DE102016214229A1 - Method for additive production and component for a turbomachine - Google Patents

Abstract

The present invention relates to a method for additive production of a component (10), comprising the additive construction of a structure (1) with a powder bed based manufacturing method, such that the structure (1) defines an interior, wherein a powdery base material (3) for the production the component (10) remains in the interior space (2), the sintering of the powdery base material (3) into a porous material (4), and the mechanical working of the structure (1) and / or the porous material (4) at least one surface (5) of the porous material (4) is exposed.

Description

The present invention relates to a method for the additive production of a component and a corresponding component.

The component is preferably intended for use in a turbomachine, preferably a gas turbine. The component is preferably made of a nickel-based or superalloy, for example a nickel- or cobalt-based superalloy. The superalloy may be precipitation hardened or precipitation hardenable.

Alternatively, the component may be a component used in the field of internal combustion engines.

The component may be, for example, a component of a turbomachine, such as a burner component of a gas turbine, in particular a burner tip. The component may also be referred to another component or a semifinished product for a corresponding turbomachine.

Preferably, the component is used in a hot gas path or hot gas region of a gas turbine.

Generative or additive manufacturing processes include, for example, jet melting and / or jet welding processes. These include, in particular, selective laser melting (SLM) or electron beam melting (EBM) and laser deposition welding (LMD), in particular laser powder build-up welding.

A method for selective laser melting is known, for example EP 2 601 006 B1 ,

Additive manufacturing processes (English: "additive manufacturing") have proven to be particularly advantageous for complex or complicated or filigree designed components, such as labyrinthine structures, cooling structures and / or lightweight structures. In particular, the additive manufacturing is particularly characterized by a particularly short chain of process steps, for example, a manufacturing or manufacturing step of a component can be done directly on the basis of design data, such as a corresponding CAD file.

Furthermore, the additive manufacturing is particularly advantageous for the development or production of prototypes, which can not or can not be produced efficiently, for example for cost reasons, by means of conventional, subtractive or metal-cutting processes or casting technology.

The present method preferably relates to a powder bed-based production method, in particular the selective laser melting.

In the rapidly evolving field of additive manufacturing, it is important for both research and component development to improve existing processes or even further develop them in terms of principles. A disadvantage of conventional additive manufacturing processes is often the time-consuming layered production. Therefore, there is a need in particular for the production of complex and / or with regard to their temperature resistance and / or surface quality highly specialized components and filigree powder bed based, layered manufacturing processes to accelerate the production and or, for example, to combine the layered production with other construction strategies.

It is therefore an object of the present invention to provide means which enable the improvement of existing additive manufacturing processes. Furthermore, it is possible with the described method to provide additively produced and / or manufactured components with novel and advantageous properties.

This object is solved by the subject matter of the independent patent claims. Advantageous embodiments are the subject of the dependent claims.

One aspect of the present invention relates to a method for the additive production of a component, a material, a semifinished product or a component comprising the additive construction of a structure with a powder bed-based production method, such that the structure defines an interior space (of the component and / or the structure) , wherein a powdery base material for the production of the component remains in the interior.

The structure may be a first material region, in particular a coherent solid.

In the present case, the powder bed-based production method preferably denotes selective laser melting or electron beam melting, which are particularly expedient for the additive production of components for turbomachines.

The method further comprises sintering the powdery base material into a porous material. The porous material may be a second material region, preferably a foam-like solid.

The method further includes mechanical working, for example, cutting, such as ablation, such as laser ablation, turning or milling, the structure and / or the porous material such that at least one surface of the porous material is exposed.

In particular, the mechanical processing comprises in particular the removal of said structure. In other words, preferably, the above-mentioned inner space, which is filled with powder, provided with the porous material and the surfaces then later - by erosion - exposed. Preferably, multiple surfaces of the porous material are exposed, such as surfaces on two opposite sides of the structure.

