DE102017210392A1 - Method and device for the additive production of a component - Google Patents

Abstract

The invention relates to a method for the additive production of a component (3), in which a component geometry for a component to be manufactured (3) is specified, and several material layers (12) are successively provided and each with at least one energy, in particular laser beam (6). locally melted in accordance with the predetermined component geometry, each provided a layer (12) and melted by means of at least one energy, in particular laser beam (6) and then provided on the previously molten layer (12) the next layer (12) and by means of at least one energy, in particular laser beam (6) is melted, wherein the material layers are provided in the form of films (12). Moreover, the invention relates to a device for the additive production of a component (3).

Description

• - eine Bauteilgeometrie für ein zu fertigendes Bauteil vorgegeben wird, und
• - nacheinander mehrere Materiallagen bereitgestellt und jeweils mit wenigstens einem Energie-, insbesondere Laserstrahl gemäß der vorgegebenen Bauteilgeometrie lokal aufgeschmolzen werden, wobei jeweils eine Lage bereitgestellt und mittels des wenigstens einen Energie-, insbesondere Laserstrahls aufgeschmolzen und anschließend auf der zuvor aufgeschmolzenen Lage die nächste Lage bereitgestellt und mittels des wenigstens einen Energie-, insbesondere Laserstrahls aufgeschmolzen wird.

The invention relates to a method for the additive production of a component, in which

• - Given a component geometry for a component to be manufactured, and
• - Provided successively several layers of material and are locally melted with at least one energy, in particular laser beam according to the predetermined component geometry, each provided a layer and melted by means of at least one energy, in particular laser beam and then provided on the previously molten layer, the next layer and is melted by means of the at least one energy, in particular laser beam.

• - einen insbesondere oberhalb einer Arbeitsplattform definierten Arbeitsbereich,
• - Mittel zur Bereitstellung übereinanderliegender Materiallagen in dem Arbeitsbereich, und
• - eine Energiestrahl-, insbesondere Laserstrahleinrichtung, die ausgebildet und eingerichtet ist, um wenigstens einen Energie-, insbesondere Laserstrahl zu emittieren und in dem Arbeitsbereich bereitgestellte Materiallagen mit dem wenigstens einen Energie-, insbesondere Laserstrahl gemäß einer vorgegebenen Bauteilgeometrie lokal aufzuschmelzen.

Moreover, the invention relates to a device for the additive production of a component, comprising

• a working area defined in particular above a work platform,
• - means for providing superimposed material layers in the work area, and
• - An energy beam, in particular laser beam device, which is designed and adapted to emit at least one energy, and laser beam in the work area provided material layers with the at least one energy, especially laser beam locally according to a predetermined component geometry.

Components, in particular those with complex geometrical shapes, can not be realized comparatively costly or under certain circumstances by machining production methods. In recent years, alternatives have emerged as additive additive manufacturing processes.

Method and apparatus for the additive production of components are well known in the prior art. An example of such a method is the selective laser melting (SLM) from the powder bed called. This is a build-up method in which a multiplicity of powdery layers of material are successively provided one above the other and each layer is locally melted by means of one or more energy beams, in particular laser beams, according to a predetermined component geometry. In this case, so many layers are provided, and each scanned with the at least one energy beam until the component to be produced is completed.

From the DE 10 2014 222 302 A1 For example, a method and apparatus for additive fabrication of components by SLM is apparent from the powder bed. The layered structure of a component is carried out on a bottom of a manufacturing cylinder forming height-adjustable work platform and means for providing powder layers are provided, which arranged next to the work platform storage cylinder with a liftable floor and a squeegee trained distribution device, by means of which powder from the supply - Can be conveyed into the production cylinder and smoothed, include. Powder provided in the stock cylinder is gradually pushed up from the bottom by lifting the bottom thereof and transferred in layers to the adjacent build platform with the squeegee.

