Method for Sintering Metals, Non-Oxide Ceramics and Other Oxidation-Sensitive Materials

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This patent describes an innovative method for sintering metals, non-oxide ceramics, and other materials sensitive to oxidation. The process involves enveloping the components to be sintered in a dense layer of metal halide salt, compressing them to create gas-tight protection, and then heating them for sintering within the salt, either in solid or molten form. After cooling, the salt is dissolved to release the final sintered part. Remarkably, the process can be carried out in the presence of air, removing the need for protective gas or vacuum environments typically required to prevent oxidation during sintering.

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• Manufacturing of metal parts (e.g., aluminum, copper, titanium) where oxidation during sintering must be minimized.
• Production of non-oxide ceramic components used in electronics, automotive, or aerospace fields.
• Additive manufacturing (3D printing) of oxidation-sensitive materials, where sintering in air is desirable for cost and scalability.
• Mass production of advanced structural materials for industrial and engineering applications.
• Fabrication of specialized components for medical devices that require dense, oxidation-sensitive materials.

BenefitsContent extracted from patent full text and abstract with AI.

• Eliminates the need for expensive protective atmospheres or vacuum systems during sintering, greatly reducing production costs.
• Prevents oxidation of sensitive materials, resulting in higher material quality and better physical properties.
• Suitable for a wide range of metals and non-oxide ceramics.
• The process can be adapted for large-scale manufacturing and is compatible with common shaping/molding techniques including powder metallurgy and 3D printing.
• Post-sintering removal of salt is simple, using readily available solvents like water or alcohol.
• Can be conducted using standard, non-hermetic furnaces, making it accessible to more manufacturers.
• Improves safety by reducing the need for flammable or hazardous gases (e.g., hydrogen) in the sintering environment.

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Patent Abstract

The invention relates to a method for sintering metal and/or non-oxide components. According to the invention, corresponding green bodies comprising metal and/or non-oxide components are first enveloped in a metal halide salt (NZ), then compressed in a gas-tight manner, and then heated for sintering in a metal halide salt (NZ). The green bodies optionally produced by powder-metallurgical methods can also be enveloped in a metal halide salt and compressed in a gas-tight manner at room temperature. In a first form of embodiment, the green body enveloped in this way is directly supplied to a bath of molten salt. Alternatively, the green body enveloped with a metal halide salt is first embedded in a porous salt bath and, together with same, is heated until it reaches at least the melting temperature of the salt. A maximum temperature of 1400°C should not be exceeded regularly. After the cooling, the salt can be dissolved for example in water, an aqueous solution or a short-chain alcohol. The sintered components can be removed. Advantageously, the method can be carried out in the presence of air.