CN104684667A - Additive manufacture of turbine component with multiple materials - Google Patents

Additive manufacture of turbine component with multiple materials Download PDF

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Publication number
CN104684667A
CN104684667A CN201380052507.5A CN201380052507A CN104684667A CN 104684667 A CN104684667 A CN 104684667A CN 201380052507 A CN201380052507 A CN 201380052507A CN 104684667 A CN104684667 A CN 104684667A
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CN
China
Prior art keywords
powder
laser energy
laser
powder bed
layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201380052507.5A
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Chinese (zh)
Inventor
R.苏布拉马尼安
M.奥特
D.托迈迪斯
A.萨多福伊
J.明策
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Siemens AG
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Siemens AG
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Publication of CN104684667A publication Critical patent/CN104684667A/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/008—Producing shaped prefabricated articles from the material made from two or more materials having different characteristics or properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—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
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/53—Nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
    • F05D2230/31—Layer deposition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24521—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness with component conforming to contour of nonplanar surface
    • Y10T428/24545—Containing metal or metal compound

Abstract

A method for additive manufacturing with multiple materials. First (48), second (50), and third (52) adjacent powder layers are delivered onto a working surface (54A) in respective first (73), second (74), and third (75) area shapes of adjacent final materials (30, 44, 45) in a given section plane of a component (20). The first powder may be a structural metal delivered in the sectional shape of an airfoil substrate (30). The second powder may be a bond coat material delivered in a sectional shape of a bond coat (45) on the substrate. The third powder may be a thermal barrier ceramic delivered in a section shape of the thermal barrier coating (44). A particular laser intensity (69A, 69B) is applied to each layer to melt or to sinter the layer. Integrated interfaces (57, 77, 80) may be formed between adjacent layers by gradient material overlap and/or interleaving projections.