In the case of the known SLM processes, it is sometimes considered disadvantageous that the structure in layers or layers of the powder bed is comparatively time-consuming. This is not least because layers of uniform thickness are to provide a flat surface and this means must be provided. Furthermore, it is sometimes considered to be disadvantageous that the additive mechanical properties of the powder bed are dependent on the construction direction when additive components are produced by selective laser melting from the powder bed. Highly loaded ergometrically complex components, however, require mechanical material properties that are identical in all spatial directions.

Starting from the prior art, it is therefore an object of the present invention to provide a method for the additive manufacturing of components, which can be carried out with respect to the prior art reduced effort and allows the production of components with improved material properties. Another object of the present invention is to provide a device which is suitable for carrying out such a method.

In a method of the type mentioned above, this object is achieved in that the material layers are provided in the form of films.

In a device of the type mentioned above, the object is achieved in that the means for providing layers of material are formed to provide films as material layers in the work area.

The basic idea of the present invention is therefore to dispense with the additive by selective laser melting on the powder bed and the component alternatively from a plurality of superimposed films to generate. A complex distribution process of the powder and a costly smooth drawing are no longer necessary in the result and any associated effort is saved. The films used according to the invention as an alternative to powder layers are provided completely superimposed, completely analogous to the procedure with pulverulent build-up material, and selectively melted in each case with at least one or more energy beams, in particular laser beams according to the predetermined component geometry.

The method according to the invention and the device according to the invention offer a multiplicity of advantages. On the one hand, a very fast 3D printing is made possible because the use of films eliminates the comparatively complicated provision of powder layers. Even components of very complex geometry can be generated, whereby even forms with overhangs are possible because the films - as opposed to powder - are solid and need no support over their entire bottom. The procedure according to the invention is suitable in particular for components without closed cavities. In addition, the production is economically more attractive than the conventional selective laser melting with powdery building material, since the film, for example metal foil production, is significantly cheaper than the powder, for example metal powder production. Finally, the inventive method and device according to the invention are also environmentally friendly, since no harmful powder, such as metal powder is used. The space can be opened as a result without protective clothing and the component can be taken out immediately, without having to suck powder consuming.

In the context of carrying out the method according to the invention or when using the device according to the invention, all material layers required for the production of a component are preferably provided in the form of films, so that it is entirely possible to dispense with powder.

Furthermore, it can be provided that for the production of a component films of different material and / or different thickness and / or different contour and / or different size are provided. It is conceivable, for example, that for producing a component which tapers from the bottom upwards, films of smaller area are gradually provided, that is to say the component shape is followed by the film size and the waste is thus kept to a minimum. Using foils of different material for the production of a component, in particular also components with graded material can be obtained and / or components which consist of different materials in different sections.

In principle, films of different materials are suitable for carrying out the process according to the invention, with films of metals or metal alloys in particular being proven. In this case, virtually any metals and alloys can be used, provided that the material allows provision in the form of films. By way of example, aluminum foil is mentioned. The choice of material is - completely analogous to the conventional selective laser melting from the powder bed - depending on the particular application of the components to be manufactured. If, for example, components are to be produced from the turbine area, it is possible, in particular, to use films of such metals or metal alloys as have proven themselves for the turbine sector, for example superalloys. As another example in addition to metal (alloy) s are called plastic films.

As far as the thickness of the use of incoming films is concerned, this can be oriented in particular with the layer thicknesses of conventional selective laser melts from the powder bed. Film thicknesses may, for example, be in the range from 10 to 80 .mu.m, in particular from 20 to 60 .mu.m, for example 20 .mu.m, 40 .mu.m or 60 .mu.m.

The size of the films used can vary greatly and will be based, in particular, on the size of the cross-section of the component (s) to be produced. This already, to avoid unnecessarily large waste. By way of example and thus by no means limitative films are mentioned whose area in square meters corresponds to those of DinA10 to DinA0 paper sheets and whose outer contour is circular, rectangular or square, for example.