The described method can advantageously produce a porous material or foam material, preferably a metallic foam material, and / or provide structures to be produced with the porous material in an additive manner. This is preferably done in one step without consuming and / or time-consuming, layered structure.

The method described is particularly advantageous or expedient for the additive production of burner components, in particular components for mixing or injecting or atomizing gases or fluids, in particular into a combustion chamber.

The mechanical processing of the structure, preferably of the porous material serves, in particular, to expose surfaces of the porous material, so that at an exposed surface, a fluid, in particular a combustion gas, enter the porous material from the outside and / or at this surface from the porous material can emerge. The porosity of the porous material in particular causes a spreading, scattering or effusion of a fluid or gas stream.

In one embodiment, the structure is constructed in such an additive manner that an energy beam, in particular a laser or electron beam, only solidifies areas of the powdery base material for the structure in which, in particular, only these areas are rasterized and exposed by the energy beam.

In one embodiment, the powder does not impart base material in the interior exposed to the energy beam. Through these embodiments, during the additive construction of the structure for the component, preferably the base material may remain within the interior space.

In one embodiment, the sintering is carried out only under a heat treatment, for example below 700 ° C. In other words, according to this embodiment, preferably no external pressure is applied to the powdery base material. The heat treatment advantageously makes possible, on the one hand, the sintering process. Furthermore, an advantageous reduction of mechanical stresses can be achieved. Alternatively or additionally, a desired microstructure of or for the component can be set by the heat treatment.

In an alternative embodiment, the sintering is performed in addition to a heat treatment using external pressure.

In one embodiment, the mechanical processing is performed by grinding, milling, turning and / or ablation, such as laser ablation. As a result of the mechanical processing, a surface of the porous material is preferably exposed so that it can be passed, for example, for a fluid flowing through the porous structure during operation of the component.

Another aspect of the present application relates to a component which is manufactured and / or manufacturable according to the described method.

In one embodiment, the component, semifinished product or a component of a turbomachine, in particular a gas turbine.

In one embodiment, the component is a component, semifinished product or a component of an internal combustion engine, in particular of the internal combustion system of an internal combustion engine.

In one embodiment, the component comprises a first region, which is formed from a coherent solid, for example a superalloy. The first region can be a burner head or a burner body for a flow or internal combustion engine. Accordingly, the first region may preferably consist of or comprise a high temperature resistant material, for example, a high temperature resistant and / or hot crack resistant material.

In one embodiment, the first region is a nickel base or superalloy. The said superalloy may be precipitation-hardened or precipitation-hardenable, for example by the precipitates of the γ or γ 'material phase (s).

In one embodiment, the component comprises a second region, which has a functionally predetermined porosity. The second region may consist of the same material as the first region or of the same material composition.

In one embodiment, the second area is at least partially enclosed by the first area.

In one embodiment, at least one surface, preferably at least two surfaces or a mantle or end surface of the second region is exposed or is accessible to an environment or in fluidic contact with it. According to this embodiment, the component may preferably be particularly simple burner components, such as burner tip or act as a gas or fluid nozzle (see above).

In one embodiment, the first region or its material is arranged to hold the second region in a form-fitting and / or cohesive manner.

Preferably, the component is made additive such that the second material preferably also after mechanical processing, i. exposing surfaces of the porous material of the second region, still being positively held by the first region. By this configuration, a connection of the porous material can be ensured. Preferably, however, in the course of the additive production, the second region is also connected to the first region in a materially bonded manner.

In one embodiment, the interior has a stepped or stepped geometry.

In one embodiment, the predetermined porosity of the second region is between 40% and 60%. With the above information, the ratio of void volume to total or contour volume of the corresponding substance is preferably referred to.

In one embodiment, the second region is formed by a porous metallic material, in particular a metallic foam.

In one embodiment, the component is a burner component, in particular a burner tip, for a gas turbine, wherein the second region is designed for injection or injection and / or mixing of fluids or gases.