Description

Use the interpolation manufacture of the turbine components of multiple material
The application's request submission date is the U.S. Provisional Patent Application number 61/710 on October 08th, 2012,995(attorney docket 2012P24077US) and the submission date be the U.S. Provisional Patent Application number 61/711 on October 10th, 2012,813(attorney docket 2012P24278US) rights and interests, both is incorporated herein all by reference.
Technical field
The present invention relates to adding layers manufacture, and relate to particularly and make many material metals/ceramic gas turbine engine component by the selective laser sintering of the adjacent powder layer of different materials and selective laser melting.
Background technology
Selective layer adds the selective laser melting (SLM) and selective layer sintering (SLS) that manufacture and comprise powder bed, sets up parts layer by layer to realize whole type (net shape) or near-net-shape (near net shape).The powder bed deposition of the final material of parts or persursor material on the work surface.Laser energy optionally guides in the powder bed of the cross section shape following parts, thus form one deck or a chip part, and it becomes the new working surface of lower one deck subsequently.Routinely, in a first step, powder bed is sprawled on the work surface, and then in a subsequent step, laser limits or the cross section of " brushing " parts in bed, such as, pass through raster scanning.
Correlated process (so-called micro-coated) via motion nozzle or other conveying device by powder deposition on parts.Laser simultaneously at saltation point place by powder smelting, thus on parts, form material pearl when conveying device is moved.Process in succession can set up one or more layers material, for repairing or the manufacture of parts.
Accompanying drawing explanation
Based on accompanying drawing, the present invention is described in the following description, accompanying drawing shows:
Fig. 1 is the sectional view of the gas turbine blades of prior art.
Fig. 2 is the sectional view of the powder conveying device forming adjacent powder layer on the work surface.
Fig. 3 is the sectional view of the laser beam of fusing and sintering adjacent powder layer.
Fig. 4 shows the pattern of the scanning pattern that powder is carried and/or laser is carried for the non-linear cross-section profile parallel with parts.
Fig. 5 shows the scanning pattern substituted with parallel linear path.
Fig. 6 shows the scanning pattern of the wall vertically or approximately perpendicular to parts.
Fig. 7 shows second of being formed on the first of parts.
Fig. 8 shows with the adjacent powder layer of different-thickness deposition.
Fig. 9 shows the interlocking interface between adjacent materials.
Figure 10 shows the flow chart of some aspects of embodiments of the invention.
Detailed description of the invention
The present invention has designed a kind of method that interpolation for parts manufactures, and described parts have the multiple adjacent material of different in kind.It uses the strong binding of adjacent materials (comprising metal to pottery) and generates whole type or near-net-shape.This is particularly advantageous when Production Example is as having a gas turbine engine component of the superalloy blade of ceramic heat-barrier coating and fin.Such aerofoil profile is difficult to manufacture, because they have the complicated shape of band serpentine cooling channel, is lined with turbulator and film Cooling Holes in this cooling duct.
Fig. 1 is the view in transverse section of typical gas turbine airfoil type 20, and aerofoil profile 20 has leading edge 22, trailing edge 24, on the pressure side 26, suction side 28, metallic matrix 30, cooling duct 32, partition wall 34, turbulator 36, film coolant outlet hole 38, cooling pin 40 and trailing edge outlet opening 42.The outside of aerofoil profile matrix scribbles ceramic heat-barrier coating 44.Metlbond coat 45 can be coated between matrix and thermal barrier coating.Turbulator is protuberance in cooling duct 32, nest portion, spine or recess, and it increases surface area and the fluid boundary layer of freezing mixture flowing.
Fig. 2 shows a kind of method and apparatus, for first, second, and third adjacent powder bed 48,50,52 is delivered to working surface 54A with the first, second, and third respective cross section shape of the adjacent final material of first, second, and third in the given section of parts.Such as, the first powder bed 48 can be with the structural metal of the region shape of the aerofoil profile matrix 30 shown in Fig. 1 conveying.Second powder bed 50 can be with the bonding coat 45(Fig. 1 on matrix) the bonding coat carried adjacent to the first powder 48 of region shape.3rd powder bed 52 can be with thermal barrier coating 44(Fig. 1) the ceramic with heat resistance carried adjacent to the second powder of region shape.
Interface 56 between the first and second powder beds can be transferred, and to make to form overlay region 57, it provides material gradient transition between two adjacent powder beds 48,50.Can be transferred at the second and the 3rd interface 58 between powder 50,52, to make to form the mechanical interlocked of through engineering approaches, such as, alternately from second and the 3rd outstanding staggered finger (illustrating after a while) of powder.Powder conveying device 60 can have the one or more nozzles 62 powder spray coat 64 being transported to focus 66.
Powder conveying device 60 can comprise the multi-axis motions 61 relative to working surface 54A, thus nozzle can follow non-linear cross-section profile in given horizontal plane, different planes or distance can be moved to relative to working surface 54A, and can with the angle conveying powder of change.Axis can be implemented by the motion of workbench 55 and/or powder conveying device 60 via track and swivel bearing under the control of the computer.The powder transportation parameters of such as nozzle translation speed, mass transport rate and jet angle can be pre-determined by discrete particle modeling Simulation, thus optimizes the geometry of final piece.After the spray application, powder can before LASER HEATING by such as electromagnetic energy and/or machinery or acoustic vibration compacted and fixing.
Powder can spraying before or period use water, alcohol, setting agent or adhesive soak, make described powder keep expect shape, until laser is melted or is sintered into the bonding sheet of parts.Co-pending U.S. Patent Application Publication US 2013/0140278A1(attorney docket 2012P22347US as being incorporated herein by reference) in more completely describe, together with flux material can being included in dusty material, so that coated process.
