DE102016211068A1 - Method for producing at least one component - Google Patents

Abstract

The invention relates to a method for producing at least one component (14), in particular a component of a turbomachine. The method comprises at least the steps a) generative production of at least a first subregion (12) of the component (14) from a powder solidified by means of a selective beam melting and / or jet sintering device b) provision of at least a second subregion (22) of the component (14 c) arranging the second partial region (22) on the first partial region (12) and d) welding the first partial region (12) to the second partial region (22) by means of the beam melting and / or jet sintering device. The invention further relates to a corresponding component (14).

Description

The invention relates to a method for producing at least one component as well as a component, in particular for a turbomachine.

Methods and apparatus for making individual component areas or complete components are known in a wide variety. In particular, additive or additive manufacturing methods (so-called rapid manufacturing or rapid prototyping methods) are known in which the component, which may be, for example, a component of a turbomachine or an aircraft engine, is built up in layers. Primarily metallic components can be produced, for example, by laser or electron beam melting or sintering methods. In this case, at least one powdered component material is initially applied in layers to a component platform in the region of a buildup and joining zone of the device. Subsequently, the powder is locally hardened in layers by selectively supplying the powder in the region of the buildup and joining zone with energy by means of at least one high-energy beam, for example an electron or laser beam, whereby the component material melts and / or sinters. The high-energy beam is controlled in dependence on a layer information of the component layer to be produced in each case. The layer information is usually generated from a 3D CAD body of the component and subdivided into individual component layers. After solidification, the component platform is lowered layer by layer by a predefined layer thickness. Thereafter, the said steps are repeated until the final completion of the desired component area or the entire component. In particular, components with a high geometric complexity can be produced in this way.

A disadvantage of the known generative manufacturing process is the fact that components can usually only be made from a single component material. Accordingly, components that consist of two or more subregions for additional functional integration, can not be made or only with great effort, since a change of the component material during manufacture is problematic. The object of the present invention is to provide a method which enables a more flexible production of at least one component with two or more subregions. Another object of the invention is to provide a corresponding component which consists of two or more subregions.

The objects are achieved by a method having the features of patent claim 1 and by a component according to claim 14. Advantageous embodiments with expedient developments of the invention are specified in the respective subclaims, wherein advantageous embodiments of the method are to be regarded as advantageous embodiments of the component and vice versa.

A first aspect of the invention relates to a method for producing at least one component, in particular a component of a turbomachine. According to the invention, at least the steps a) generative production of at least a first portion of the component from a solidified by a selective beam melting and / or jet sintering powder, b) providing at least a second portion of the component, c) arranging the second portion of the first portion and d) welding the first portion to the second portion by means of the beam melting and / or jet sintering device. In other words, it is thus provided according to the invention that only a first portion or portion of the component is produced generatively. Thereafter, at least a second partial region of the component is provided, arranged on the first partial region and welded to the first partial region with the aid of the selective beam melting and / or jet sintering device. Accordingly, the second subarea is not constructed together with the first subarea, but is manufactured separately and welded to the first subarea using the already existing selective beam melting and / or jet sintering device. This makes it possible to produce the component via a hybrid construction, in which the second portion may consist of a different material than the first portion, in principle, identical materials may be provided for the first and second portion. Furthermore, it is possible to produce the second subarea with the aid of deviating, that is to say non-generative production methods, as a result of which a corresponding time and cost savings can be realized. For example, a large area and / or geometrically simple constructed second portion can be made separately and with the first portion, which may be smaller and / or geometrically complex, welded, for example. This allows a more flexible and faster production of at least one component with two or more subregions.

In an advantageous embodiment of the invention, provision is made for the first subregion to be constructed generatively on a component platform and / or on a support structure in step a). A component platform allows in a simple manner a layer-by-layer lowering by a predefined layer thickness, whereby the layer-by-layer construction of the first subregion is carried out correspondingly precisely can be. In powder-based manufacturing processes, the unbonded powder primarily supports the first portion of the component. If the component density increases greatly during production, however, the first portion can sink in the powder bed. Therefore, it may be advantageous to use one or more support structures for support. In the thermal production of large components or components with unfavorable cross-sectional jumps made of powder material support structures can also prevent distortion. Furthermore, heat can be dissipated via a support structure, for example, into a construction platform or other heat sinks. Likewise, it is possible that the first portion enters into a firm connection with the building platform during its manufacture. For better removal, the first subarea can therefore be constructed on a support structure which, for example, conveys the connection to a construction platform. The support structure can basically also be generatively built or made separately.

