DE102015201637A1 - Apparatus for additive production with electron beam preheating and laser consolidator and method - Google Patents

Apparatus for additive production with electron beam preheating and laser consolidator and method Download PDF

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DE102015201637A1
DE102015201637A1 DE102015201637.4A DE102015201637A DE102015201637A1 DE 102015201637 A1 DE102015201637 A1 DE 102015201637A1 DE 102015201637 A DE102015201637 A DE 102015201637A DE 102015201637 A1 DE102015201637 A1 DE 102015201637A1
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electron beam
powder bed
laser
powder
component
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German (de)
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Christian Brunhuber
Thomas Soller
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Siemens AG
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Siemens AG
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    • 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
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/362—Process control of energy beam parameters for preheating
    • 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
    • B22F12/10—Auxiliary heating means
    • 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
    • B22F12/10—Auxiliary heating means
    • B22F12/13—Auxiliary heating means to preheat the material
    • 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
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • 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

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  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Optics & Photonics (AREA)
  • Automation & Control Theory (AREA)
  • Plasma & Fusion (AREA)
  • Powder Metallurgy (AREA)
  • Laser Beam Processing (AREA)

Abstract

Durch die Kombination einer Elektronenstrahlvorheizung und einer selektiven Laserverfestigung wird die Qualität von Bauteilen, die durch additive Fertigungsverfahren hergestellt werden, deutlich verbessert.The combination of electron beam preheating and selective laser solidification significantly improves the quality of components produced by additive manufacturing processes.

Description

Die Erfindung betrifft ein Verfahren und eine Vorrichtung der additiven Fertigung (Additive Manufacturing, AM), bei dem ein Elektronenstrahl zur Vorheizung des Bauteils und ein Laserstrahl zur Verfestigung verwendet wird. The invention relates to a method and an apparatus of additive manufacturing (AM), in which an electron beam for preheating the component and a laser beam for solidification is used.

Das Selektive Laserschmelzen (SLM) als ein AM-Verfahren findet zunehmend Verwendung bei der Herstellung komplexer Gasturbinenkomponenten. Selective laser melting (SLM) as an AM process is finding increasing use in the manufacture of complex gas turbine components.

Thermisch und mechanisch hochbelastete Bauteile wie etwa Gasturbinenschaufeln werden aus warmfesten Ni-Basislegierungen mit hohem Anteil an Ɣ‘-Bildnern wie Titan und Aluminium gefertigt, die als schwer schweißbar gelten. Bei der Herstellung mittels SLM treten während der Herstellung Heißrisse auf. Thermally and mechanically highly stressed components such as gas turbine blades are made of heat-resistant Ni-base alloys with a high proportion of Ɣ'-formers such as titanium and aluminum, which are considered to be difficult to weld. During production by means of SLM, hot cracks occur during production.

Aufgrund der schlechten Schweißbarkeit der in Frage kommenden Materialen werden die hochbelasteten Komponenten heute ausschließlich über Feinguss hergestellt. Die Prozessierung von schwer schweißbaren warmfesten Ni-Basisstählen befindet sich heute noch im R&D-Stadium. Due to the poor weldability of the materials in question, the highly stressed components are now produced exclusively by precision casting. The processing of difficult-to-heat, heat-resistant Ni base steels is still in the R & D stage today.

Bei den meisten der in Entwicklung befindlichen Konzepte wird der AM-Prozess bei hohen Temperaturen durchgeführt, wodurch ein schnelles Auskühlen und die damit verbundenen Heißrisse vermieden werden können. Zur Beheizung der Prozesskammer kann eine resistive Heizung, eine induktive Heizung oder eine Heizung mittels IR-Strahlern zum Einsatz kommen. In most of the concepts in development, the AM process is performed at high temperatures, thereby avoiding rapid cooling and associated hot cracks. For heating the process chamber, a resistive heating, an inductive heating or a heating by means of IR radiators can be used.

Es ist daher Aufgabe der Erfindung oben genanntes Problem zu lösen. It is therefore an object of the invention to solve the above-mentioned problem.

Die Aufgabe wird gelöst durch eine Vorrichtung gemäß Anspruch 1 und ein Verfahren gemäß Anspruch 4. The object is achieved by a device according to claim 1 and a method according to claim 4.

In den Unteransprüchen sind weitere vorteilhafte Maßnahmen aufgelistet, die beliebig miteinander kombiniert werden können, um weitere Vorteile zu erzielen. In the dependent claims further advantageous measures are listed, which can be combined with each other in order to achieve further advantages.

Es zeigen Show it

1, 2 Ausführungsbeispiele der erfindungsgemäßen Vorrichtung. 1 . 2 Embodiments of the device according to the invention.

Die Beschreibung und die Figuren stellen nur Ausführungsbeispiele der Erfindung dar. The description and the figures represent only embodiments of the invention.

