DE102014217115A1 - INTERMEDIATE REMOVAL OF INTERACTION PRODUCTS IN A GENERATIVE MANUFACTURING METHOD - Google Patents

Abstract

The present invention relates to a method for the generative production of components by laminating powder particles to one another and / or with a semifinished product or substrate already produced by selective interaction of the powder particles with a high-energy beam (13), wherein the high-energy beam (13) during production a layer along one or more first tracks (22) is passed over the powder to be connected, wherein the one or more first tracks (22) are guided so that the one or more first tracks (22) to each other and / or with each other in each other parallel spaced sections so that spaces remain without interaction of high energy jet and powder, wherein the powder of the spaces subsequently in the guidance of the high energy beam along one or more second tracks (23) interacts with the high energy beam (13), and wherein zwis The guidance of the high energy beam (13) along one or more first tracks (22) and the guidance of the high energy beam (13) along one or more second tracks (23) removes interaction products (21) from the spaces.

Description

BACKGROUND OF THE INVENTION

FIELD OF THE INVENTION

The present invention relates to a method and a device for the generative production of components by layer-wise joining of powder particles to one another and / or with an already produced semi-finished product or substrate by selective interaction of the powder particles with a high-energy beam, in particular a method and a device for selective laser or electron beam melting.

STATE OF THE ART

Generative manufacturing processes for producing a component, such as selective laser melting, selective electron beam melting or laser deposition welding, in which the component is built up in layers using powder material, are in the industry for the so-called rapid tooling, rapid prototyping or for the production of series products in the frame used in rapid manufacturing. In particular, such methods can also be used for the production of turbine parts, in particular of parts for aircraft engines, in which, for example, due to the material used, such generative production methods are advantageous. An example of this can be found in the DE 10 2010 050 531 A1 ,

In generative production with a layered application of material, however, it may lead to the formation of material evaporations from the melt or the formation of weld spatter, which can affect the generative manufacturing. Thus, deposition of weld spatters or generally interaction products between high-energy jet and powder on not yet melted powder material may cause material defects in subsequent welding processes. This can lead to failure and failure of the component in the subsequent application, which must be avoided accordingly.

DISCLOSURE OF THE INVENTION

OBJECT OF THE INVENTION

It is therefore an object of the present invention to provide a method and a device for the generative production of components by layering of powder particles with each other and / or with an already produced semi-finished or substrate by selective interaction of the powder particles with a high-energy beam, in which the above-described Problem of material defects can be avoided or at least reduced by welding spatter. Nevertheless, the method should be easy to carry out and the device should be simple to set up and operate in order to use the corresponding generative production in industrial processes.

TECHNICAL SOLUTION

This object is achieved by a method having the features of claim 1 and a device having the features of claim 9. Advantageous embodiments are the subject of the dependent claims.

The invention, in the generative fabrication of a device by layering layers of powdered material to solve the problem outlined above, contemplates possible interaction products from the interaction of a high energy jet with the powder deposited on regions adjacent to the interaction region, prior to further irradiation remove and / or relocate the area contaminated with interaction products. This avoids that interaction products, such as welding spatter, are built into the component to be manufactured or cause a faulty interaction of the high-energy beam with the powder, which can also lead to component defects.

Removal and / or rearrangement of the interaction products is understood to reduce the interaction products at least in the ranges provided for subsequent irradiation and interaction of the high-energy beam with the powder, such that adverse effects of incorporation of undefined interaction products into the product the layer to be deposited can be avoided or at least reduced as much as possible. If the interaction products are not removed, but only rearranged, ie shifted into uncritical regions, further processing can be carried out in the sense of removal before the deposition of a new layer, or the rearrangement is sufficient to produce a uniform distribution of the interaction products or reduction of interaction product concentrations make further deposition of a layer or sub-layer. Accordingly, the term of a material removal device is to be understood, which can also effect the removal and / or rearrangement of interaction products.

To make the generative production of the component efficient, the Irradiation strategy, ie the order of irradiation of a powder layer with the high-energy beam for depositing a layer to be adjusted in a suitable manner. It can thus be provided that the high-energy beam is guided in first movement paths relative to the powder such that intermediate spaces remain between the first tracks or adjacent sections of a first continuous track which are not initially irradiated. Prior to irradiating these gaps along one or more second paths of the high energy beam relative to the powder, interaction products of the high energy beam with the powder may then travel along the first path (s) extending in the gaps or future second trajectory (s) ) have been removed.