Further advantages result if the first subarea is separated from the component platform and / or the support structure by a separation process, in particular by wire erosion. The separation of the portion from the component platform or the support structure is preferably carried out only after completion of the component. In particular, wire EDM allows a particularly fast and precise separation, since the spark generated thereby always jumps at the point at which the distance between the component and the wire used for wire EDM is minimal. Wire erosion also allows all conductive materials to be processed, regardless of their hardness. Even with large material thickness extremely small cutting widths are possible. The machined contours are also particularly dimensionally accurate and dimensionally accurate.

Further advantages result if the generatively produced first subregion has at least one cavity with unconsolidated powder. In other words, the first portion is constructed so as to have one or more cavities filled with non-solidified powder. Apart from the fact that the powder contained in the cavity ensures the dimensional accuracy of the first portion, this is particularly advantageous in the manufacture of components which are to have at least one damping element, for example of pulse detuners. The powder in the cavity can act as cushioning. In addition, the at least one cavity can in principle be closed or open towards at least one side, for example with respect to the construction direction upwards.

In a further advantageous embodiment of the invention, it is provided that the at least one cavity is at least partially emptied before arranging the second portion in step c). By a partial emptying a simple optimization in the direction of a desired acoustic behavior or adaptation to a desired resonant frequency can be made. It is also possible to completely empty the at least one cavity, for example by suction of the unconsolidated powder. It may further be provided that a part or all of the non-solidifying powder is removed from the installation space of the selective jet melting and / or jet sintering device, so that the first partial area is powder-free in the selective beam melting and / or jet sintering device. This facilitates in particular the implementation of step d), that is, the welding of the first and second partial area.

Further advantages result if, prior to step c), at least one damping element is arranged in the at least partially emptied cavity. This also allows a simple optimization in the direction of a desired acoustic behavior or adaptation to a desired resonance frequency, as needed, instead of unconsolidated powder one or more damping elements, which have a defined geometry and may optionally consist of a different material, in at least one cavity can be arranged. For example, in each cavity a spherical damping element may be arranged whose diameter is a multiple of the mean particle diameter of the powder.

In a further advantageous embodiment of the invention, it is provided that the second portion is arranged in step c) on the first portion such that it closes the at least one cavity of the first portion. In other words, it is inventively provided that the second portion is formed as a cover or support structure for the at least one cavity of the first portion. It can also be provided that two or more cavities of the first subregion are closed by means of the second subregion.

In a further advantageous embodiment of the invention, the second subregion is produced by at least one production process from the group of additive manufacturing processes, prototyping, forming, separating and / or joining. This allows a high constructive freedom in the production of the second portion. It can also be provided that the second portion is produced by a combination of two or more of said manufacturing methods.

In a further advantageous embodiment of the invention, the first subregion is produced in step a) with a depression into which the second subregion is used in step c). This simplifies both the arrangement in step c) and the welding in step d). Preferably, a contour of the depression corresponds to a contour of the second partial region, so that it can be arranged flush with the first partial region and preferably in a manner that is suitable for swapping or rotation.

Further advantages result if the second portion is welded circumferentially to the first portion in step d). As a result, a particularly reliable cohesive connection is ensured. If the second portion is used as the lid of one or more cavities, this additionally ensures that the one or more in the cavity (s) damping element (s) can not fall out.

In a further advantageous embodiment of the invention, it is provided that by means of the selective beam melting and / or jet sintering device after step d), a third subregion of the component is constructed generatively on the first and / or the second subregion. In other words, at least one further (third) subregion of the component is constructed generatively, after the first and second subregions have been welded together. As a result, it is possible to produce particularly complex components in the hybrid construction according to the invention. Likewise, a simple tolerance compensation can be carried out in this way, by a certain undersize after the welding of the first and second partial area by the need to build up the third portion until the desired final height of the component is reached, is compensated.

In a further advantageous embodiment of the invention it is provided that by means of the selective beam melting and / or jet sintering device at least two components, in particular at least 400 components are produced in a construction job. In other words, at least two, and preferably 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600 or more first sections in parallel or produced side by side, each provided with associated second portions and welded. In this way, particularly high quantities of the component in the hybrid construction according to the invention can be produced, which can be realized corresponding time and cost savings.

