CN111225757A - 从粉末床在预先存在的部件上增材制造结构的方法 - Google Patents

从粉末床在预先存在的部件上增材制造结构的方法 Download PDF

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CN111225757A
CN111225757A CN201880052040.7A CN201880052040A CN111225757A CN 111225757 A CN111225757 A CN 111225757A CN 201880052040 A CN201880052040 A CN 201880052040A CN 111225757 A CN111225757 A CN 111225757A
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O·安德森
J·埃里克松
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Siemens Energy Global GmbH and Co KG
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Abstract

从粉末床在预先存在的部件上增材制造结构的方法。提供了一种在预先存在的部件(2)上增材制造结构(1)的方法，该方法包括：将预先存在的部件(2)设置在粉末状基底材料(3)的床中，并且整平部件(2)，使得部件(2)的制造平面(MP)可以用基底材料(3)重新涂覆，以及用能量束(4)交替地重新涂覆和照射制造平面(MP)，以便增材构建结构(1)，其中照射以如下方式被执行：制造平面(MP)由束(4)以非连续的方式扫描，其中对于根据用于结构(1)的第二矢量(V2)的照射，束(4)仅相对于先前的第一矢量(V1)平行地被引导，或在第一矢量(V1)的照射之后，照射过程被暂停1/10秒至2秒之间的时间跨度，直到用第二矢量(V2)继续照射。此外，提出了一种新装置。