In generative fabrication, such as selective laser melting or selective electron beam melting, with a powder bed, a shifter which produces the powder bed in layers may be used to remove interaction products of the interaction between the high energy jet and the powder during deposition of a layer , For this purpose, a slide of a sliding device can be moved over the powder layer after a first partial irradiation of the powder layer in order to remove interaction products, such as spatter, of the first partial irradiation, so that a subsequent, at least second partial irradiation is carried out unloaded by possible interaction products of the first or a preceding partial irradiation can.

When using a slide to remove the interaction products, which is usually used between the deposition of the individual layers for powder application, additional new powder can also be tracked during the deposition of a single layer.

Instead of using the slider of a slide device which is originally and mainly used to apply a new powder layer, a corresponding device for the additive production of components may comprise additional components of a material removal device, with the aid of which interaction products from the processing area and in particular the irradiation area for the irradiation of Powder can be removed to deposit the next layer. In addition to a disposal area for interaction products, such as a waste collection bin into which the interaction products may be emptied, a material removal facility may include additional components specifically designed for the removal or rearrangement of interaction products. These additional components may, for example, be coupled to the powder applicator, such as a corresponding slider. Additionally or alternatively, corresponding components of a material removal device may also be coupled to the irradiation device, for example in such a way that the material removal device or components thereof is guided in coordination with the high-energy beam over the processing region or the powder layer to be deposited in order to produce interaction products of a preceding interaction of the high-energy Remove the jet with the powder from the area to be irradiated next.

The material removal device may, for example, comprise a plow or a kind of plow which is movable along the webs not yet irradiated, in order to push or displace interaction products from preceding irradiations into adjacent regions. A corresponding plow may have a complete independent movement device with the aid of which the plow can be guided over the processing area.

According to a further alternative, the material removal device may comprise a type of dustpan and / or a suction device for receiving interaction products, which may also be guided over the processing area. These may for example be combined with a coating device in the form of a slider or sliding element for applying a new powder layer, so that on the slider of a powder application device on one side a coater blade is arranged, which makes it possible to apply a defined powder layer, while on the other side a dustpan and / or a suction device for receiving interaction products are provided. Depending on the direction of movement or orientation, the sliding element can then be used either for applying new powder for a new powder layer or for suction and absorption of interaction products.

According to a further embodiment, the material removal device may comprise a separate clearing element which, independently of a powder application device with a slide element for applying a powder layer, serves only for the removal and / or displacement of interaction products. For example, the additional clearing element can be designed as a flexible cable or band element, which is fastened on an axis of rotation, in order to rotate by rotating the axis of rotation over the processing area to be panned so as to strip or clear off interaction products.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying drawings show in a purely schematic manner in FIG

1 a schematic representation of an apparatus for the generative production of components using the example of selective laser melting,

2 a representation of the interaction of the laser beam with the powder,

3 a sectional view through a layer to be applied with first and second movement paths of the laser beam,

4 a representation of the beam movement and the irradiation order in a plan view of the powder bed or the component receiving a device 1 .

5 a representation of a first material removal device,

6 a plan view of a processing area with a second embodiment of a material removal device, and in

7 a plan view of a processing area and the powder supply and a disposal area for interaction products with a hinged belt according to a material removal device according to another embodiment.

EMBODIMENTS

Further advantages, characteristics and features of the present invention will become apparent in the following detailed description of embodiments, wherein the invention is not limited to these embodiments.

The 1 shows in a purely schematic representation of a device 1 as can be used, for example, for the selective laser melting for the generative production of a component. The device 1 includes a lift table 2 on whose platform a semi-finished product 3 is arranged, is deposited on the layered material to produce a three-dimensional component. For this purpose, by means of the slider 8th Powder, which is above a lifting table 9 in a powder supply 10 is in layers over the semifinished product 3 pushed and then by the laser beam 13 a laser 4 by melting with the already existing semi-finished product 3 connected. After complete application of a layer 5 becomes the lift table 2 according to the arrow 7 indicated movement possibility lowered to the slider 8th to be able to apply a new layer of powder.

