CN107206488A - 利用较厚的粉末层进行的增材制造方法和构件 - Google Patents

利用较厚的粉末层进行的增材制造方法和构件 Download PDF

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CN107206488A
CN107206488A CN201680007724.6A CN201680007724A CN107206488A CN 107206488 A CN107206488 A CN 107206488A CN 201680007724 A CN201680007724 A CN 201680007724A CN 107206488 A CN107206488 A CN 107206488A
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powder
powder bed
component
bed
layer
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CN107206488B (zh
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克里斯蒂安·布伦胡贝尔
托马斯·索勒
大卫·勒涅里
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Siemens AG
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    • 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
    • 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
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/05—Metallic powder characterised by the size or surface area of the particles
    • B22F1/052—Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/06—Metallic powder characterised by the shape of the particles
    • 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
    • B22F12/60—Planarisation devices; Compression devices
    • B22F12/67—Blades
    • 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
    • B23K26/14—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
    • B23K26/144—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor the fluid stream containing particles, e.g. powder
    • 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
    • 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
    • B23K26/70—Auxiliary operations or equipment
    • 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
    • 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

Abstract

在选择性的制造方法中通过使用厚的粉末层(7，10)提高生产速度。

Description

利用较厚的粉末层进行的增材制造方法和构件
技术领域
本发明涉及一种增材制造(AM)领域中的方法或构件，其中使用厚的粉末层，以便加速制造方法。
背景技术
射束熔化法，如选择性激光熔化(SLM)或者电子束熔化法(EBM)是现今所选择的技术，以便生产复杂的燃气轮机部件，尤其燃烧器部件。由于受所力求达到的精度所决定的大约0.05mm的相对小的层厚度，并且由于因借助于刮刀或辊来进行放置而引起的耗费时间地涂覆这种薄的层，造成构造速度缓慢。低的构造速度(～20cm3/h)是许多构件如今还是能够以常规的方式更有利地制造的原因。
设想了不同的技术解决方案来加速所述方法。大多数的制造商试图通过大的激光功率并且通过整合多个激光(多束)来缩短构造速度。然而，通过这种方式提高了构件中的因热机械引起的应力和扭曲的危险。
发明内容
因此，本发明的目的是解决上述问题。
所述目的通过根据权利要求1的方法和根据权利要求9的构件来实现。
在从属权利要求中列举出其他有利的措施，所述措施能够彼此任意地组合，以便实现其他的优点。
图1至4示出本发明的实施例。
说明书和附图仅描述本发明的实施例。
本发明所基于的思想是：加速粉末沉积的费时的步骤。在此，除了常用的在0.025mm至0.045mm的范围中的粒度之外，优选也使用一种或多种更粗的粉末级分，即粒度在至少0.1mm的范围中的粉末级分，其中所述在0.025mm至0.045mm的范围中的粒度对于产生精细的结构是必需的。
在本发明的一个具体的设计方案中，一种或多种粗的粉末级分包含非球形的，优选扁圆和/或扁长的颗粒，以便获得尽可能高的堆积密度进而获得层内部的尽可能最佳的热传递。
一种或多种较粗的粉末级分能够借助于刮刀涂覆，所述刮刀垂直于用于更精细的粉末的刮刀工作——粉末堆可能需要相应地设置。增材制造工艺的射束功率，优选SLM工艺的射束功率，和构造平台的下降，根据所涂覆的粉末层厚度来调整。
根据本发明的步骤在增材制造工艺中尤其在使用具有较大的金属颗粒的第二粉末时存在(所述第二粉末具有单峰或多峰的粒度分布)。对于构件而言，或在构件的部段中，其中轮廓精度允许涂覆较粗的粉末，可能产生显著的速度优势。在粒度处于至少0.1mm的范围中的粉末的情况下，这种粉末涂覆对于粒度处于0.025mm至0.045mm范围中的粉末而言可能是其粉末涂覆的2-4倍快。
此外，通过优化第二粉末的形态和粒度组成，更高的堆积密度是可行的进而更快的且缺陷更少的熔化是可行的，这附加地改进了构造速度和质量。
附图说明
图1示出根据本发明的处理方法。
具体实施方式
待制造的构件具有基底4，在所述基底上根据增材制造方法沿涂覆方向22'涂覆呈粉末形式的材料。在此，通过多个层7、10实现至少0.1mm的厚的层，其中设置相应的刮刀间隙宽度或者将刮刀多次移动经过已经存在的、尚未被射束熔化的粉末层。
粉末层7、10具有粒度≤50μm的粉末。通过匹配的熔化射束11来熔化厚的粉末层7、10，其中熔化选择性地进行，以便实现待制造的构件1'的特定的轮廓。
图2示出另一处理方法，其中与图1相比相同地产生厚的粉末层13，然而其中在此使用粉末层13的层片，所述层片优选具有较粗的颗粒。较粗的颗粒优选具有0.1mm的最小粒度。
具有较粗的粉末颗粒的该粉末层13同样通过熔化射束11熔化，以便产生构件1″。
图3示出构件1″′的具有不同部段的横截面，其中在第一端部部段15'中使用薄的粉末层，即明显小于0.1mm的粉末层，以便实现一定的轮廓精度，而在另一端部部段15″′中使用较粗的颗粒或根据图1和2的处理方法的多个粉末层，因为在该部段15″′中不那么需要轮廓精度。
在可能存在的中间部段15″中，将所述处理方法用于部段15'或15″′，或者它们的组合。
图4沿涂覆方向22IV示出构件1IV的俯视图，其中在外部部段18″中与在其他部段18'中相比应实现更高的轮廓精度，使得在那里使用薄的粉末层、即≤50μm的粉末层，并且在另一区域18″中选择根据图1或图2的处理方法。

