CN113195133A - 制造装置 - Google Patents

制造装置 Download PDF

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CN113195133A
CN113195133A CN201980084602.0A CN201980084602A CN113195133A CN 113195133 A CN113195133 A CN 113195133A CN 201980084602 A CN201980084602 A CN 201980084602A CN 113195133 A CN113195133 A CN 113195133A
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energy beam
component
laser
impact
impact member
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塞巴斯蒂安·约恩·普泽
皮埃尔·安东尼
达米安·库帕德
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Safran Aircraft Engines SAS
Safran SA
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Safran SA
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Abstract

本发明涉及一种用于制造由金属材料制成的部件(100)的装置(1)，该装置包括由所述金属材料制成的沉积构件(2)。该装置(1)还包括通过发射能量束(5)沉积材料，以局部改变材料的晶体结构的冲击构件(4)。

Description

制造装置
技术领域
本发明涉及钛基合金部件制造领域。
本发明更具体地、但不唯一地应用于钛合金壳体的制造，钛合金壳体包括例如所述壳体的钩状部或密封部，该钩状部或密封部径向地向内延伸。
背景技术
为了一体地制造钛基合金壳体，通常需要由相同的材料形成主环形部分和次要部分。而且，通常难以铸造大型钛基合金壳体。因此，需要一种能够容易且廉价地生产大型部件的装置和制造工艺。一种已知的解决方案包括使用增材制造装置通过直接金属沉积(DMD)提供金属。增材制造使得能够一体地生产形状复杂的大型部件。然而，这种方法导致柱状微结构的产生，这对于承受机械应力的部件来说是不可接受的。此外，这种方法在制造过程中会在部件中产生可能导致部件失效的残余应力。
因此，希望有一种解决方案使得能够通过材料沉积来制造具有更好的晶体结构的部件。
发明内容
在此背景下，本发明的目的是提供一种制造装置，该制造装置用于沉积材料，以制造具有改进的结晶性能的部件，来降低所制造的部件中的残余应力。
根据第一方面，本发明涉及一种用于制造由金属材料制成的部件的装置，该装置包括用于沉积所述金属材料的构件。该装置还包括如下构件：该构件用于通过发射能量束来冲击正在沉积的材料，以局部改变材料的晶体结构。
从属权利要求将在文本达成一致后粘贴在此处。
附图说明
本发明的其它特征和优点将通过以下说明来显现，以下说明完全是说明性的而非限制性的，且应该结合附图来阅读，在附图中：
-图1为根据本发明的装置的图。
-图2为冲击激光束聚焦在沉积材料上的图。
具体实施方式
制造装置
根据第一方面，本发明涉及一种用于制造钛基合金部件100的装置1。
制造装置1基本上包括构件2和至少一个冲击构件4，构件2用于沉积熔融金属珠101(以形成部件100)，冲击构件4发射能量束5。
沉积构件
典型地，沉积构件2是已知的DMD型沉积构件。
因此，沉积构件2可包括沉积头21，沉积头21发射能量束(例如，电子束或激光)，能量束与来自材料供应部22的金属丝或金属粉末流相遇。来自沉积头21的束被聚焦以使金属熔融。沉积头21使熔融金属以珠101的形式沉积。优选地，沉积金属可以是钛基合金，典型地是TA6V型合金。
根据这里示出的实施例，沉积头21由第一电源8a供电。
冲击构件
冲击构件4是本发明的特别有利的设置。根据这里示出的实施例，冲击构件4是激光器。通常，且如下文将进行解释的，冲击构件4适于将能量束5聚焦在新沉积的材料珠101上，以改变金属部件100的晶体结构，特别是改变成基本上等轴的结构。如下文将进行解释的，冲击构件使得材料局部应变硬化，并使得机械波在部件中传播。如下文将详细描述的，所述机械波使得材料松弛(即，改变材料的晶体结构)，以消除任何残余应力。