In the context of the method according to the invention, films are preferably provided as material layers which are characterized by an at least substantially constant thickness. Tolerances to some extent are of course acceptable.

Furthermore, it can be provided that alternately a predetermined number of foils of a first same material and a predetermined number of foils of a second same material, which is different from the first material, is provided.

The predetermined number can then always be the same for example. Purely by way of example, this is called a configuration in which a component - from bottom to top - from 10 Slides of a first material followed by 10 Slides of a second material, again followed by 10 Slides of the first material and again 10 Foils of the second material is constructed. Other numbers of films per group are of course equally possible.

Alternatively, the predetermined number, as regards the films of the first material, decrease from bottom to top and / or, as regards the films of the second material increase from bottom to top. Again purely by way of example, this is called a configuration in which a component - seen from bottom to top - out 10 Films of a first material, followed by a film of a second material, followed by 5 Foils of the first material, followed by 5 Foils of the second material, followed by a foil of the first material, followed by 10 Foils of the second material is constructed. Of course, alternative configurations are equally possible to achieve a gradual material transfer.

In a further particularly preferred embodiment of the method according to the invention, it is provided that material is melted in at least one, preferably in each material layer in the region of the outer contour of the defined component geometry with a different, preferably higher energy, in particular laser beam intensity than in the remaining region of the material layer to be melted in order to separate a residual section of the film which is not to be melted in accordance with the specified component geometry. According to this embodiment, contouring takes place with the at least one energy beam, in particular the laser beam, by stronger exposure in the area of the body edge, whereby in each case the remaining film separates from the component to be produced. The separated as a result of the contouring remnants of the films can then be removed, for example, simply by hand.

As far as the provision of the films is concerned, it has proven to be particularly suitable to store and supply them in a printer similar to paper sheets.

Accordingly, a further particularly preferred embodiment of the method according to the invention is characterized in that foils are held in at least one cassette, which feeding means for conveying films from the cassette are assigned to a work area, and that conveyed films from the at least one cassette in the work area become.

The at least one cartridge is configured to receive a stack of films. The collection means preferably comprise at least one roll for conveying films. They are designed, in particular, analogously to the drawing-in means which are known from paper printers and serve to take paper sheets out of the paper stacks holding a paper cassette and supply them to the printing area. Lifting means can be provided in a manner known per se from conventional paper printers in order to lift a film stack stored in the at least one cassette against at least one roll of the feed means and thus to ensure that regardless of the filling level of the cassette, the top of the topmost film of one held therein Film stack is in contact with the at least one role of catchment and can be pulled out by a rotation of this out of the cassette and in particular in a work area.

In a further preferred embodiment, it is provided that films of different material and / or different thickness and / or different size held in different cassettes and promoted from these in the work area. The provision in and supply from cassettes makes it possible to provide different types of foil one after the other in the work area very quickly and conveniently, in particular automatically.

The cassette or the cassettes with the films are furthermore particularly preferably held vertically adjustable. This makes it possible, on the one hand, for the cassette or cassettes to follow the currently achieved component height. A working platform on which the components to be manufactured, for example, be built, then does not have to be moved. In addition, in the case where more than one cassette is provided, the height adjustment makes it possible for films from the plurality of cassettes, in particular one above the other and / or different films, to be fed quickly and easily to the working area. For this purpose, the cassettes are then in particular always adjusted in height so that the cassette with the desired type of film is level with the work area or the top of an arranged in this, already generated portion of a component to be produced and then a film in particular in the horizontal direction on the last melted layer, or, if it is the very first layer, be mounted on a working platform.

As far as the device according to the invention is concerned, in an advantageous embodiment it may be characterized by the fact that the means for providing material layers comprise at least one cassette arranged and / or height-adjustable, in particular laterally of the working area, for holding foils, the feeding means are associated for conveying foils from the cassette into the working area.

