DE102010026139A1 - Manufacturing component, preferably e.g. guide vane of a turbomachine, comprises selective laser melting raw material powder using process gas, hot isostatic pressing resulting component, and precipitation hardening resulting component - Google Patents

Abstract

Manufacturing component, comprises: (i) beam melting (preferably selective laser melting or selective laser sintering) raw material powder by using a process gas comprising helium and/or neon, to obtain the component; (ii) hot isostatic pressing the above obtained component for compacting the structure of the component; and (iii) precipitation hardening the above obtained component for increasing hardness and strength of the component. An independent claim is also included for the component manufactured by using the above method.

Description

The present invention relates to a method for manufacturing a component and such a component.

Components, such as vanes or blades of a turbomachine, can be manufactured by various manufacturing processes. In order to achieve a high degree of flexibility and, in particular for small batches, low production costs, today fast manufacturing processes are used, such. B. selective laser melting or selective laser sintering.

Selective laser melting represents a manufacturing process in which a component is built up by layer-by-layer melting of material particles by means of a laser. Due to the layered melting of the material particles any three-dimensional geometries can be generated in a relatively short time, such. B. workpieces that can be produced in conventional mechanical or casting production only with great effort.

The DE 198 53 947 C1 describes a process chamber for the selective laser melting of material powder for the production of moldings. The process chamber of DE 198 53 947 C1 consists of a closed chamber with bottom surface and top surface, a storage volume and a build-up volume in the bottom surface, wherein in the region of the side walls first inlet and outlet openings are provided for a process gas. In the top surface above the body volume, a raised area with side surfaces is provided, in which a coupling window transparent to a laser radiation to be coupled is arranged.

In this approach according to the prior art for the production of components by selective laser melting, it has proved to be disadvantageous that the components produced have an inhomogeneous material structure, which also has large-volume bubbles and porosities. The large-volume bubbles and porosities are formed by process gas atoms trapped in the material structure, which are arranged in the material structure of the material on the one hand during production of the material powder by atomizing a material and on the other hand during selective laser melting. These imperfections, in particular the bulky bubbles and porosities in the material structure, disadvantageously lead to a reduced density, elasticity and strength of the component. Such disadvantages also occur in electron beam sintering processes.

These bubbles and porosities could possibly be temporarily reduced by hot isostatic pressing, whereby these defects would no longer be visible to the outside. Subjecting these hot isostatic pressed components but a heat treatment such. B. a precipitation hardening process, the dissolved process gas atoms would expand again and it would again bubbles and porosities in the material structure of the component arise. This is a condition to be improved.

The object of the present invention is therefore to provide a method for producing a component and such a component, which have an improved material structure.

This object is achieved by a method having the features of claim 1 and by a component having the features of claim 6.

Accordingly, a method for producing a component is provided with the following method steps: providing a material powder; Producing a component by jet melting, in particular selective laser melting, selective laser sintering or electron beam sintering, of the material powder using a process gas comprising helium or neon or a mixture of helium and neon; Hot isostatic pressing of the manufactured component for compacting the structure of the component; and precipitation hardening of the component to increase the hardness and strength of the component.

According to a particularly preferred embodiment, the material powder is produced by atomizing a melt stream of a material by means of a gas flow which comprises helium or neon or a mixture of helium and neon.

The idea underlying the present invention consists in the process steps for producing a component, a process gas with a small atomic size or atomic mass, such. As helium or neon or a mixture of helium and neon to use.

Helium and neon dissolve easily in the material of the component and only slightly distort the metal lattice of the material, so that the structure of the material is much firmer, more elastic and dense than when using a conventional process gas with a large atomic diameter or a large atomic mass.

Due to the very small atomic size of helium or neon, the process gas can be advantageous In addition, it diffuses out of the material structure more easily, without resulting in lasting large-volume bubbles or pores in the material structure. Furthermore, a very homogeneous material structure is formed, which additionally leads to a reduced tendency of the material of the component to crack.

A component produced by means of this method advantageously has a higher density, elasticity and strength than a component which has been produced using the previously known devices and methods. Furthermore, this method significantly reduces the production costs and the use of materials since the number of defective components can be significantly reduced.

In a preferred embodiment, the hot isostatic pressing is carried out in a device provided therefor in a pressure range of about 100 MPa to 200 MPa and a temperature of up to 2000 ° C. Hot isostatic pressing is also carried out with a process gas which contains helium or neon or a mixture of helium and neon. The hot isostatic pressing gives the component isotropic material properties and is also compressed.

The precipitation hardening is preferably carried out in a multi-hour process in a temperature range of 500-700 ° C in a suitable device. However, the temperature and duration of this precipitation hardening process must be adjusted to the materials used.

Advantageous embodiments and further developments of the invention will become apparent from the other dependent claims and from the description with reference to the figures of the drawing.