In one embodiment, the second region is arranged and the predetermined porosity chosen such that the component undergoes a vibration damping during operation. This property is preferably inherent to the porous material because the porous material can have damping properties due to its reduced material density.

Embodiments, features and / or advantages which in the present case relate to the method may also relate to the component or vice versa.

Further details of the invention are described below with reference to the figures.

1 indicates a process step for the additive production of a component.

2 indicates a further process step for the additive production of a component.

3 indicates a further process step for the additive production of a component.

4 indicates the structure of a porous material according to the invention.

5 indicates in a schematic flowchart process steps of the method according to the invention.

In the exemplary embodiments and figures, identical or identically acting elements can each be provided with the same reference numerals. The elements shown and their proportions with each other are basically not to be regarded as true to scale, but individual elements, for better presentation and / or better understanding exaggerated be shown thick or large.

1 shows a component 10 , which - as in 1 shown - while still in production. The component is produced as described below, preferably by an additive manufacturing method, in particular powder-bed-based additive manufacturing method, such as selective laser melting or electron beam melting.

The component 10 can be rotationally symmetrical, for example, with respect to the axis A, be formed.

Is exemplary in the 1 to 3 the component 10 or a partially constructed structure thereof during manufacture as a burner component, injection system, nozzle, gas or fluid mixing device.

Although in 1 Sections of the component 10 are shown, is preferably a single component, wherein the two "arms" shown are preferably connected via a fuselage or base structure.

The component shown 10 may be a rotationally symmetrical component according to the illustrations of the figures, which is shown only in a sectional view.

In a middle part of the arms shown, the component 10 an interior 2 on. The interior 2 is preferably formed during the additive manufacturing by solidifying only the walls of the inner space and not the inner space by an energy beam such as a laser beam (by exposure).

For this purpose, the component is initially a structure according to the invention 1 built up additive for the component (see step a) in 5 ). This can, for example, by conventional methods (see above) from a particular powdery base material 3 be carried out.

The powdery base material 3 is suitably selected according to the desired material properties of the component.

The interior 2 may have a complex structure, especially stages 8th , Regardless of the complexity or geometry of the interior 2 or the structure defining this 1 , points the interior 2 preferably the powdery base material 3 on which during the construction of the structure 1 was not solidified. For example, in the powder bed-based production of complex structures, after the application of each layer of about 20 to 40 μm in thickness, only one area defined by the structural design of the component is solidified; all other areas are ideally still in powder form.

In 2 is a further step in the process of the invention indicated (see also step b) in 5 ). In contrast to the representation of the 1 is due to a different filling of the interior 2 , indicated that the powdered base material 3 or powder preferably to a porous material (see in particular 4 ) was sintered.

This sintering step takes place in one step and preferably not in layers by a heat treatment above a corresponding sintering temperature of the pulverulent base material 3 ,

By the sintering process, the powdery base material 3 preferably to a porous material 4 , in particular a metal foam sintered. The metal foam preferably denotes a foamed material of the corresponding base alloy (see above).

The structure 1 preferably designates a first region of or for the component and a contiguous solid. The first area may, for example, designate burner hull.

With the porous material 4 or the porous structure may be, for example, a second area or portion of or for the component 10 act.

A sintering delay or sintering shrinkage is preferably prevented as far as possible during the described sintering process or carried out in such a way that it only acts on the side or on the surfaces (cf. reference symbols 5 in 3 ) occurs.

3 shows a further process step of the method according to the invention. In contrast to the representation of the 2 is by means of a machining tool 20 indicated that the component 10 , or the structure 1 or the porous material 4 is mechanically processed after the described sintering process, in particular by grinding, milling, turning or another suitable machining process, such as an ablation process, for example laser ablation. In particular material of the porous structure becomes due to said mechanical processing 4 removed, so that surfaces thereof are exposed (compare reference numerals 5 in 3 and process step c) in 4 ).