Then, two or more cassettes are preferably provided with these respectively assigned feed means, wherein in particular at least two cassettes are arranged on two opposite sides of the work area.

Alternatively or additionally, the catch means associated with each cassette may each comprise at least one roller for conveying films.

Furthermore, it is preferably possible to provide a plurality of cassettes arranged one above the other. If there are several cassettes for holding films, they can furthermore preferably all be held vertically adjustable.

Finally, in a further preferred embodiment of the device according to the invention, a control device designed and configured for carrying out the method according to the invention is provided. This is then connected in particular both with the means for providing superimposed material layers, in particular the cassette or cassettes for holding films and associated catchment means on the one hand, and the energy, in particular laser beam device on the other hand and controls these for generating components of predetermined geometry from a plurality of superimposed films , The control device can also be designed as a control and computing device and be set up to determine a suitable configuration of superimposed films, in particular for different, available film types, for example, to determine a configuration for a tapered component based on a given component geometry of which the size of the films follows the component, so that the waste is kept low.

• 1 eine rein schematische Schnittdarstellung einer erfindungsgemäßen Vorrichtung zur additiven Herstellung eines Bauteils,
• 2 ein Blockdiagramm mit den Schritten einer Ausführungsform des erfindungsgemäßen Verfahrens,
• 3 eine rein schematische Schnittdarstellung einer beispielhaften Folienanordnung für ein Bauteil, und
• 4 eine rein schematische Schnittdarstellung einer weiteren beispielhaften Folienanordnung für ein Bauteil.

Other features and advantages of the present invention will become apparent from the following description of a method and apparatus for additive manufacturing of a component according to an embodiment of the present invention with reference to the accompanying drawings. That's it

• 1 a purely schematic sectional view of an inventive device for the additive production of a component,
• 2 a block diagram with the steps of an embodiment of the method according to the invention,
• 3 a purely schematic sectional view of an exemplary film assembly for a component, and
• 4 a purely schematic sectional view of another exemplary film assembly for a component.

The 1 shows a purely schematic sectional view of an embodiment of a device according to the invention. The device comprises a construction platform 1 above which is a workspace 2 is defined and on which components to be manufactured 3 be built up additive. In the 1 is a nearly finished component 3 on the build platform 1 to recognize.

The device further comprises a laser beam device 4 that have a laser 5 for emitting a laser beam 6 and a scanning device 7 , by means of which the laser beam 6 in the direction of the work area 2 is deflected, and its location can be varied in a conventional manner includes.

Finally, the device has means for providing layers of material in the work area 2 on, the present four cassettes 8th . 9 . 10 . 11 include, two each on opposite sides of the build platform 1 are arranged, and which are each formed to a stack of films, in this case metal foils 12 take. Each of the four cassettes 8th . 9 . 10 . 11 is held vertically adjustable on a not shown in the figures frame of the device, which in the 1 through arrows 13 next to the cassettes 8th . 9 . 10 . 11 is indicated.

In the four cassettes 8th . 9 . 10 . 11 There are different metal foils 12 , In the cassettes 8th . 9 and 10 are metal foils 12 the same thickness but held different size, specifically in the cassette 10 bigger and in the cassette 9 smaller slides 12 than in the cassette 8th , In the cassette 11 there are slides 12 whose size and thickness are those of cassette 10 corresponds, but which consist of a different metal alloy. All slides 12 are characterized by an at least substantially constant thickness.

Each of the four cassettes 8th . 9 . 10 . 11 are each catchment for horizontal feeding of films 12 from the respective cassette 8th . 9 . 10 . 11 in the workspace 2 above the build platform 1 which also belong to the means for providing material layers. In the present case, the catchment means each comprise a roller 14 , by means of which the uppermost metal foil 12 one in the respective cassette 8th . 9 . 10 . 11 stockpiled stack of metal foils 12 in the horizontal direction in the work area 2 can be promoted by the role 14 is set in rotation. There is every role for this 14 assigned a not shown in the figure drive. To make sure the role 14 regardless of the current level of the respective cassette 8th . 9 . 10 . 11 with the top of the top sheet 12 of the stack are in each cassette 8th . 9 . 10 . 11 provided below the respective stack in the figure, not shown lifting means, by means of which the stack against the associated role 14 is pressed.