优选地，冲击构件4是脉冲纳秒激光器，适于在5至150纳秒的持续时间内发射脉冲。以特别优选的方式，激光器发射脉冲的持续时间为10至100纳秒。此外，优选地，激光束的能量介于5至15焦耳之间，特别优选地介于9至11焦耳之间。如下文将描述的，冲击构件4被布置成能够将能量束5聚焦在先前由沉积构件2沉积的珠101上。
此外，激光器的频率介于5Hz至15Hz之间，优选地介于9Hz至11Hz之间。
根据这里示出的实施例，冲击构件4由第二电源8b供电。
规定装置1可以由单一电源供电。使用两个不同的电源对冲击构件4的激光功率要求作出最好的响应。
伺服控制
沉积构件2和冲击构件4是从动构件且同步。实际上，如下文将描述的，冲击构件4需要将能量束5聚焦在最近沉积的材料珠101上且在规定的温度下(将在随后指定)进行聚焦。因此，沉积构件2和冲击构件4可以附接到同一机械臂。可选地，沉积构件2和冲击构件4可以各自附接到不同的机械臂。这种布置在路径的产生方面提供更大的自由度。在这种情况下，两个臂必须是从动臂且一致地被驱动。
此外，装置1可包括温度控制系统，该温度控制系统包括联接到高温计的相机。因此，可能不变地控制装置1的温度，更具体地，不变地控制珠101的温度。
在这里示出的示例中，在沉积TA6V型钛基合金的情况下，有利的是在材料在800℃左右发生相变之前阻止晶粒的生长。因此，冲击必须恰好在凝固之后且在微结构形成之前进行。特别有利地，使用激光器作为冲击构件4使得能够在从1600℃至800℃的冷却期间执行冲击，这使对微结构的影响最大化。应该回想起来，冲击在一个方向上施加约束，这阻止晶粒在该同一方向上的生长。因此获得了具有更好的力学性能的、等轴的、因此各向同性的微结构。
为了使激光冲击与沉积构件2的位移同步，需要控制沉积构件2产生的液体池与冲击区域之间的距离。该距离必须足够小，以保持较高的温度(例如800℃以上)，但是该距离必须足够大，以不干扰沉积(例如1600℃以下)。通过估计沉积的珠的冷却梯度和沉积构件2的进给速度，该距离必须在5mm至50mm之间。不同沉积工艺特有的众多参数和可变性使得不能够简单地设置该距离。为了控制该距离，如前所述，进行温度控制。
为此，高温计测量冲击区域中心的温度，以产生控制触发激光冲击的TTL信号。两个激光脉冲之间设置等待时间，是考虑到冲击区域的直径。
计算该等待时间(toff)，以考虑重叠率(百分比)(Tau)、期望冲击的直径(D)和沉积喷嘴的前进速度(V)，等待时间由数控根据公式toff＝(D×(1-Tau/100))/A给出。高温计可以由通过图像处理进行温度监测的热像仪代替。同样，根据冲击区域中心的像素值水平产生信号，以触发发射。
封闭外壳
有利地，装置1可以具有封闭外壳(未示出)，用于在受控制的气氛中制造部件100。感应器可用于控制部件的温度。优选地，感应器连接到温度控制装置，以保证对温度的精细控制。
装置的制造方法和操作
根据第二方面，本发明涉及一种使用装置1制造钛合金部件100的方法。
基本上，该方法包括沉积多个金属珠101以形成金属部件100，并将能量束5聚焦在多个珠101中的至少一个上，以将金属部件100的晶体结构改变成等轴结构。
更确切地，沉积构件2根据确定的路径对多个珠101进行沉积以制造部件100。该原理就是众所周知的一种增材制造。因此，通过连续地对多个熔融金属珠101进行沉积来逐层制造部件100。同时，冲击构件4将束5聚焦在多个珠101上以改变晶体微结构，从而改变整个部件100的晶体结构。
如图2所示，当激光束聚焦在沉积在制造中的部件100上的珠101上时，在激光束冲击液滴101期间形成等离子体103。等离子体的形成所释放的能量产生机械波105，该机械波将破坏珠101的金属微结构(以获得精细的等轴微结构)并使材料局部应变硬化。此外，机械波105在制造中的部件100中传播时，将使材料松弛，并因此消除任何残余应力。也就是说，材料局部受到约束(应变硬化)但整体松弛。为了更好地理解，所讨论的现象可以与锻造比较。这样，在锻锤的冲击点处，材料局部应变硬化，但是在整体上，冲击的冲击波使部件的内部结构松弛。需要说明的是，这仅仅是为了解释根据本发明的方法而进行的比较。每个珠101的局部应力在珠101的顶层沉积期间和在与顶层的珠101上的激光冲击有关的机械波传播期间得到松弛。
因此，特别有利地，连续地将能量束5聚焦到珠101的沉积处，使得能够在部件100的制造期间改变部件100的微结构，从而避免长柱状晶粒的形成和残余应力的产生。
需要说明的是，当能量束5聚焦在其温度介于30℃至200℃之间、优选地介于50℃至150℃之间的珠101上时，获得最优结果。
通过该方法获得的部件
根据第三方面，本发明涉及一种部件100，该部件直接通过根据本发明的方法获得。如上所述，根据本发明的方法使得能够制造可以具有复杂几何形状的大型部件。
例如，部件100可以是涡轮机壳体。