Further advantages result from using a selective laser melting device and / or a selective laser sintering device and / or a selective electron beam melting device and / or a selective electron beam sintering device as the selective beam melting and / or beam sintering device. As a result, partial regions can be produced whose mechanical properties correspond at least essentially to those of the component material. To generate a laser beam, for example, a CO ₂ laser, Nd: YAG laser, Yb fiber laser, diode laser or the like may be provided. It can also be provided that two or more high-energy or laser beams are used. Alternatively or additionally, one or more electron beams of high-energy beam can be used to produce components or subregions of virtually any geometry directly from design data. Depending on the component material and the exposure parameters, melting may occur during exposure and / or sintering of the powder, so that in the context of the present invention the term "welding" can also be understood as meaning "sintering" and vice versa.

A second aspect of the invention relates to a component, in particular for a turbomachine, which comprises at least one generatively produced first partial region and at least one second partial region, which is welded to the first partial region. In other words, it is provided according to the invention that the component is produced in hybrid construction from at least one generatively produced first partial region and a second partial region, which is welded to the first partial region. As a result, the component according to the invention can be made more flexible and faster than a corresponding component, which is exclusively generative or exclusively non-generatively manufactured. The component is preferably obtainable and / or obtained by a method according to the first aspect of the invention. The resulting advantages are described in the descriptions of the first aspect of the invention, advantageous embodiments of the first aspect of the invention are to be regarded as advantageous embodiments of the second aspect of the invention and vice versa.

In an advantageous embodiment of the invention, the component is designed as Impulsverstimmer for a gas turbine. For this purpose, the component may comprise at least one cavity in the first portion, in which at least one damping element is arranged. An opening of the cavity may be closed by means of the second portion. The component can thus be used to prevent or attenuate resonances in a gas turbine, such as an aircraft engine, whereby both a noise and a dynamic long-term behavior of appropriately equipped assemblies can be advantageously improved.

Further features of the invention will become apparent from the claims, the figures and the description of the figures. The features and feature combinations mentioned above in the description, as well as the features and feature combinations mentioned below in the description of the figures and / or shown alone in the figures, can be used not only in the respectively specified combination but also in other combinations without the scope of the invention leave. Thus, embodiments of the invention are to be regarded as encompassed and disclosed, which are not explicitly shown and explained in the figures, however, emerge and can be produced by separated combinations of features from the embodiments explained. Embodiments and combinations of features are also to be regarded as disclosed, which thus do not have all the features of an originally formulated independent claim. Showing:

1 a schematic sectional side view of a generatively constructed on a support structure first portion of a component;

2 a schematic sectional side view of the first portion, on which a second portion is arranged;

3 a schematic sectional side view of the first portion, which is welded circumferentially with the second portion; and

4 a schematic sectional side view of the first and second portion on which a third portion is generatively constructed.

1 shows a schematic side sectional view of a generative on a support structure by means of a selective laser melting device (not shown) 10 constructed first section 12 a component 14 (S. 4 ). The support structure 10 is in turn in a conventional manner generative on a component platform 16 built the selective laser melting device. In principle, instead of a laser melting or sintering device, it is also possible to use an electron beam melting and / or sintering device. It can be seen that the first subarea 12 two cavities open towards the top or in the direction of construction 18 includes. After the generative structure of the first portion, which in the present embodiment has a height h of about 2.80 mm, the powdered component material is completely from the component platform 16 and thus also from the cavities 18 aspirated. Thus lies the first subarea 12 powder-free in the selective laser melting device. It is understood that the said height h of about 2.80 mm is merely exemplary and that larger or smaller height parameters h can also be provided.

In a following step, the empty cavities 18 each with a spherical damping element 20 stocked. Subsequently, a second subarea 22 into a depression 24 of the first subarea 12 used and closes the cavities 18 , The second part 22 can therefore also be referred to as a support structure or cover. This is in 2 shown in a schematic side sectional view. The depression 24 has one with the thickness of the second portion 22 corresponding depth d of about 0.2 mm. The second part 22 can in principle also be produced generatively. Because the second subarea 22 but has a relatively simple geometry, other manufacturing methods such as archetypes, forming, cutting and the like, individually and in any combination, are preferred. The second part 22 can be made from the same component material as the first part 12 consist. Alternatively, a different component material can be used.

