# US 2024/0189902 A1 · Joined solid production method

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- Number: US 2024/0189902 A1
- Document ID: US20240189902A1
- Status: Published application
- Kind: A1
- Application number: 18/550,668
- Filed: 2021-12-13
- Published: 2024-06-13
- Earliest claimed: 2021-03-15
- Assignees: K.K. Sun Metalon
- Applicants: K.K. Sun Metalon
- Inventors: Kazuhiko NISHIOKA; Koji KAGEYAMA
- Web page: https://patentgrep.com/patent/US20240189902A1

## CPC

- B22F 10/22: Direct deposition of molten metal
- B22F 1/12: Metallic powder containing non-metallic particles (containing lubricating or binding agents or organic material B22F1/10)
- B22F 3/004: {Filling molds with powder (feeding material to presses in general B30B15/302)}
- B22F 3/14: simultaneously
- B22F 3/16: in successive or repeated steps
- B22F 3/24: After-treatment of workpieces or articles {(B22F3/1146 takes precedence)}
- B22F 5/00: Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F 7/008: {characterised by the composition}
- B22F 7/02: of composite layers {(B22F7/002 takes precedence)}
- B22F 7/04: with one or more layers not made from powder, e.g. made from solid metal
- B22F 7/062: {involving the connection or repairing of preformed parts}
- B22F 7/08: with one or more parts not made from powder {(B22F7/062 takes precedence)}
- B22F 9/20: starting from solid metal compounds
- B22F 10/10: Formation of a green body
- B22F 10/14: by jetting of binder onto a bed of metal powder
- B22F 10/20: Direct sintering or melting
- B22F 10/25: Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 10/43: characterised by material
- B22F 10/66: by mechanical means
- B22F 12/41: characterised by the type, e.g. laser or electron beam
- B22F 12/50: Means for feeding of material, e.g. heads
- B22F 12/60: Planarisation devices; Compression devices
- B22F 12/70: Gas flow means
- B23K 1/005: Soldering by means of radiant energy
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
- C04B 35/117: Composites
- C04B 37/021: {in a direct manner, e.g. direct copper bonding [DCB]}
- B22F 12/90: Means for process control, e.g. cameras or sensors
- B22F 2003/1054: {by microwave}
- B22F 2007/042: {characterised by the layer forming method}
- B22F 2007/045: {accompanied by fusion or impregnation}
- B22F 2201/01: Reducing atmosphere
- B22F 2201/10: Inert gases
- B22F 2201/50: air
- B22F 2202/11: Use of irradiation
- B22F 2301/052: Aluminium
- B22F 2301/35: Iron
- B22F 2998/10: Processes characterised by the sequence of their steps
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- C04B 2235/422: Carbon
- C04B 2235/94: Products characterised by their shape
- C04B 2235/945: Products containing grooves, cuts, recesses or protusions
- C04B 2235/95: Products characterised by their size, e.g. microceramics
- C04B 2237/34: Oxidic
- C04B 2237/341: Silica or silicates
- C04B 2237/343: Alumina or aluminates
- C04B 2237/346: Titania or titanates
- C04B 2237/348: Zirconia, hafnia, zirconates or hafnates
- C04B 2237/363: Carbon
- C04B 2237/365: Silicon carbide
- C04B 2237/402: Aluminium
- C04B 2237/405: Iron metal group, e.g. Co or Ni
- C04B 2237/406: Iron, e.g. steel
- C04B 2237/407: Copper
- C04B 2237/408: Noble metals, e.g. palladium, platina or silver
- C04B 2237/68: Forming laminates or joining articles wherein at least one substrate contains at least two different parts of macro-size, e.g. one ceramic substrate layer containing an embedded conductor or electrode
- C04B 2237/704: of one or more of the ceramic layers or articles
- C04B 2237/706: of one or more of the metallic layers or articles
- C04B 2237/765: at least one member being a tube
- C04B 2237/84: Joining of a first substrate with a second substrate at least partially inside the first substrate, where the bonding area is at the inside of the first substrate, e.g. one tube inside another tube
- 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
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE

## Abstract

A method for producing a joined solid, the method comprising placing a metal powder on a solid; covering at least a portion of the periphery of the metal powder with a high-melting-point material having a melting point higher than the melting point of the metal powder; and irradiating the metal powder, at least a portion of the periphery of which is covered with the high-melting-point material, with microwaves to heat the metal powder, thereby sintering or melt-solidifying the metal powder to form a metal solid on the solid.