Description

从粉末床在预先存在的部件上增材制造结构的方法
技术领域
本发明涉及一种从粉末床在预先存在的(优选是单晶的)部件上增材制造结构的方法。该方法可以涉及用于燃气轮机部件(诸如燃烧器或叶片)的维修或翻新方法。此外，提出了一种包括能够生成束图案的辐射源的相应装置。
优选地，部件表示应用于涡轮机中(例如燃气轮机的流动路径硬件中)的部件。部件优选地由高温合金和/或镍基合金制成，特别是由沉淀合金、固溶合金或时效硬化合金制成。
背景技术
增材制造技术包括例如粉末床方法，诸如选择性激光熔化(SLM)或选择性激光烧结(SLS)或电子束熔化(EBM)。
例如，在EP 2 601 006 B1中描述了一种选择性激光熔化的方法。
在原型部件或复杂且精细设计的部件(诸如轻量化设计或包括迷宫状内部结构的冷却部件)的制造中，增材制造(AM)方法已经被证明是有益且有利的。此外，增材制造就其短链的过程步骤而言是出色的，因为制造步骤可以直接基于对应的CAD/CAM和/或建造数据被执行。
在制造的上下文中，术语“增材”特别地表示分层的、生成的和/或自下而上的制造过程。如本文中所描述的增材制造可以是快速原型制造或涉及快速原型制造。
例如，诸如选择性激光熔化或选择性激光烧结的粉末床制造方法是用于由粉末材料制造零件或部件的、相对众所周知的方法。用于这样的方法的常规装置或设置通常包括制造平台或构建平台，在该平台上，部件被逐层构建，在馈送基底材料层之后，该基底材料层继而可以例如由激光束的能量熔化，并且随后被固化。层厚度例如由刮刀确定，该刮刀(例如自动地)在粉末床之上移动并且去除多余材料。典型的层厚度为20μm或40μm。在制造期间，所述激光束在表面之上扫描并且融化在所选择的区域上的粉末，这些区域可以根据待制造的部件的几何形状由CAD文件预先确定。
在燃气轮机技术中，特别是在制造来自于对应的流动路径硬件的部件时，迫切需要提供具有优异的机械特性和热特性的部件，以便使得部件能够忍受恶劣的涡轮环境。特别地，几乎只有当赋予部件以单晶结构时，才能符合部件的所需的抗蠕变性和抗断裂性。在常规地借助于激光熔覆或激光金属沉积来翻新涡轮叶片的情况下，与铸根或基底相比，经翻新的结构通常具有较差的结构质量。即使可以使经翻新的结构在LMD过程中至少在一定程度上采用基底的结晶度，但在基于粉末床的过程(诸如SLM或EBM)的情况下，尚未实现提供经翻新的结构的这种假晶“生长”或外延“生长”。特别地，当旨在提供一种具有与下层基板结构和预先存在的基板结构相同的(单)晶体特性的经翻新的结构时，熔池动力学是重要的。
发明内容
因此，本发明的一个目的是提供一种手段，该手段允许在与粉末床有关的增材过程中，改进在预先存在的基板的顶部上的经翻新和/或被制造的结构的材料相和晶体织构。
上述目的由独立权利要求的技术方案来实现。有利的实施例是从属权利要求的技术方案。
本发明的一个方面涉及一种在预先存在的部件上增材制造所述结构的方法。在维修或混合制造方法的情况下，该预先存在的部件与经涂覆或经翻新的结构一起则可以表示经翻新的零件或物品。
该方法包括将预先存在的部件设置在粉末状基底材料的床中，并且整平部件，使得部件的制造平面可以用基底材料重新涂覆。因此，优选地使制造平面接近粉末床的表面，反之亦然。这必须适当地以非常精确的方式被执行，因为经重新涂覆的粉末层厚度总计小至50μm或更小。
该方法进一步包括利用能量束交替地重新涂覆和照射制造平面，以便增材构建结构，其中照射如下执行，以使得(经涂覆的)制造平面被束以非连续的方式扫描。换句话说，照射可以以中断的方式被执行，即，以时间和/或空间上被中断的方式被执行。
对于根据用于结构的第二矢量的照射，照射还以如下方式被执行：粉末床上的束或束点仅相对于先前的第一矢量而被平行地引导，或者照射过程在第一矢量的照射之后在例如1/10秒至2秒之间的时间跨度上被暂停，直到照射利用第二矢量而继续。如本文中所使用的术语“矢量”应描述粉末床上的束点的条带或轨迹，根据该条带或轨迹，基底材料首先被熔化并且随后被固化。因此，矢量可以是“条带”或区段，根据该“条带”或区段，粉末床的区域必须利用能量束暴露以进行固化。必须注意的是，当所期望的区域无法作为整体被暴露时，待固化的任何区域必须根据特定的矢量图案利用能量束暴露。
通过给定的手段，可以实现从液体到固体的有利的相变，这允许所沉积的结构根据与预先存在的部件相同的结晶度被织构化。在单晶、柱状晶体或被定向固化的部件的情况下，结构还可以被赋予与部件相同的有利的晶体机械特性。这以如下方式实现：优选地，选择扫描矢量或照射方向，使得熔池总是在“前进”方向上移动，并且不“返回”到受先前矢量的热量影响的、先前经加热的区域或区块中。因此，结构的有利的晶体织构被保持或占主导并且未被破坏，就像射束“折回”时的情况一样。本发明解决了提高用于AM制造的工业化的过程效率的需求。特别地，该构思为混合零件的制造提供了优点。
在一个实施例中，对于根据用于结构的第二矢量的照射，射束不在反平行于第一矢量的方向上被引导，而只是在平行于第一矢量的方向上被引导。
在一个实施例中，射束以线型或排型在制造平面之上被扫描，并且优选地不以曲折状的方式被扫描。换句话说，选择用于制造过程的矢量几何形状，使得照射根据看书的方式被执行，即，逐行扫描，例如从左向右，反之亦然。
在一个实施例中，预先存在的部件是晶体(优选是单晶)结构或被定向固化的结构。
在一个实施例中，选择照射参数使得结构还以单晶织构被建立。
在一个实施例中，选择照射参数使得结构以柱状晶体织构被建立。
在一个实施例中，选择照射参数使得结构以树枝状晶体织构被建立。
这些实施例，特别是预先存在的部件以及结构的单晶实施例，允许赋予结构以优选的材料特性，并且因此赋予易于翻新的物品以优选的材料特性，例如在物品的应用中(例如涡轮叶片在其预定的操作期间)允许最高的抗(热)蠕变性和断裂强度的特性。