Ein AM-Prozess soll bei hohen Temperaturen ablaufen. Zum Aufheizen soll ein Elektronenstrahl dienen, der insbesondere mit elektromagnetischen Linsen über ein Pulverbett verteilt wird. An AM process should take place at high temperatures. For heating, an electron beam is to be used, which is distributed in particular with electromagnetic lenses over a powder bed.

Die erfindungsgemäß verwendete Heizvorrichtung besteht insbesondere somit im Wesentlichen aus dem Equipment, wie es beim sogenannten Elektronenstrahlschmelzen zum Einsatz kommt. Ein schnelles Scannen mit einem fokussierten Elektronenstrahl – wie beim Elektronenstrahlschmelzen – oder eine gleichmäßige Bestrahlung des Pulverbetts, oder Teilen des Pulverbetts, stellen Möglichkeiten der Realisierung der Vorheizung dar. Es bestehen verschiedene Möglichkeiten die Strahlführung des Elektronenstrahls zu gestalten, insbesondere kann der Elektronenstrahl einen Fokus durchlaufen. Da eine elektromagnetische Strahloptik zudem eine außerordentlich schnelle Scan-Geschwindigkeit von bis 1000 m/s und mehr erlaubt, verglichen mit ~10 m/s bei mechanisch bewegten AM-Lichtoptiken, besteht insbesondere die Möglichkeit, neben einer flächig-homogenen Beleuchtung des Pulverbetts eine schnelle punktuelle Abrasterung durchzuführen. Das Abrastern kann dabei entweder (zwecks homogener Durchwärmung) gleichförmig erfolgen oder in Mustern, um gezielt Wärmequellen und -senken im Pulverbett zu schaffen und damit die Wärmeableitung sowie das resultierende Gefüge der AM-gefertigten Komponente zu steuern. In Konsequenz können dadurch die mechanischen Eigenschaften der AMgefertigten Komponente beeinflusst werden. The heating device used in accordance with the invention thus consists in particular essentially of the equipment used in so-called electron beam melting. A fast scanning with a focused electron beam - as in electron beam melting - or a uniform irradiation of the powder bed, or parts of the powder bed, represent ways of implementing the preheating. There are various ways to design the beam guidance of the electron beam, in particular, the electron beam can pass through a focus , In addition, since an electromagnetic radiation optics allows an extremely fast scanning speed of up to 1000 m / s and more, compared with ~ 10 m / s for mechanically moved AM light optics, there is the possibility, in addition to a flat-homogeneous illumination of the powder bed, a fast to perform selective scanning. Scanning can be done either uniformly (for the purpose of homogeneous heating) or in patterns to specifically create heat sources and sinks in the powder bed and thus control the heat dissipation and the resulting microstructure of the AM-manufactured component. As a consequence, this can influence the mechanical properties of the AM-manufactured component.

Zum selektivem Schmelzen im Pulverbett soll ein Laser verwendet werden, da mit dem Laser kleinere Fokusdurchmesser und damit höhere Auflösungen technisch realisiert werden können und somit auch die Oberflächenrauhigkeit bei Laser-Prozesssierung geringer ausfällt. Der Laser und die Laseroptik sind vorzugsweise so anzuordnen, dass keine Teile der Elektronenstrahl-Vorrichtung im Strahlgang des Lasers liegen. Die Heizung per Elektronenstahl kann vor bzw. nach dem Laserstrahlschmelzen, oder auch kontinuierlich erfolgen, da Laser- und Elektronenstrahl sich nur wenig behindern und die Streustrahlung relativ gering ausfallen wird. For selective melting in the powder bed, a laser should be used, since with the laser smaller focal diameter and thus higher resolutions can be technically realized and thus the surface roughness of laser processing is lower. The laser and the laser optics are preferably to be arranged so that no parts of the electron beam device lie in the beam path of the laser. The heating by electron beam can be done before or after the laser beam melting, or continuously, since the laser and electron beam will interfere only slightly and the scattered radiation will be relatively low.

Der erfinderische Schritt liegt in der Verwendung eines Elektronenstrahls zum Vorheizen des Pulverbetts beim AM-Verfahren. Diese Vorheizung ist aufgrund des hervorragenden Wechselwirkungsquerschnitts und der guten Regelbarkeit des Elektronenstrahls bzgl. Form und Intensität den anderen Heizverfahren (IR-Heizung, resistive und induktive Heizung) überlegen. Da die Erzeugung eines Elektronenstrahls vergleichsweise einfach technisch realisierbar ist, können Strahl und damit Heizleistungen im kW-Bereich mit moderaten Kosten realisiert werden. The inventive step is to use an electron beam to preheat the powder bed in the AM process. This preheating is superior to the other heating methods (IR heating, resistive and inductive heating) due to the excellent interaction cross-section and the good controllability of the electron beam in terms of shape and intensity. Since the generation of an electron beam is relatively easy to implement technically, beam and thus heating power in the kW range can be realized with a moderate cost.