## Claims

### Claim 1

A method for producing a joined solid, the method comprising:
placing a metal powder on a solid;
covering at least a portion of the periphery of the metal powder with a high-melting-point material having a melting point higher than the melting point of the metal powder; and
irradiating the metal powder, at least a portion of the periphery of which is covered with the high-melting-point material, with microwaves to heat the metal powder, thereby sintering or melt-solidifying the metal powder to form a metal solid on the solid,
wherein in the portion of the metal powder covered with the high-melting-point material, the metal powder and the high-melting-point material are in close contact with each other, and
the high-melting-point material includes a mixture of:
an insulation material that has a lower degree of absorption of the microwaves than the metal powder, and
an absorbent material that absorbs the microwaves in a temperature zone at least a portion of which is lower than a temperature zone in which the metal powder absorbs the microwaves.

### Claim 2 (depends on 1)

The method for producing a joined solid according to claim 1, further comprising:
placing the metal powder on the metal solid;
covering at least a portion of the periphery of the metal powder on the metal solid with the high-melting-point material; and
irradiating the metal powder, at least a portion of the periphery of which is covered with the high-melting-point material, on the metal solid with microwaves to heat the metal powder, thereby sintering or melt-solidifying the metal powder to form an additional metal solid on the metal solid.

### Claim 3 (depends on 2)

The method for producing a joined solid according to claim 2, wherein laminated the metal solids are formed.

### Claim 4

(canceled)

### Claim 5

(canceled)

### Claim 6

(canceled)

### Claim 7 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the high-melting-point material includes from 1 mass % to 70 mass % of the absorbent material.

### Claim 8 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the insulation material includes an oxide.

### Claim 9

(canceled)

### Claim 10 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the absorbent material includes a carbon material.

### Claim 11

(canceled)

### Claim 12 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the metal powder includes a metal.

### Claim 13

(canceled)

### Claim 14 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the metal powder includes a metal compound.

### Claim 15

(canceled)

### Claim 16 (depends on 12)

The method for producing a joined solid according to claim 12, wherein the metal powder further includes an alloy component.

### Claim 17

(canceled)

### Claim 18

(canceled)

### Claim 19 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the metal powder includes a metal oxide, and the metal powder is reduced in the irradiation of the metal powder with microwaves.

### Claim 20 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the metal powder includes a metal oxide, and the metal powder is sintered in the irradiation of the metal powder with microwaves.

### Claim 21 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the high-melting-point material is in the form of a mold or a container.

### Claim 22 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the metal powder is in the form of a green compact.

### Claim 23 (depends on 1)

The method for producing a joined solid according to claim 1, further comprising applying a pressure to the metal powder before irradiating the metal powder with microwaves.

### Claim 24

(canceled)

### Claim 25 (depends on 1)

The method for producing a joined solid according to claim 1, further comprising applying a pressure to the metal powder while the metal powder is irradiated with microwaves.

### Claim 26

(canceled)

### Claim 27 (depends on 1)

The method for producing a joined solid according to claim 1, further comprising applying a pressure to the metal powder after irradiating the metal powder with microwaves.

### Claim 28

(canceled)

### Claim 29 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the irradiating the metal powder with microwaves is performed in an inert gas atmosphere.

### Claim 30 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the irradiating the metal powder with microwaves is performed in a reducing atmosphere.

### Claim 31 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the metal powder includes a metal oxide, and the method further includes reducing the metal oxide before irradiating the metal powder with microwaves.

### Claim 32 (depends on 1)

The method for producing a joined solid according to claim 1, wherein the covering at least a portion of the periphery of the metal powder with a high-melting-point material having a melting point higher than the melting point of the metal powder includes:
forming a layer of the high-melting-point material;
forming a recess in the layer of the high-melting-point material; and
placing the solid and the metal powder in the recess.

### Claim 33 (depends on 32)

The method for producing a joined solid according to claim 32, wherein the forming the recess in the layer of the high-melting-point material includes:
curing a portion of the layer of the high-melting-point material; and
removing an uncured portion of the layer of the high-melting-point material.

### Claim 34 (depends on 33)

The method for producing a joined solid according to claim 33, wherein the curing the portion of the layer of the high-melting-point material includes incorporating a curable material into the portion of the layer of the high-melting-point material.

### Claim 35 (depends on 34)

The method for producing a joined solid according to claim 34, wherein the portion of the layer of the high-melting-point material is impregnated with the curable material.

### Claim at position 36

36-73. (canceled)