {with at least one alloying element having a minimum content above 5%}
- Y02P 10/25: Process efficiency
- C21D: MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING (surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by this subclass C23F17/00; unidirectional solidification of eutectic materials or unidirectional demixing of eutectoid materials C30B)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- 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
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

Alloy compositions for 3D metal printing procedures which provide metallic parts with high hardness, tensile strengths, yield strengths, and elongation. The alloys include Fe, Cr and Mo and at least three or more elements selected from C, Ni, Cu, Nb, Si and N. As built parts indicate a tensile strength of at least 1000 MPa, yield strength of at least 640 MPa, elongation of at least 3.0% and hardness (HV) of at least 375.

## Claims

### Claim 1

A 3D printed metallic part comprising: one or more iron based metallic alloy layers including the elements C, Cr and Mo, wherein C is present at 0.1 wt. % to 0.35 wt. %, Cr is present at 10.0 wt. % to 19.0 wt. %, and Mo is present at 0.5 wt. % to 3.0 wt. %; and at least two elements from Ni, Cu, Nb, Si and N, wherein if present, Ni is present at 0 to 5.0 wt. %, if present, Cu is present at 0 to 5.0 wt. %, if present, Nb is present at 0 to 1.0 wt. %, if present, Si is present at 0 to 1.0 wt. %, and if present, N is present at 0 to 0.25 wt. %, and the balance of the alloy composition contains Fe; the layers each having thickness in the range of 2.0 microns to 200.0 microns; and the printed metallic part is an as-built part without post-heat treatment wherein the as-built part without post-heat treatment has tensile strength of at least 1000 MPa, a yield strength of at least 640 MPa, an elongation of at least 3.0%, and a hardness (HV) of at least 375.

### Claim 2 (depends on 1)

The printed metallic part of claim 1 wherein Cr is present at 10.0 wt. % to 18.3 wt. %, Mo is present at 0.89 wt. % to 2.5 wt. %, C is present at 0.1 wt. % to 0.30 wt. %, Ni is present at 0 to 2.5 wt. %, Cu is present at 0 to 2.56 wt. %, Nb is present at 0 to 0.7 wt. %, Si is present at 0 to 0.7 wt. % and N is present at 0 to 0.25 wt. %, the balance Fe.

### Claim 3 (depends on 1)

The printed metallic part of claim 1, wherein the alloy includes at least three elements selected from Ni, Cu, Nb, Si and N.

### Claim 4 (depends on 1)

The printed metallic part of claim 1, wherein the alloy includes at least four elements selected from Ni, Cu, Nb, Si and N.

### Claim 5 (depends on 1)

The printed metallic part of claim 1, wherein the alloy includes Ni, Cu, Nb, Si and N.

### Claim 6 (depends on 1)

The printed metallic part of claim 1, wherein the as-built part without post-heat treatment has the tensile strength of 1000 MPa to 1900 MPa, the yield strength of 640 MPa to 1500 MPa, the elongation of 3.0% to 25.0%, and the hardness (HV) of 375 to 600.

### Claim 7 (depends on 1)

The printed metallic part of claim 1, wherein the part is heat-treated and comprises the hardness (HV) of at least 475.

### Claim 8 (depends on 1)

The printed metallic part of claim 1, wherein C is present at 0.1 wt. % to 0.30 wt. %, Cr is present at 10.5 wt. % to 12.0 wt. %.

### Claim 9 (depends on 1)

The printed metallic part of claim 1, wherein the as-built part without post-heat treatment has the yield strength of at least 800 MPa.

### Claim 10 (depends on 1)

The printed metallic part of claim 1, wherein the as-built part without post-heat treatment has the elongation of at least 7%.

### Claim 11 (depends on 1)

The printed metallic part of claim 1, wherein the as-built part without post-heat treatment has the hardness (HV) of at least 400.

### Claim 12

A 3D printed metallic part comprising: one or more layers of an iron based metallic alloy including the elements C, Cr and Mo, wherein C is present at 0.1 wt. % to 0.35 wt. %, Cr is present at 10.0 wt. % to 19.0 wt. %, and Mo is present at 0.5 wt. % to 3.0 wt. %; and at least two elements from Ni, Cu, Nb, Si and N, wherein if present, Ni is present at 0 to 5.0 wt. %, if present, Cu is present at 0 to 5.0 wt. %, if present, Nb is present at 0 to 1.0 wt. %, if present Si is present at 0 to 1.0 wt. %, if present, N is present at 0 to 0.25 wt. %, and the balance of the alloy composition contains Fe; the layers each having thickness in the range of 2.0 microns to 200.0 microns; and the printed metallic part is an as-built part wherein the as-built part, has a tensile strength of at least 1000 MPa, a yield strength of at least 640 MPa, an elongation of at least 3.0%, and a hardness (HV) of at least 400.

### Claim 13 (depends on 12)

The printed metallic part of claim 12, wherein Cr is present at 10.0 wt. % to 18.3 wt. %, Mo is present at 0.89 wt. % to 2.5 wt. %, C is present at 0.1 to 0.30 wt. %, Ni is present at 0 to 2.5 wt. %, Cu is present at 0 wt. % to 2.56 wt. %, Nb is present at 0 to 0.7 wt. %, Si is present at 0 to 0.7 wt. % and N is present at 0 to 0.25 wt. %, the balance Fe.

### Claim 14 (depends on 12)

The printed metallic part of claim 12, wherein the alloy includes at least three elements selected from Ni, Cu, Nb, Si and N.

### Claim 15 (depends on 12)

The printed metallic part of claim 12, wherein the alloy includes at least four elements selected from Ni, Cu, Nb, Si and N.

### Claim 16 (depends on 12)

The printed metallic part of claim 12, wherein the alloy includes Ni, Cu, Nb, Si and N.

### Claim 17 (depends on 12)

The printed metallic part of claim 12, wherein the as-built part without post-heat treatment, has the tensile strength of 1000 MPa to 1900 MPa, the yield strength of 640 MPa to 1500 MPa, the elongation of 3.0% to 25.0%, and the hardness (HV) of 375 to 600.

### Claim 18 (depends on 12)

The printed metallic part of claim 12, wherein the as-built part does not have a post-heat treatment.

### Claim 19 (depends on 12)

The printed metallic part of claim 12, wherein the part is heat-treated and has the hardness (HV) of at least 475.

### Claim 20 (depends on 12)

The printed metallic part of claim 12, wherein C is present at 0.1 wt. % to 0.30 wt. %, and Cr is present at 10.5 wt. % to 12.0 wt. %.