Heraeus has patented an additive manufacturing method for moldings using refractory metal powders, specifically niobium and tungsten, with an oxygen content of at least 500 mol ppm. The process involves multiple layers selectively melted by an electron beam, resulting in a final product with reduced oxygen content. GlobalData’s report on Heraeus gives a 360-degree view of the company including its patenting strategy. Buy the report here.
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According to GlobalData’s company profile on Heraeus, Ceramic membrane fuel cells was a key innovation area identified from patents. Heraeus's grant share as of July 2024 was 54%. Grant share is based on the ratio of number of grants to total number of patents.
The patent US12064812B2 outlines a novel additive manufacturing method specifically designed for producing moldings using refractory metal powders, such as niobium and tungsten. The process involves several key steps: applying a first layer of refractory metal powder onto a substrate, selectively melting portions of this layer with an electron beam at a specified energy level, and cooling the melt to form a solid material layer. This layering process is repeated until the molding is fully constructed. Notably, the method ensures that the oxygen content in the final molding is significantly lower—at least 15%—than that of the initial refractory metal powder, which must have an oxygen content of at least 500 mol ppm. Additionally, the layers applied do not contain substances that react with oxygen, enhancing the integrity of the final product.
Further claims detail specific parameters for the refractory metal powder, including its particle size, oxygen content limits, and the absence of carbon or carbonaceous compounds. The average particle size is specified to be between 10 to 150 µm, with additional claims narrowing this range further. The method also emphasizes achieving a high relative density of at least 95% in the constructed molding and stipulates that each volume element of the molding undergoes melting and solidification at least twice. The patent highlights the potential for using either niobium or tungsten as the refractory metal, with a focus on optimizing the properties of the powder to enhance the quality and performance of the final molded product.
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