Claims (9)

1.一种用于制造构件(1'，……，1IV)的方法，其中逐层地将粉末涂覆为粉末层(7，10，13)，并且
选择性地致密化，
尤其选择性地熔化，
其特征在于，
至少部分地并且至少逐层地涂覆至少0.1mm的厚的粉末层(7，10，13)，并且
致密化，
尤其熔化。
2.根据权利要求1所述的方法，
其中利用粒度≤50μm的精细粉末实现厚的所述粉末层(7，10，13)。
3.根据权利要求2所述的方法，
其中在一个工序(13)中涂覆厚的所述粉末层(13)。
4.根据权利要求2所述的方法，
其中通过涂覆多个粉末层(7，10)实现厚的所述粉末层(7，10)。
5.根据权利要求1、3或4所述的方法，
其中使用至少0.1mm的粒度，以便实现厚的所述粉末层(13)。
6.根据上述权利要求中一项或多项所述的方法，
其中使用扁长和/或扁圆的粉末颗粒。
7.根据上述权利要求中一项或多项所述的方法，
其特征在于，
借助于两个刮刀涂覆所述粉末层，所述刮刀尤其彼此垂直地设置。
8.根据上述权利要求中一项或多项所述的方法，
其中使用粉末混合物作为粉末，尤其根据要求2使用粉末混合物作为粉末，和尤其根据权利要求5或6使用粉末混合物作为粉末。
9.一种构件(1'，……1IV)，尤其通过根据权利要求1、2、3、4、5、6、7或8中一项或多项所述的方法来制造的构件，
所述构件具有不同的区域(15'，15”，15”'；18'，18”)，
其中所述构件(1'，……，1IV)具有至少一个区域，所述区域关于待致密化的，尤其待熔化的粉末层的厚度是不同的，并且与之相应地具有不同的粗糙度。
CN201680007724.6A 2015-01-30 2016-01-13 利用较厚的粉末层进行的增材制造方法和构件 Expired - Fee Related CN107206488B (zh)

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DE102015201686.2A DE102015201686A1 (de) 2015-01-30 2015-01-30 Additives Herstellungsverfahren unter Verwendung dickerer Pulverschichten und Bauteil
DE102015201686.2 2015-01-30
PCT/EP2016/050550 WO2016120069A1 (de) 2015-01-30 2016-01-13 Additives herstellungsverfahren unter verwendung dickerer pulverschichten und bauteil

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WO2016120069A1 (de) 2016-08-04
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US20180001424A1 (en) 2018-01-04
CN107206488B (zh) 2020-01-03

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