Manufacturing method of multilayer shell-core composite structural component

摘要

A manufacturing method of a multilayer shell-core composite structural component comprises the following procedures: (1) respectively preparing feeding material for injection forming of a core layer, a buffer layer and a shell layer, wherein the powders of feeding material of the core layer and the shell layer are selected from one or more of metallic powder, ceramic powder or toughening ceramic powder, and are different from each other, and the powder of feeding material of the buffer layer is gradient composite material powder; (2) layer by layer producing the blank of multilayer shell-core composite structural component by powder injection molding; (3) degreasing the blank; (4) sintering the blank to obtain the multilayer shell-core composite structural component. The multilayer shell-core composite structural component has the advantages of high surface hardness, abrasion resistance, uniform thickness of the shell layer, stable and persistent performance.

主权项

1. A method for manufacturing a multilayer shell-core composite structural component in medical fields, wherein the multilayer shell-core composite structural component is a femoral ball head, and the method for manufacturing the femoral ball head comprises:
(1) preparing feedstocks of a shell layer, a transition layer and a core layer for powder injection molding, respectively, the feedstocks being obtained by mixing a powder, a binder and an additive comprising a surface active agent and a plasticizer; wherein the powder of the feedstock of the core layer is made of a niobium metal powder; the powder of the feedstock of the shell layer is made of an alumina powder which has a purity greater than 99.9 wt % and a particle size ranging from 0.5 μm to 10 μm; and the powder of the feedstock of the transition layer includes at least one group of gradient composite material which is formed by mixing the powder of the feedstock of the shell layer with the powder of the feedstock of the core layer; (2) performing a powder injection molding using the prepared feedstocks in step (1), to obtain a green body of the multilayer shell-core composite structural component comprising the shell layer, the transition layer and the core layer; (3) performing catalytic debinding on the green body obtained in step (2) in an atmosphere furnace with a temperature ranging from about 110° C. to about 120° C., where hydrogen nitrate is used as debinding catalyst, nitrogen is used as debinding carrier gas, and the catalytic debinding process lasts for about 5 hours; and (4) sintering the green body after being debound in step (3) in a controlled atmosphere hot isostatic pressing furnace, where the sintering is performed at a temperature of about 1450° C., a pressure of about 35 MPa, and the soaking time is about 1 hour, to obtain the multilayer shell-core composite structural component.