即使当结构在单晶部件上被设置有树枝状和/或某种程度上的多晶织构时，发明优点仍可以至少部分地被利用。
根据所提出的方法，结构可以在动力学上被迫“生长”或根据与部件相同的“结晶度”被建立。这是可能的，因为可以选择制造参数，使得便于结构的种子化生长、外延生长或假晶生长。
术语“假晶”是指结构采用下层部件的至少一定厚度的结晶度。
在一个实施例中，方法是选择性激光熔化方法。
在一个实施例中，方法是选择性激光烧结方法。
在一个实施例中，方法是电子束熔化方法。
在一个实施例中，方法是维修过程，其中结构是经翻新的结构或翻新结构。
本发明的另一个方面涉及一种用于从粉末床增材制造结构的装置，该装置包括基板或支撑件以及能够生成束图案(能量束)的辐射源。装置进一步被配置为使得可以用至少一个能量束选择性地照射或暴露基板的制造平面，以便在基板上增材构建结构，其中基板能够相对于束图案仅由诸如门架系统的机械装置移位，例如水平地或横向地移位。有利地，这允许省却在过程期间用于束移动的昂贵的光学扫描仪。
在一个实施例中，辐射源被配置为生成多个能量束的排型束图案。
在一个实施例中，装置被设置为使结构在横向于排方向的方向上移位。根据该实施例，装置可以设置有激光点的条或刷，该激光点的条或刷可以由机械装置相对于支撑件或基板机械地被替换。因此，可以为装置提供一种具有成本效益的“低技术”方法，即，无需使用复杂的光学措施，其中同时可以实现方法的发明优点。
与所描述的方法和/或所描述的结构有关的优点还可以与装置有关，反之亦然。
附图说明
从结合附图的对示例性实施例的以下描述，另外的特征、便利性以及有利的改进方案将变得明显。
图1示出了现有技术的增材制造过程的示意性透视图。
图2示出了根据本发明的从粉末床在预先存在的部件的顶部上增材制造结构的示意性透视图。
图3示出了根据本发明的装置的示意性透视图。
图4示出了本发明的方法步骤的示意性流程图。
在附图中，相似元件、同类元件以及作用相同的元件可以用相同的附图标记表示。
具体实施方式
图1示出了物品或零件10。实际上，零件10从粉末床3以如下方式被增材制造：所述粉末由能量束4固化。能量束4可以是激光束。能量束4优选地由辐射源21生成。借助于扫描仪11或相应的光学器件，能量束可以例如以曲折状的方式在粉末床3之上被移动，如图1中的箭头所示出并指示的。
所提出的如图1所示的方法描述了照射粉末床的常规方法。粉末床之上的束4的轨迹的每条线、每个区段或每个部分可以由矢量来描述，矢量限定或构成上述曲折形状。在基底材料3的单个层被固化之后，承载部件10的基底或支撑件通常被降低与层厚度相对应的距离。
根据该常规方法，例如沿第一水平线引导能量束4之后，能量束仅向下稍稍被引导，以便朝向起点“折回”或沿反平行于第一矢量的方向“折回”。由此，第一照射线的一部分或(多个)矢量再次被暴露于能量束4的热量，即，在短时间跨度内第二次。因此，熔池(未在图1中明确指示；参见图2中的附图标记MP)再次被移向最近被熔化过的区域。这为待建立的结构提供了不利的结构缺陷或差的结晶度，因为在结构被固化之后，该结构可能会(再次)被重新熔化。例如，特别地，这阻止了根据与下层相同的结晶度来建立结构。
图2图示了与图1所示的情况类似的情况，但是，其中在预先存在的部件2的顶部上，根据发明方法从粉末床3建立新近待制造的结构1。部件2和结构1在被完全制造后则可以表示经翻新的物品10。
在预先存在的部件2被设置或布置在粉末床3中之后(参见图4中的步骤a))，部件2或者视情况可以是部件2的制造平面MP，必须被整平(参见图4中的步骤b))，使得部件的制造平面可以用基底材料3重新涂覆和/或用能量束4照射(参见图4中的步骤c))。
根据本发明，照射以如下方式被执行：用于结构1的不同矢量由激光束4以非连续和/或排型的方式被扫描，例如根据阅读书中各行的方式从左向右，或反之亦然。
在本实施例中，能量束4优选地在粉末床3之上从左向右被引导，如图2中的箭头或矢量所指示的。顶部的线、条带或轨迹表示矢量V1。
然后，基底材料3根据随后的矢量(用矢量V2表示)被照射或扫描。与图1相反，在扫描第一线或矢量V1之后，照射被中断，并且激光束4优选地被移动到零件的左侧，以便以与矢量V1相同的方式扫描矢量V2。因此，预先存在的部件2或承载该部件的支撑件可以被移动，例如向左移动。备选地，能量源21可以被移动，例如向右移动。
在一个备选实施例中，例如矢量V2可以从右向左(即，相对于矢量V1反平行地)被扫描。但是，在这种情况下，照射必须及时被暂停例如十分之一秒到2秒的时间跨度，使得从能量束向粉末床提供的热量可以已经被消散，直到能量束4以及随能量束的熔池MP再次被移动通过已经被固化的区域，能量束4可以在多个矢量之上延伸。
因此，矢量的非连续的(即，及时被暂停的)扫描/照射方向还提供了发明的优点，即，以与预先存在的部件的晶体织构相同的晶体织构建立结构。
图3示出了根据本发明的装置20。装置20包括门架系统或辐射源21。辐射源21包括多个激光发射器和/或激光束4。辐射源21能够提供排型的束图案22。辐射源21可以是激光条或包括激光条。附图标记21可以是门架。
装置20进一步包括支撑件或基板5。基板5优选地能够相对于束图案22是水平地移位，即，在与束图案22的排方向正交的方向上移位。这由在图3中下方所示的箭头指示。
在图3中连同发明的优点进一步被指出的是：为了制造结构1或为了翻新零件10，整排能量束可以同时且相对于支撑件被移动(通过支撑件的相对于辐射源21的移动或反之亦然)。
由此，可以省却通常在SLM过程中用于移动能量束的昂贵的光学器件或扫描仪。
本发明的保护范围不限于在上文中所给出的示例。本发明被体现在每个新特征以及特征的每种组合中，特别地包括权利要求中所述的任何特征的每种组合，即使该特征或特征的该组合未在权利要求或示例中明确地被陈述。