Claims (12)

1.一种用于制造由金属材料制成的部件(100)的装置(1)，所述装置包括用于沉积所述金属材料的构件(2)，其特征在于，所述装置还包括用于通过发射能量束(5)来冲击正在沉积的材料，以局部改变材料的晶体结构的构件(4)。
2.根据权利要求1所述的装置(1)，其中，所述沉积构件(2)被构造成沉积多个熔融金属珠(101)。
3.根据权利要求2所述的装置(1)，其中，所述沉积构件(2)被构造成沉积多个熔融钛基合金珠(10)。
4.根据权利要求2所述的装置(1)，其中，所述冲击构件(4)被构造成将所述能量束(5)聚焦在所述多个珠(101)中的至少一个上。
5.根据权利要求1至3中的一项所述的装置(1)，其中，所述冲击构件(4)适于将所述晶体结构局部地改变成基本上等轴的结构。
6.根据权利要求1至4中的一项所述的制造装置(1)，其中，所述冲击构件(4)是激光器，优选地是脉冲持续时间介于5纳秒至150纳秒之间的脉冲激光器。
7.根据权利要求1至5中的一项所述的装置(1)，所述装置包括封闭外壳，所述封闭外壳限定所述沉积构件(2)和所述冲击构件(4)。
8.根据权利要求6所述的装置(1)，所述装置包括感应器和相机，所述感应器用于调节封闭外壳中的温度，所述相机联接到高温计，用于在所述冲击构件(4)发射所述能量束(5)之前观察所述构件并测量所述温度。
9.一种用于制造钛基合金部件(100)的方法，所述方法使用根据权利要求1-7中的一项所述的装置(1)，所述方法包括将能量束(5)聚焦在正在沉积的材料上，以局部改变所述材料的晶体结构。
10.根据权利要求8所述的方法，所述方法包括通过所述能量束(5)使所述材料局部应变硬化。
11.根据权利要求2、4和9的组合所述的方法，其中，当激光与所述珠(101)接触时，所述激光产生等离子体(103)，所述等离子体(103)的产生释放机械波(105)，以使所述珠(101)应变硬化，并使所述部件(100)的至少一部分松弛。
12.一种部件(100)，直接通过根据权利要求8至10中的一项所述的方法获得。
CN201980084602.0A 2018-12-18 2019-12-18 制造装置 Pending CN113195133A (zh)

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