Finally, the device comprises a control and computing device 15 , which with the laser device 4 the cassettes 8th . 9 . 10 . 11 and every cassette 8th . 9 . 10 . 11 associated catchment means connected and formed for their control and for carrying out the method described below for the additive production of a component 3 is designed and furnished.

Specifically, in step S1 a geometry for a component to be produced 3 provided in the form of a CAD data set and to the control and computing device 15 to hand over. In the manufactured component 3 it is an upwardly tapering solid body.

Based on the provided geometry will be in step S2 by means of the control and computing device 15 determines what number of slides 12 are ideally provided, from bottom to top, to obtain as little waste as possible.

In step S3 becomes the cassette 8th from the control and computing device 15 at least approximately the height of the construction platform 1 procedure, so that first slides 12 out of this in a horizontal direction on the build platform 1 can be pulled.

In step S4 is done by means of the cassette 10 assigned role 14 a slide 12 out of the cassette 10 on the build platform 1 drawn. So it will be with the biggest slides 12 began.

The on the construction platform 1 provided foil 12 will be in step S5 by means of the laser 5 emitted laser beam 6 by the scanning device 7 is moved accordingly, according to the predetermined component geometry, specifically according to the cross section according to CAD dataset in the lowermost component area selectively melted. In this case, material is melted in the outer contour of the defined component geometry with a higher laser beam intensity than in the remaining region of the film to be melted 12 to a - according to the predetermined component geometry - not to be melted residual portion of the film 12 separate. So there is a contouring.

After the melting of the film 12 has been completed, in step S6 another slide 12 out of the cassette 10 on the already with the laser beam 6 processed foil 12 hung up and in step S7 also these selectively with the laser beam 6 melted according to the component geometry. Also for this slide 12 and for all subsequent slides 12 The rule is that a contouring is done so that film residues are easily removable.

The steps S6 and S7 will be repeated 8 times, until a total of 10 films 12 the largest size sequentially provided and each with the laser beam 6 were selectively melted.

Then in step S8 from the control and computing device 15 the height of the cassette 8th set in such a way that from this in a horizontal direction slides 12 with the assigned role 14 on the top sheet 12 previously removed from the cassette 10 was taken, can be pulled and in step S9 becomes a first slide 12 from this cassette 8th on the last edited slide 12 deployed and in step S10 again with the laser beam 6 melted. The steps S9 and S10 are repeated nine times, so that also ten slides 12 medium size provided successively and melted.

Finally, the cassette 9 with slides 12 smallest size in step S11 brought the right height and out of this is in step S12 a slide 12 on the previous edited slide 12 deployed and in step S13 with the laser beam 6 melted. Also the steps S12 and S13 are repeated nine more times and then the component is 3 completed.

Existing film remnants can - especially because of each film 12 contouring - can be easily removed by hand.

The steps S1 to S12 can also look like the block dyad 2 be removed.

In the 3 and 4 are - also purely schematically - two foil arrangements shown, which represent purely exemplary alternatives to the film arrangement described above.

The film arrangement according to 3 includes a total of 50 slides 12 all of the same thickness and size, but with 30 sheets 12 from a first and 20 slides 12 consist of a different, second material. Specifically, from the bottom up, there are ten slides at first 12 of the first material, then ten slides 12 of the second material, followed by ten slides 12 the first, then another ten slides 12 of second and finally ten slides 12 provided the first material.