Fig. 3 shows for melting with laser energies different separately and/or sintering the method and apparatus of different powder bed 48,50,52.Such as, matrix superalloy power 48 and bonding coat powder 58 can melt with the first and second laser energies, and ceramic thermal barrier powder 52 can sinter with the 3rd laser energy of only partial melting ceramic particle.Different laser energy 69A, 69B can be provided by the single generating laser 68A with variable output, or are provided by different multiple generating laser 68A, the 68B exported that have for different powder bed.Generating laser can comprise the multi-axis motions 70 relative to working surface 54A, make it can follow non-linear cross-section profile in given plane, different planes or distance can be moved to relative to working surface 54A, and can locate and guide laser beam, to obtain angle and the spot size of expectation.
Fig. 4 shows the pattern in the path 72 of the non-linear cross-section shape profile 73,74,75 following parts 20.The powder conveying focus 66 of Fig. 2 can be controlled to follow such path.This scanning pattern 72 being parallel to cross sectional shape profile allows for each powder bed 48,50,52 and changes powder type.
Laser energy 69A-B(Fig. 3) also can follow the nonlinear scanning path of 72 of such as Fig. 4.The change quantity of laser intensity for different dusty material minimizes by this path type.First laser energy can be directed with the profile of the cross sectional shape 73 following the first powder bed 48, second laser energy can be directed with the profile of the cross sectional shape 74 following the second powder bed 50, and the 3rd laser energy can be directed with the profile of the cross sectional shape 75 following the 3rd powder bed 52.When the region (such as film Cooling Holes 38) that laser process is intended to the blank portion remained in formed parts is upper, the circulation of laser can be closed.
Fig. 5 shows the alternative scanning pattern with parallel linear path 74 of laser energy.Fig. 6 show perpendicular to or approximately perpendicular to the path 76 of the wall of parts.Except circulating for the close/open in blank portion 38, pattern 74 and 76 may also need to change laser intensity when crossing interface 56,58 of different powder bed at every turn.The spacing of scanning 72,74,76 depends on beam width at powder surface place or spot size.Multiple generating laser can use together, to produce wider width (swath), to reduce the quantity of scanning.The width of (one or more) laser beam can be adjusted by the distance changing transmitter distance working surface, and/or the size and dimension of light beam can be adjusted by adjustable lens, mirror or shadow shield, with little, the sharp-pointed or bending element of limiting part better, such as chamfering (fillet), and without the need to sweep span and spot size.
Fig. 7 shows the first cured sheets 74 of parts, which provides new working surface 54B, is coated on working surface 54B by the powder bed 48,50,52 of second of parts 76.
Fig. 8 shows with the powder bed 48,50,52 of differing heights conveying, and described different height depends on that their respective processing is shunk, to realize final uniform sheet thickness.The powder of the first and second adjacent layers 48,50 can be deposited in overlay region 57, makes powder overlapping in functionally gradient material (FGM) transition.Overlapping widths can be such as at least 0.2 mm.Second and the powder of third phase adjacent bed 50,52 also can be deposited in overlay region 77, make powder overlapping in functionally gradient material (FGM) transition.Overlapping widths can be such as at least 0.2 mm or 0.4 mm, or nearly 1 mm or nearly 2 mm.
Fig. 9 shows the interface between second and third layer 50,52, and it is formed with the interlock feature 80 of through engineering approaches between second and third layer 50,52, such as staggered profile, and it forms the 3D intertexture finger of alternately giving prominence to from adhesive layer 50 and ceramic layer 52.Replace the functionally gradient material (FGM) district 77 shown in Fig. 8 or except functionally gradient material (FGM) district 77, such interlocked mechanical interface can be provided.Crack 82 can be formed in ceramic layer 52, for operability strain relief by the circulation of the close/open laser energy when laser energy ceramic layer 52.Hollow ceramic ball 84 can be included in the material of ceramic layer 52, to reduce thermal conductivity.Spherical blank portion hollow ceramic ball is included in thermal barrier coatings 52 and for good and all reduces its thermal conductivity, because can not be reduced due to operability sintering.
Figure 10 shows the flow chart of the method 84 of the aspect of embodiments of the invention, includes following steps:
Multiple adjacent powder layers of respective different materials are transported on working surface with the respective region shape of the given section representing many material components by 86..
88. by least two overlaps in adjacent powder bed, to form functionally gradient material (FGM) transition region between described at least two adjacent powder beds.
Specific laser energy is applied to each powder bed by 90., and to melt or to sinter described layer, wherein, at least two in described layer receive different laser intensities respectively.
92. repeat from step 86 for section in succession, manufacture described parts to add manufacture by selective layer.
In certain embodiments, the ceramic particle of included nanoscale can make the sintering temperature of ceramic layer reduce nearly 350 DEG C.This can be convenient to common sintering and the bonding of metal and ceramic layer.The reduction of temperature occur in especially when ceramic powders comprise at least 2% and nearly 100% volume be less than the particle of the average diameter of 100 nm time, and it occurs in average diameter of particles when being less than 50 nm especially.This method allows by only partly melting such nano particle to sinter.When with plasma spray technology coated with ceramic coating, this is impossible, because it is tending towards fully melting less particle.
The nickel based super alloy be used in high temperature gas turbine machine parts is strengthened mutually by the gamma primary precipitate in gamma phase matrix usually.These superalloy can the character of durable in high temperature environments also make it be difficult to manufacture and repair.But it can be produced by method described herein and be linked to the adjacent layer of different materials (comprising pottery).The casting with the gas turbine blades of the serpentine channel in band turbulator and film coolant outlet hole is difficulty and costliness.This method reduces cost while more completely connecting different material layer.This allows complete many material components of to produce such as turbine blade with a process, and instead of casting superalloy blade and then apply it in independent process (such as heat is sprayed).
Although illustrate and described each embodiment of the present invention in this article, be apparent that, such embodiment only provides by means of the mode of example.Under the prerequisite not departing from invention herein, many distortion, change and replacement can be carried out.Therefore, it is intended that the restriction that the present invention is only subject to the spirit and scope of appended claims.