The compound of the powder material in a powder layer 5 with the semi-finished product 3 done by the laser 4 depending on the desired contour of the component to be manufactured, so that any three-dimensional shapes can be generated. Accordingly, the laser beam becomes 13 over the powder bed 12 guided to melt by different impact points on the powder bed according to the contour of the three-dimensional component in the powder layer plane corresponding cutting plane of the component to be produced powder material and to connect with the already generated part of a component or an initially provided substrate. Here, the laser beam 13 by a suitable deflection unit over the surface of the powder bed 12 be guided and / or the powder bed could be compared to the laser beam 13 to be moved.

As in 2 shown schematically in detail, can in the interaction of the laser beam 13 with the powder and the formation of the melt 20 Evaporation or spattering occurs as an interaction product 21 on to the train 22 of the laser beam 13 Separate adjacent areas. These interaction products 21 According to the invention before a further interaction of the laser beam 13 with the powder in the area of the deposited interaction products 21 away.

In the device of 1 this can be the slider 8th used after an interaction of the laser beam 13 with the powder of the applied layer 5 along a first lane 22 over the layer 5 is driven to supernatant interaction products 21 to remove and to the disposal area 6 for the device's interaction products 1 to push. At the same time additional new powder can be provided for the areas to be subsequently irradiated. However, the height of the lift table 2 not adjusted, since no new layer is yet to be applied, but only the current layer is to be completed.

To remove the interaction products 21 can effectively shape the laser beam 13 at a first irradiation along several first tracks 22 or a continuous first web 22 be guided with a plurality of mutually adjacent sections, wherein between the first tracks 22 and / or corresponding sections of a single first lane 22 Gaps remain to prevent Interaction products of a previous interaction between laser beam 13 and powder are incorporated in the subsequent interaction in the layer or interfere with the interaction between laser beam and powder. The interaction products deposited in the interstices become prior to further irradiation of the powder along one or more second lanes 23 away. The spaces correspond to the areas for the second track (s) 23 , This is in 3 shown in a sectional view, where it can be seen that between first tracks 22 in each case a gap is provided, the second tracks 23 equivalent. The 3 shows the second tracks 23 before their irradiation and before the removal of the interaction products 21 caused by the interaction of the laser beam 13 during the irradiation of the powder along the first tracks 22 originated by the slider 8th ,

In 4 is a plan view of the powder bed 12 or the processing area of the device 1 represented in the one irradiation order or irradiation strategy with corresponding trajectories 22 . 23 of the laser beam 13 is shown above the powder bed.

The 5 shows a first embodiment of a material removal device, as in the apparatus for selective laser melting according to 1 can be used. In the 5 shown device can in combination with the slider 8th for applying a powder layer 5 on the semifinished product to be coated used.

As the lateral cross-sectional view of 5 can be seen, the slide shows 8th on its underside on one side a coater blade 14 on which it allows a powder layer with a defined layer thickness on the powder bed 12 applied. Regarding the direction of movement of the slider 8th opposite to the other side of the sliding element 8th is a kind of dustpan 16 arranged at the free end of a rotating brush 17 is provided with the material on the dustpan 16 can be applied. In addition, in the embodiment of the 5 at the dustpan 16 a suction device 15 provided with a suction nozzle, over the material which is on the dustpan 16 passes, can be sucked off.

As can be seen directly from the 5 can be obtained by moving the dustpan 16 along the surface of a partially exposed layer of interaction products 21 be removed at the edges of the partially irradiated areas, which are for example in areas for a subsequent exposure. To the slide either with the material removal device or with the coater blade 14 to use, the slider can 8th be rotatable, so in the direction of movement either the coater blade 14 or the material removal device is leading.

The 6 shows a plan view of a processing area with tracks 22 which are already fully or partially exposed, and trains 23 that are unexposed. On the tracks 23 are partially interaction products 21 from the previous exposure of the webs 22 , which with a plow 30 moving along the unexposed pathways 23 can be moved from the unexposed areas 23 can be pushed so that subsequent exposure undisturbed by the interaction products 21 can be done. The plow 30 can be coupled to the high-energy beam, for example the laser beam so that the plow is moved immediately ahead of the laser beam. Accordingly, in the presentation 6 the melt 20 following to the plow 30 shown, with the plow 30 moved towards the top.