Claims (7)

1.一种在预先存在的部件(2)上增材制造结构(1)的方法，包括以下步骤：
-将所述预先存在的部件(2)设置在粉末状基底材料(3)的一个床中，并且整平所述部件(2)，使得所述部件(2)的一个制造平面(MP)能够利用所述基底材料(3)重新涂覆，
-利用一能量束(4)交替地重新涂覆和照射所述制造平面(MP)，以便增材构建所述结构(1)，其中所述照射如下执行，以使得所述制造平面(MP)被所述束(4)以非连续的方式扫描，其中
-对于根据用于所述结构(1)的一个第二矢量(V2)的所述照射，所述束(4)仅相对于先前的一个第一矢量(V1)而被平行地引导，或者所述照射过程在所述第一矢量(V1)的所述照射之后在1/10秒至2秒的时间跨度上被暂停，直到所述照射利用所述第二矢量(V2)而继续。
2.根据权利要求1所述的方法，其中对于根据用于所述结构(1)的所述第二矢量(V2)的所述照射，所述束(4)不在反平行于所述第一矢量(V1)的方向上被引导。
3.根据权利要求1或2所述的方法，其中所述束以线状、非曲折状的方式在所述制造平面(MP)之上被扫描。
4.根据前述权利要求中的任一项所述的方法，其中所述预先存在的部件包括一个晶体结构，优选单晶结构，并且其中多个照射参数被选择使得所述结构(1)还以一个晶体织构、柱状晶体织构或树枝状晶体织构被建立，所述晶体织构优选是单晶织构。
5.根据前述权利要求中的任一项所述的方法，所述方法是选择性激光熔化、选择性激光烧结和/或电子束熔化方法。
6.根据前述权利要求中的任一项所述的方法，所述方法是维修过程，其中所述结构(1)是翻新结构。
7.一种用于从粉末床(3)增材制造结构(1)的装置(20)，所述装置(20)包括一个基板(5)以及能够生成一个束图案(22)的一个辐射源(21)，所述装置(20)被配置为使得所述基板(5)上的一个制造平面(MP)能够利用至少一个能量束(4)选择性地照射，以便在所述基板(5)上增材构建所述结构(1)，其中所述基板(5)能够相对于所述束图案(22)仅由机械装置移位，所述机械装置诸如是一个门架系统，其中所述辐射源(21)被配置为生成多个能量束的一个排型束图案，并且其中所述装置(20)被设置为使所述基板(5)在横向于一个排方向的方向上移位。
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CN113814413A (zh) * 2021-09-24 2021-12-21 武汉工程大学 激光增材制造无裂纹、强度和韧性可控的高温合金的制备方法
CN113814413B (zh) * 2021-09-24 2024-04-05 武汉工程大学 激光增材制造无裂纹、强度和韧性可控的高温合金的方法

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