By exposing the surfaces, the porous material can 4 , in particular an environment (not explicitly indicated), for example, a gas inlet or a gas drain or a fluid flow are made accessible. In other words, a fluid, such as combustion gas, may enter the porous material from within 4 flow in or be introduced there, and of the porous structure 4 or in which by flow of this scattered or mixed with another gas, such as an ambient gas.

In a reduced plan view DS is in 3 shown that the exposed surface 5 may have any geometry, as indicated, for example, a star-shaped geometry. The aforementioned surface shape or geometry may be predetermined by, for example, a fluid flow or defined by it.

By the mechanical processing are preferably parts of the structure 1 and / or the porous material 4 so worn away that - even the graded geometry of the interior owed - the porous material 4 positive fit through the structure 1 is held. Likewise, the porous material 4 preferably at least partially cohesively from the structure 1 or the first area or connected to this. Accordingly, the mechanical stability of the porous material is preferably determined by the geometry of the structure 1 given and / or supported.

4 Fig. 1 shows a simplified example of a structure of the porous material 4 , In particular, the material shown may have a porosity of 40% to 60%, in particular 50% or another porosity.

Unlike shown in the figures, the component may be any component in which, for example, metallic foam materials or porous metallic structures are used or by the described method foamed metallic materials.

The invention is not limited by the description based on the embodiments of these, but includes each new feature and any combination of features. This includes in particular any combination of features in the patent claims, even if this feature or combination itself is not explicitly stated in the patent claims or exemplary embodiments.

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

• EP 2601006 B1 [0007]

Claims (13)

Method for the additive production of a component ( 10 ), comprising: - additive structure of a structure ( 1 ) with a powder bed-based production process such that the structure ( 1 ) defines an interior, wherein a powdery base material ( 3 ) for the production of the component ( 10 ) in the interior ( 2 ), - sintering of the powdery base material ( 3 ), to a porous material ( 4 ), and - mechanical processing of the structure ( 1 ) and / or the porous material ( 4 ) such that at least one surface ( 5 ) of the porous material ( 4 ) is exposed. Process according to claim 1, wherein the structure ( 1 ) is constructed so additive that an energy beam only areas of the powdery base material ( 3 ) for the structure ( 1 ) and wherein the powdery base material ( 3 ) in the interior ( 2 ) is not exposed to the energy beam.  The method according to claim 1 or 2, wherein the sintering is performed only under a heat treatment.  Method according to one of the preceding claims, wherein the sintering is carried out in addition to a heat treatment using external pressure.  Method according to one of the preceding claims, wherein the mechanical processing is performed by grinding, milling, turning and / or ablation. Component ( 10 ), for a turbomachine, in particular a gas turbine, which is produced or producible in accordance with the method according to one of the preceding claims. Component ( 10 ) according to claim 6, comprising a first area ( 1 ), which is formed from a coherent solid, and a second region ( 4 ), which has a functionally predetermined porosity, wherein the second region ( 4 ) at least partially from the first area ( 1 ) and at least one surface ( 5 ) of the second region is exposed. Component ( 10 ) according to claim 6 or 7, wherein the first region is arranged to hold the second region in a form-fitting manner. Component ( 10 ) according to one of claims 6 to 8, wherein the interior has a stepped geometry. Component ( 10 ) according to any one of claims 6 to 9, wherein the predetermined porosity is between 40% and 60%. Component ( 10 ) according to any one of claims 6 to 10, wherein the second region ( 4 ) is formed by a porous metallic material. Component ( 10 ) according to one of claims 6 to 11, which is a burner component for a gas turbine and, wherein the second region is designed for atomizing and / or mixing of fluids. Component ( 10 ) according to one of claims 6 to 12, wherein the second region ( 4 ) and the predetermined porosity is selected such that the component ( 10 ) experiences a vibration damping during operation.

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