The 7 shows a third embodiment of a material removal device, which is a flexible Räumelement 40 comprises in the form of a band or in the manner of a whip, which on an axis of rotation 41 arranged so that by rotation of the axis of rotation 41 the ribbon 40 over the processing area in the form of the powder bed 12 is pivoted and so interaction products that are located on the layer in the disposal area 6 slides for interaction products.

Although the present invention has been described in detail with reference to the embodiments, it will be understood by those skilled in the art that the invention is not limited to these embodiments, but rather changes in the manner that individual features can be omitted or other combinations of features can be realized as long as the scope of protection of the appended claims is not abandoned. The present disclosure includes all combinations of the features presented.

LIST OF REFERENCE NUMBERS

1

Device for selective laser melting

2

Lift table

3

Workpiece

4

laser

5

layer

6

Disposal area for interaction products

7

Movement of the lifting table

8th

pusher

9

Lift table

10

powder storage

11

casing

12

powder bed

13

laser beam

14

application blade

15

suction

16

dustpan

17

brush

20

melt

21

Interaction products

22

first tracks

23

second tracks

30

plow

40

flexible clearing element

41

axis of rotation

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102010050531 A1 [0002]

Claims (13)

Process for the generative production of components by layer-wise joining of powder particles to one another and / or with an already produced semi-finished product or substrate by selective interaction of the powder particles with a high-energy jet ( 13 ), whereby the high-energy beam ( 13 ) in the production of a layer along one or more first tracks ( 22 ) is passed over the powder to be connected, characterized in that interaction products ( 21 ), which is due to the interaction of the high-energy beam adjacent to the at least one first path (FIG. 22 ), before further interaction of the high-energy beam ( 13 ) with the powder when moving along at least one second path ( 23 ) are removed. Method according to claim 1, characterized in that the one or more first tracks ( 22 ) are guided so that the one or more first tracks ( 22 ) are laterally spaced apart from each other and / or each other in mutually adjacent sections, so that gaps remain without interaction of high-energy jet and powder, wherein the powder of the interstices subsequent to the guidance of the high-energy beam along one or more second tracks ( 23 ) with the high-energy beam ( 13 ), wherein between the guidance of the high-energy beam ( 13 ) along one or more first tracks ( 22 ) and the guidance of the high-energy beam ( 13 ) along one or more second tracks ( 23 ) Interaction products ( 21 ) from the spaces or the area of the second track ( 23 ) are removed. Method according to claim 1 or 2, characterized in that the high-energy beam ( 13 ) is a laser or electron beam. Method according to one of the preceding claims, characterized in that the powder in a powder bed ( 12 ) is applied to the already produced semi-finished product or substrate. Method according to one of the preceding claims, characterized in that the removal of the interaction products ( 21 ) by stripping over a surface plane ( 24 ) of the layer to be applied ( 5 ) protruding interaction products takes place. Method according to one of the preceding claims, characterized in that a scraper or slide ( 8th ) for applying powder in a powder bed to remove the interaction products ( 21 ) is used. Method according to one of the preceding claims, characterized in that between the guidance of the high-energy beam ( 13 ) along one or more first tracks ( 22 ) and the guidance of the high-energy beam ( 13 ) along one or more second tracks ( 23 ) in the area of the second track ( 23 ) new powder is applied. Process according to claim 7, characterized in that the application of new powder coincides with the removal of the interaction products ( 21 ) he follows. Device for the generative production of components by layer-wise joining of powder particles to one another and / or with an already produced semi-finished product or substrate by selective interaction of the powder particles with a high-energy jet ( 13 ), in particular according to a method according to one of the preceding claims, with an irradiation device ( 4 ) for providing a high-energy jet and a processing area in which a powder layer can be arranged, wherein the high-energy beam and the processing area are movable relative to each other so that the high-energy beam can selectively interact with a powder in the processing area, characterized in that the apparatus further a material removal device, with the interaction products can be removed or relocated from the processing area. Apparatus according to claim 9, characterized in that the material removal device with a powder application device and / or the irradiation device ( 4 ) is coupled. Apparatus according to claim 9 or 10, characterized in that the material removal device comprises a plow which can be guided over the processing area, in particular in the flow to the high-energy beam to push interaction products from a path of movement of the plow. Apparatus according to claim 9 or 10, characterized in that the material removal device comprises a dustpan and / or a suction device for receiving interaction products, which can be guided over the processing area. Device according to claim 9 or 10, characterized in that the material removal device has a clearing element which can be guided over the processing region.

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