Zum Schmelzen wird ein gut fokussierbarer Laserstrahl verwendet. Auf diese Weise werden, entgegen heutiger Anordnungen, die Elektronenstrahlung und Laserstrahlung – ihren physikalischen Eigenschaften entsprechend – am effektivsten für die Vorwärmung und das Pulver-Strahlschmelzen eingesetzt. For melting, a well-focused laser beam is used. In this way, contrary to current arrangements, the electron beam and laser radiation - according to their physical properties - most effectively used for preheating and powder jet melting.

Es zeigt 1 eine erfindungsgemäße Vorrichtung 1‘. It shows 1 a device according to the invention 1' ,

Die Vorrichtung 1‘ zur additiven Fertigung weist zumindest einen Fertigungszylinder 4 auf, in dem oder auf dem ein Pulverbett 7 vorhanden ist. The device 1' for additive manufacturing has at least one production cylinder 4 on, in or on the a powder bed 7 is available.

Das Pulverbett 7 wird gespeist aus einem Pulverreservoir 28, das mittels geeigneter Mittel Pulver in den Fertigungszylinder 4 bzw. über ein Bauteil 10‘ aufbringt. The powder bed 7 is fed from a powder reservoir 28 by means of suitable means powder in the production cylinder 4 or via a component 10 ' applies.

Das lose Pulver kann über einen Laser 13, der Laserstrahlen 16 und einer entsprechenden Optik 19 das Pulver des Pulverbetts 7 selektiv zu dem Bauteil 10‘ verfestigen, insbesondere verdichten. The loose powder can be lasered 13 , the laser beams 16 and a corresponding optics 19 the powder of the powder bed 7 selective to the component 10 ' consolidate, in particular compact.

Mittels einer Elektronenstrahlquelle 25 wie ein Wehneltzylinder wird ein Elektronenstrahl 23‘ erzeugt, der über ein elektromagnetisches Linsensystem 22‘ den Elektronenstrahl 23‘ großflächig dem Pulverbett 7 beaufschlagt. By means of an electron beam source 25 like a Wehnelt cylinder becomes an electron beam 23 ' generated by an electromagnetic lens system 22 ' the electron beam 23 ' large area of the powder bed 7 applied.

Gemäß 2 und ausgehend von 1 ist das Linsensystem 22‘ der 1 anders angeordnet oder ausgebildet, bei dem es zu einer Fokussierung des Elektronenstrahls 23‘‘ kommt. Damit kann der Elektronenstrahl 23‘‘ mittels des Linsensystems 22‘ über das Pulverbett 7 verfahren werden. According to 2 and starting from 1 is the lens system 22 ' of the 1 arranged differently or formed, in which there is a focusing of the electron beam 23 '' comes. Thus the electron beam can 23 '' by means of the lens system 22 ' over the powder bed 7 be moved.

Die Elektronenstrahlquelle 25 ist über dem Pulverbett 7 angeordnet (1, 2). The electron beam source 25 is above the powder bed 7 arranged ( 1 . 2 ).

Claims (8)