Claims (20)

1., for making a method for parts, comprise the following steps:
By multiple adjacent powder layers of respective different dusty materials to represent that the respective region shape of the respective final material in the given section of many material components is transported on working surface;
By at least two overlaps in adjacent powder bed, to form material gradient district between described at least two adjacent powder beds;
First laser energy of the first intensity is applied to the first powder bed in described powder bed, and the second laser energy of the second different laser intensity is applied to the second powder bed in described powder bed; And
Section in succession for described parts repeats from supplying step, to manufacture described parts.
2. the method for claim 1, wherein, described first powder bed comprises metal, described second powder comprises ceramic with heat resistance, described first laser energy is directed to follow more than first scanning pattern parallel with the non-linear periphery of described first powder bed, and described second laser energy is directed to follow more than second scanning pattern parallel with the non-linear periphery of described second powder bed.
3. method as claimed in claim 2, also comprises: the circulation opening and closing described first and second laser energies while following described first and second scanning patterns, to form the passage through the described first and second final materials.
4. method as claimed in claim 2, also comprises: the circulation opening and closing described second laser energy while following the second scanning pattern, to form strain relief crack in the described second final material.
5. the method for claim 1, also comprise: described working surface make to have staggered profile betwixt by the first and second dusty materials are transported to and between the described first and second final materials, form mechanical interlocking interface, forming the staggered finger through described interface.
6. the method for claim 1, also comprise: with the first and second respective thickness, described first and second powder beds are deposited on described working surface, and pre-determine described respective laser energy described powder bed to be reduced to the uniform thickness of the described final material in described given section.
7. the method for claim 1, also comprise: by being provided described first and second laser energies by the laser beam along linear scan Route guiding in succession, each linear scan path is process on described first and second powder beds, and comprises: change the intensity of described laser beam along each scanning pattern to provide described first and second intensity.
8. the product formed by the method for claim 1.
9. make a method for parts, comprise the following steps:
The respective first, second, and third region shape respective powder of first, second, and third adjacent layer of materials different separately being represented given many material profile of described parts to combine is transported on working surface;
Wherein, described first powder bed comprises structural metal material, and described second powder bed comprises adhesive coatings material, and described 3rd powder bed comprises ceramic with heat resistance;
Specific laser energy is applied to each described powder bed to melt or to sinter described layer, wherein, at least two in described layer receive different laser intensities respectively; And
Section is in succession repeated from supplying step, carrys out manufacture component to add manufacture by selective layer.
10. method as claimed in claim 9, also comprises: follow with the scanning pattern of the respective profile parallel of described region shape while open and close the circulation of described laser energy, to form passage in described parts.
11. methods as claimed in claim 9, also comprise: guide the first laser energy to follow the scanning pattern with the profile parallel of described first shape, guide the second laser energy to follow the scanning pattern with the profile parallel of described second shape, and guide the 3rd laser energy to follow the scanning pattern with the profile parallel of described 3rd shape.
12. methods as claimed in claim 11, also comprise: the circulation opening and closing described 3rd laser energy, to form strain relief crack in described ceramic with heat resistance.
13. methods as claimed in claim 11, also comprise: by by described second and the 3rd powder be transported to and described working surface makes to have staggered profile therebetween and between described second and third layer, form mechanical interlocking interface, in described interface, form staggered finger.
14. methods as claimed in claim 9, also comprise: make described first and second powder overlaps reach at least 0.2 mm, form functionally gradient material (FGM) district.
15. methods as claimed in claim 11, also comprise: make described second powder and the 3rd powder overlap reach at least 0.4 mm, form functionally gradient material (FGM) district.
16. methods as claimed in claim 11, also comprise: with the first and second respective different-thickness, described first and third layer are deposited on described working surface, and each self-strength of predefined described laser energy is to be reduced to uniform material thickness by three powder beds.
17. methods as claimed in claim 11, also comprise: provide described first, second, and third laser energy by by the laser beam guided along line in succession, every bar line is process on described first, second, and third layer, and comprises: change the intensity of described laser beam along every bar line to provide specific energy for by each powder bed of described line process.
18. 1 kinds of methods making gas turbine engine component, comprise the following steps:
First, second, and third adjacent powder layer is transported on working surface with the first, second, and third respective region shape of the adjacent final material of first, second, and third in the given section of described parts;
Wherein, described first material comprises structural metal, and described second material comprises adhesive coatings metal, and described 3rd material comprises ceramic with heat resistance;
Use the first and second respective laser energies by described first and second powder beds fusings, and use the 3rd laser energy only partly to be melted by described 3rd powder bed, wherein, solidify to form the new sheet face of adjacent final material; And
Repeat from supplying step for section in succession, to manufacture the parts of the described structural metal with porous ceramics thermal barrier coatings;
Wherein, described first laser energy is directed with the profile following described first shape, and described second laser energy is directed with the profile following described second shape, and described 3rd laser energy is directed with the profile following described 3rd shape.
19. methods as claimed in claim 18, also comprise:
Make described first and second powder overlaps reach at least 0.2 mm, between described first and second layers, form functionally gradient material (FGM) interface; And
By by described second and the 3rd powder be transported to and described working surface make to have staggered profile therebetween and between described second and third layer, forms mechanical interlocking interface, form the staggered finger through described interface.
20. 1 kinds of products formed by method as claimed in claim 19.
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Application publication date: 20150603