In a preferred embodiment, during the production of the component, the process gas is conducted past a respective layer surface of the component to be produced by means of a process gas stream. By using a process gas stream, which is guided past the respective layer surface of the component, it can be ensured that the process gas comes into contact with the respective layer surface of the component to be produced in an optimum composition and quality. By using this process gas stream, an increased quality of the material structure of the component to be produced can be ensured.

In a further embodiment, the process gas is filtered during manufacture of the component before reaching the respective layer surface of the component to be produced by means of a filter. By filtering the process gas upon reaching the respective layer surface of the component to be produced, the quality of the process gas is further increased. This leads to a further increase in the quality of the material structure of the manufactured component. As a filter, for example, open-pored ceramics can be used. Open-pore sintered metal filter elements can also be used for filtering the process gas.

In a further preferred embodiment, the material provided at least partially titanium, iron, nickel, chromium, platinum and / or cobalt. By using these elements, a material structure can be produced which is particularly homogeneous, dense, elastic and strong.

The above embodiments and developments can be combined as desired. Further possible refinements, developments and implementations of the invention also include combinations, not explicitly mentioned, of features of the invention described above or below with regard to the exemplary embodiments. In particular, the person skilled in the art will also add individual aspects as improvements or additions to the respective basic form of the present invention.

The present invention will be explained in more detail with reference to embodiments given in the schematic figures of the drawing. It shows:

1 a schematic representation of a device for producing a metal powder by spraying;

2 a schematic representation of an apparatus for producing a component by selective laser melting; and

3 a schematic diagram of the process steps of the inventive method for producing a component.

In the figures of the drawing are identical or functionally identical elements - unless otherwise stated - provided with the same reference numerals.

In 1 is a facility 26 for atomizing a material according to a preferred embodiment of the present invention. The device 26 has a material reservoir 23 on. In this material reservoir 23 is a material stored, the material in this material reservoir 23 is preferably heated until the material has reached a liquid state. Subsequently, the liquid material flows in the direction of a nozzle 22 , At the nozzle 22 is preferably a gas supply device 24 arranged which gas to the nozzle 22 hinleitet. The liquid material is then under strong pressure from the device 26 pressed. As soon as the material comes out of the nozzle 22 leaked, this solidifies to a fine-grained material powder. The solidified material powder is placed in a container 25 collected. As gas, which from the Gaszuführeinrichtung 24 the nozzle 22 Helium or neon or a mixture of helium and neon is preferably used. However, it is also possible to use a gas which only partially contains helium or neon or a mixture of helium or neon. Alternatively, the material can be atomized vacuum.

In 2 is a schematic representation of an apparatus for producing a component represented by selective laser melting. The device which by the reference numeral 13 is provided comprises a process chamber 14 , The process chamber 14 is isolated from its environment, so in the process chamber 14 a different pressure, temperature and / or gas composition may prevail than in the environment. For this purpose, the process chamber 14 For example, different seals and insulation layers 5 on. The inner surface 16 the process chamber 14 is preferably formed as a non-reflecting layer, for example as a black layer.

On the upper ceiling wall 18 the process chamber 14 is for example a coupling window 10 arranged. The coupling window 10 is present in a central position in the upper ceiling wall 18 the process chamber 14 , Through the coupling window 10 can a laser beam 2 in the process chamber 14 be coupled. Above the coupling window 10 is a laser device 17 arranged. The laser device 17 produces one for melting a material powder 3 suitable laser beam 2 , At the lower housing wall of the process chamber 14 are sidewalls 4 for receiving a material powder 3 shown. The material powder 3 is from these side walls 4 held in the process chamber.

The material powder 3 can be inside the sidewalls 14 be provided in layers by a Werkstoffpulverzuführeinrichtung (not shown). After providing a layer of material powder, the laser melts 2 the material powder at corresponding coordinates. As a result, melt the material particles of the material powder into each other and thereby form a solid, inherently homogeneous component 1 , Furthermore, the device 13 a lifting device, which the component in the process chamber 14 raises and / or lowers.

In addition, the device 13 According to the present embodiment, a process gas supply 6 on. Through the process gas supply 6 the process chamber, a process gas with a small atomic size or atomic mass, such. As helium or neon or a mixture of helium and neon, are supplied. The process gas supply 6 preferably has a device for this purpose 27 for applying heat to the process gas and a device 19 for pressurizing the process gas. The process gas supply 6 further preferably comprises a filter 15 on. Through the filter 15 Contaminants can be filtered in the process gas. This allows the process gas always in a high quality of the process chamber 14 be supplied. The filter 15 For example, it may be an open-pored ceramic filter.

In the process chamber 14 are according to the present embodiment on the upper ceiling wall 18 a variety of sensors 20 . 8th . 9 arranged. The sensor 20 measures, for example, the chemical composition of the process gas in the process chamber 14 , The sensor 8th For example, the pressure and the sensor 9 for example, the temperature of the process gas in the process chamber 14 measure up.