Vorrichtung (1‘, 1‘‘) zur additiven Fertigung, die (1‘, 1‘‘) zumindest aufweist: einen Fertigungszylinder (4), in dem ein Pulverbett (7) vorhanden ist oder erzeugt werden kann, ein Pulverreservoir (28) aus dem Pulver in den Fertigungszylinder (4) und/oder auf ein herzustellendes Bauteil (10‘, 10‘‘) für das Pulverbett (7) aufgebracht werden kann, einen Laser (13), der Laserstrahlen (16), insbesondere über eine entsprechende Optik (19), auf das Pulverbett (7) lokal lenken kann, um es (7) selektiv zu dem Bauteil (10‘, 10‘‘) zu verfestigen, insbesondere zu verdichten, dadurch gekennzeichnet, dass eine Elektronenstrahlquelle (25) vorhanden ist, die das Pulverbett (7) zumindest teilweise, größtenteils oder ganz erwärmen kann. Contraption ( 1' . 1'' ) for additive manufacturing, which ( 1' . 1'' ) at least comprising: a production cylinder ( 4 ), in which a powder bed ( 7 ) is present or can be generated, a powder reservoir ( 28 ) from the powder into the production cylinder ( 4 ) and / or on a component to be produced ( 10 ' . 10 '' ) for the powder bed ( 7 ) can be applied, a laser ( 13 ), the laser beams ( 16 ), in particular via a corresponding optics ( 19 ), on the powder bed ( 7 ) can direct locally to it ( 7 ) selectively to the component ( 10 ' . 10 '' ), in particular to compact, characterized in that an electron beam source ( 25 ), which is the powder bed ( 7 ) can at least partially, mostly or completely warm. Vorrichtung nach Anspruch 1, bei dem eine Optik (22‘, 22‘‘) für einen Elektronenstrahl (23‘, 23‘‘) vorhanden ist. Device according to Claim 1, in which an optic ( 22 ' . 22 '' ) for an electron beam ( 23 ' . 23 '' ) is available. Vorrichtung nach Anspruch 1 oder 2, bei dem die Elektronenstrahlquelle (25) über dem Pulverbett (7) angeordnet ist. Device according to Claim 1 or 2, in which the electron beam source ( 25 ) above the powder bed ( 7 ) is arranged. Verfahren zur Herstellung eines Bauteils (10‘, 10‘‘), insbesondere mittels einer Vorrichtung gemäß einem oder mehreren der Ansprüche 1, 2 oder 3, bei dem in einem Pulverbett (7) ein Bauteil (10‘, 10‘‘) lagenweise erzeugt wird, wobei das lose Pulver des Pulverbetts (7) durch einen Laserstrahl (16) lokal verfestigt, insbesondere verdichtet, wird, dadurch gekennzeichnet, dass eine Vorwärmung des Pulverbetts (7) durch einen Elektronenstrahl (23‘, 23‘‘) erfolgt. Method for producing a component ( 10 ' . 10 '' ), in particular by means of a device according to one or more of claims 1, 2 or 3, wherein in a powder bed ( 7 ) a component ( 10 ' . 10 '' ) is produced in layers, wherein the loose powder of the powder bed ( 7 ) by a laser beam ( 16 ) locally consolidated, in particular compacted, is characterized in that a preheating of the powder bed ( 7 ) by an electron beam ( 23 ' . 23 '' ) he follows. Verfahren nach Anspruch 4, bei dem der Elektronenstrahl (23‘‘) fokussiert wird. Method according to Claim 4, in which the electron beam ( 23 '' ) is focused. Verfahren nach Anspruch 5, bei dem der Elektronenstrahl (23‘‘) über das Pulverbett verfahren wird. Method according to Claim 5, in which the electron beam ( 23 '' ) is moved over the powder bed. Verfahren nach Anspruch 4, bei dem das Pulverbett (7) großflächig durch den Elektronenstrahl (23‘) beaufschlagt wird. Process according to Claim 4, in which the powder bed ( 7 ) over a large area by the electron beam ( 23 ' ) is applied. Verfahren nach einem oder mehreren der Ansprüche 4, 5 oder 6, bei dem im Pulverbett Wärmesenken und Wärmequellen erzeugt werden.  Method according to one or more of claims 4, 5 or 6, in which heat sinks and heat sources are produced in the powder bed.
DE102015201637.4A 2015-01-30 2015-01-30 Apparatus for additive production with electron beam preheating and laser consolidator and method Withdrawn DE102015201637A1 (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017130282A1 (en) 2017-12-18 2019-06-19 MTU Aero Engines AG Method and device for the additive production of a component and component
DE102020206161A1 (en) 2020-05-15 2021-11-18 Siemens Aktiengesellschaft Process for additive manufacturing by means of dual selective irradiation of a powder bed and preheating

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2292357A1 (en) * 2009-08-10 2011-03-09 BEGO Bremer Goldschlägerei Wilh.-Herbst GmbH & Co KG Ceramic or glass-ceramic article and methods for producing such article
FR2984778A1 (en) * 2011-12-23 2013-06-28 Michelin Soc Tech METHOD AND APPARATUS FOR REALIZING THREE DIMENSIONAL OBJECTS

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2292357A1 (en) * 2009-08-10 2011-03-09 BEGO Bremer Goldschlägerei Wilh.-Herbst GmbH & Co KG Ceramic or glass-ceramic article and methods for producing such article
FR2984778A1 (en) * 2011-12-23 2013-06-28 Michelin Soc Tech METHOD AND APPARATUS FOR REALIZING THREE DIMENSIONAL OBJECTS

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017130282A1 (en) 2017-12-18 2019-06-19 MTU Aero Engines AG Method and device for the additive production of a component and component
WO2019120847A1 (en) 2017-12-18 2019-06-27 Siemens Aktiengesellschaft Method and device for the additive production of a component and component
DE102020206161A1 (en) 2020-05-15 2021-11-18 Siemens Aktiengesellschaft Process for additive manufacturing by means of dual selective irradiation of a powder bed and preheating
WO2021228593A1 (en) 2020-05-15 2021-11-18 Siemens Aktiengesellschaft Method for additive manufacturing by means of dual selective irradiation of a powder bed and preheating

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