In a further step, the second subarea 22 circulating with the first section 12 welded. The welding takes place with the aid of the same selective laser melting device used for the construction of the first subregion 12 was used and depending on the type one or more laser beams 26 can generate. 3 shows a schematic side sectional view of the first portion for clarity 12 , which by means of a laser beam 26 circulating with the second section 22 is welded. The first and the second subarea 12 . 22 thus form a container for the damping elements 20 ,

In a further, basically optional step, by means of the selective laser melting device on the first and second partial area 12 . 22 with powder a third part 28 generically constructed with a height t between about 0.4 mm and about 0.5 mm to form the final component 14 manufacture. 4 shows for clarity a schematic sectional side view of the first and second portions 12 . 22 on which the third subarea 28 is constructed generatively. The powder may be the same component material used to make the first part 12 has been used. Alternatively, a different component material can be used. The first and the third part 12 . 28 enclose the second subarea 22 completely, leaving the cavities 18 are particularly reliable closed.

In a final step, the component designed in this case as an impulse tuner for an aircraft engine 14 by wire eroding the support structure 10 from the component platform 16 separated. The separation step takes place at a distance e of about 0.3 mm to the underside of the first portion 12 ,

Although above only the manufacture of a single component 14 has been described, the hybrid method according to the invention is also suitable for the parallel production of many components 14 , For example, at a distance of about 1 mm to the respective neighboring part about 400 to 550 or more components 14 per job on the component platform 16 getting produced.

LIST OF REFERENCE NUMBERS

10

support structure

12

first subarea

14

component

16

component platform

18

cavity

20

damping element

22

second subarea

24

deepening

26

laser beam

28

third subarea

H

height

d

thickness

t

height

e

distance

Claims (15)

Method for producing at least one component ( 14 ), in particular a component of a turbomachine, comprising the steps: a) generative production of at least a first subregion ( 12 ) of the component ( 14 ) from a powder solidified by means of a selective beam melting and / or jet sintering device; b) providing at least a second subarea ( 22 ) of the component ( 14 ); c) arranging the second subregion ( 22 ) at the first subarea ( 12 ); and d) welding the first subregion ( 12 ) with the second subregion ( 22 ) by means of the beam melting and / or jet sintering device. Method according to Claim 1, characterized in that the first subregion ( 12 ) in step a) generatively on a component platform ( 16 ) and / or on a support structure ( 10 ) is constructed. Method according to claim 2, characterized in that the first subregion ( 12 ) by a separation process, in particular by wire EDM, from the component platform ( 16 ) and / or the support structure ( 10 ) is separated. Method according to one of claims 1 to 3, characterized in that the generatively produced first portion ( 12 ) at least one cavity ( 18 ) with unconsolidated powder. Method according to claim 4, characterized in that the at least one cavity ( 18 ) before arranging the second subarea ( 22 ) in step c) is at least partially emptied. A method according to claim 5, characterized in that before step c) at least one damping element ( 20 ) in the at least partially emptied cavity ( 18 ) is arranged. Method according to one of claims 4 to 6, characterized in that the second subregion ( 22 ) in step c) in such a way at the first subregion ( 12 ) is arranged to connect the at least one cavity ( 18 ) of the first subarea ( 12 ) closes. Method according to one of claims 1 to 7, characterized in that the second subregion ( 22 ) is produced by at least one manufacturing process from the group generative manufacturing processes, prototypes, forming, cutting and / or joining. Method according to one of claims 1 to 8, characterized in that the first subregion ( 12 ) in step a) with a depression ( 24 ) into which the second subregion ( 22 ) is used in step c). Method according to one of claims 1 to 9, characterized in that the second subregion ( 22 ) in step d) circumferentially with the first subregion ( 12 ) is welded. Method according to one of claims 1 to 10, characterized in that by means of the selective beam melting and / or jet sintering device after step d), a third portion ( 28 ) of the component ( 14 ) generatively on the first and / or the second subarea ( 12 . 22 ) is constructed. Method according to one of claims 1 to 11, characterized in that by means of the selective beam melting and / or jet sintering device at least two components ( 14 ), in particular at least 400 Components ( 14 ) in a construction job. Method according to one of Claims 1 to 12, characterized in that a selective laser melting device and / or a selective laser sintering device and / or a selective electron beam melting device and / or a selective electron beam sintering device is used as the selective beam melting and / or sintering device. Component ( 14 ), in particular for a turbomachine, comprising at least one generatively produced first subregion ( 12 ) and at least a second subregion ( 22 ), which with the first subregion ( 12 ) is welded. Component ( 14 ) according to claim 14, characterized in that it is designed as a pulse tuner for a gas turbine.

Images