The sensors 20 . 8th . 9 are with a control device 7 coupled. The control device 7 For example, with the device 27 and the facility 19 be coupled. The control device 7 For example, it can be designed as a microcontroller. About the controller 7 is it possible the process gas supply 6 to control so that the process gas in an optimal composition with a suitable temperature and with a suitable pressure of the process chamber 14 is supplied. Furthermore, the control device 7 coupled to a user interface (not shown), which monitors the process conditions in the process chamber 14 represents a user.

Furthermore, the device 13 for producing a component by selective laser melting a Prozeßgasabführeinrichtung 11 on. The process gas discharge device 11 For example, it can be a fan. Also the process gas discharge device 11 can a filter 15 for filtering the process gas. Through the filter 15 Contaminants can be filtered in the process gas. The process gas, which comes from the process chamber 14 is discharged, via a circuit (not shown) back to the process gas supply 6 be fed, and again with pressure and heat through the facilities 18 and 19 be charged.

In 3 is a schematic diagram of the process steps of the inventive method for producing a component shown. In a first method step S1, a material is provided. This material may, for example, titanium, iron, nickel, chromium, platinum and / or cobalt. In a second method step S2, the material is atomized by means of a gas flow and thus converted to a fine-grained material powder. Helium or neon or a mixture of helium and neon is used as gas for atomizing the material. However, a gas may also be used which only partially contains helium or neon or a mixture of helium and neon. In a third method step S3, a component is produced from the material powder produced in method step S2. For the production of the component, a generative layer construction method is used, in particular a selective laser melting method or a selective laser sintering method. In a fourth method step S4, the component produced in method step S3 is hot isostatically pressed. The hot isostatic pressing takes place in a device designed for this purpose with a temperature of up to approximately 2000 ° C. at a pressure of approximately 100 MPa to 200 MPA in a protective gas atmosphere. The inert gas atmosphere may also include helium or neon or a mixture of helium and neon.

The hot isostatic pressing gives the component isotropic material properties and is also densified. In a fifth method step S5, the component is subjected to a precipitation hardening process. For this purpose, the component is heated in a device designed for this purpose for several hours to a temperature of about 500 to 700 ° C. In this precipitation hardening process, metastable phases of the material are precipitated in finely divided form, thus increasing the strength and hardness of the component.

Although the present invention has been fully described above with reference to preferred embodiments, it is not limited thereto but is modifiable in a variety of ways.

For example, further process steps can be added to the process, such. As a blasting of the component after the manufacture of the component by selective laser melting or by selective laser sintering. A coating process for coating the component may also be added to the process.

It should also be noted that the materials listed here are only to be understood as examples and that new boundary conditions and areas of application can be adapted. Alternatively, the method can be advantageously carried out by means of electron beam sintering.

LIST OF REFERENCE NUMBERS

1

component

2

laser beam

3

Material powder

4

side walls

5

insulation layer

6

Prozessgaszuführeinrichtung

7

control device

8th

pressure sensor

9

temperature sensor

10

Einkopplungsfenster

11

Prozessgasabführeinrichtung

12

Process channel interior

13

Device for selective laser melting

14

process chamber

15

filter

16

Process chamber inner wall

17

laser device

18

ceiling wall

19

Device for pressurizing the process gas

20

Sensor for measuring the composition of the process gas

21

Process chamber floor

22

jet

23

Material reservoir

24

gas supply

25

container

26

Device for atomizing

27

Device for applying heat to the process gas

S1

Process step Provision of the material

S2

Step of spraying the material

S3

Process step Manufacture of a component

S4

Process step hot isostatic pressing of the component

S5

Process step precipitation hardening of the component

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 19853947 C1 [0004, 0004]

Claims (6)

Method for producing a component ( 1 ) comprising the following steps: providing a material powder; Producing a component ( 1 by jet melting, in particular by selective laser melting or selective laser sintering, of the material powder using a process gas comprising helium or neon or a mixture of helium and neon; Hot isostatic pressing of the manufactured component ( 1 ) for compacting the structure of the component; and precipitation hardening of the component ( 1 ) for increasing the hardness and strength of the component ( 1 ). A method according to claim 1, characterized in that the material powder by means of atomizing a melt jet of the material by means of a gas flow which helium or neon or a mixture of helium and neon, takes place. Method according to claim 1 or 2, characterized in that during production of the component ( 1 ) the process gas by means of a process gas stream at a respective layer surface of the component to be produced ( 1 ) is passed. Method according to one of the preceding claims, characterized in that the process gas in the manufacture of the component ( 1 ) before reaching the respective layer surface of the component to be produced ( 1 ) by means of a filter ( 15 ) is filtered. Method according to one of the preceding claims, characterized in that the material provided at least partially titanium, iron, nickel, chromium, platinum and / or cobalt. Component ( 1 ), which is produced according to one of the preceding claims.

Images