In the 4 Furthermore, an example of a gradual, gradual material overlay is also shown purely schematically. Concretely come - viewed from bottom to top - 10 Slides of a first material followed by 2 Slides of a second material followed by 8th Slides of the first, 4 slides of the second, 6 of the first, 6 of the second, 4 of the first, 8th of the second, 2 of the first and 10 of the second material. Of course, the transition may also be less gradual or even more gradual, for example 10 films 12 of the first material, followed by 1 Foil of the second, 9 of the first, 2 of the second, 8th of the first, 3 of the second, etc.

The method according to the invention and the device according to the invention offer a multiplicity of advantages. On the one hand, a very fast 3D printing is possible because of the use of transparencies 12 the comparatively complex provision of evenly thick powder layers with a flat surface is completely eliminated and the supply from the cassettes 8th . 9 . 10 . 11 can be done very quickly. The production is also significantly cheaper compared to the conventional selective laser melting with powdered building material, since the metal foil production is much cheaper than the production of metal powder. Finally, the inventive method and the device according to the invention are also environmentally friendly, since no harmful metal powder is used. The component 3 Can be taken out immediately, without having to suck powder consuming.

Although the invention has been further illustrated and described in detail by the preferred embodiment, the invention is not limited by the disclosed examples, and other variations can be derived therefrom by those skilled in the art without departing from the scope of the invention.

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 102014222302 A1 [0005]

Claims (15)

Method for the additive production of a component (3), in which - a component geometry for a component to be manufactured (3) is specified, and - successively provided several material layers (12) and in each case with at least one energy, in particular laser beam (6) according to local geometry are melted locally, wherein each provided a layer (12) and melted by means of at least one energy, in particular laser beam (6) and then provided on the previously molten layer (12) the next layer (12) and by means of at least one Energy, in particular laser beam (6) is melted, characterized in that - the material layers are provided in the form of sheets (12). Method according to Claim 1 , characterized in that all material layers required for producing a component (3) are provided in the form of films (12). Method according to Claim 1 or 2 , characterized in that foils (12) of different material and / or foils (12) of different thickness and / or foils (12) of different contours and / or foils (12) of different sizes are provided. Method according to one of the preceding claims, characterized in that films (12) made of metal and / or plastic are provided. Method according to one of the preceding claims, characterized in that alternately a predetermined number of foils (12) of a first same material and a predetermined number of foils (12) of a second same material, which differs from the first material is provided. Method according to Claim 5 , characterized in that the predetermined number is always the same. Method according to Claim 5 , characterized in that the predetermined number, as regards the films (12) of the first material decreases from bottom to top and / or, as regards the films (12) of the second material increases from bottom to top. Method according to one of the preceding claims, characterized in that at least one, preferably each film (12) in the region of the outer contour of the defined component geometry with a different, preferably higher energy, in particular laser beam intensity is melted than in the remaining aufzuschmelzenden area of the film ( 12). Method according to one of the preceding claims, characterized in that foils (12), preferably in at least one height-adjustable held cassette (8, 9, 10, 11) are held, which draw-in means (for conveying sheets (12) from the cartridge into a workspace 2), which in particular comprise at least one roller (14) for conveying foils (12), and in that foils (12) are conveyed from the at least one cassette (8, 9, 10, 11) into the working area (32) , Method according to Claim 9 , characterized in that films (12) of different material and / or different thickness and / or different size in different cassettes (8, 9, 10, 11) held and conveyed from these in the work area (2). Device for the additive production of a component (3), in particular for carrying out the method according to one of the preceding claims, comprising - a working area (2) defined in particular above a working platform (1), - means for providing superimposed material layers (12) in the working area ( 2), - an energy beam, in particular laser beam device (4), which is designed and arranged to emit at least one energy, in particular laser beam (6) and in the work area (2) provided material layers (12) with the at least one energy - In particular laser beam (6) according to a predetermined component geometry locally melt, characterized in that the means for providing material layers are formed to provide films (12) as material layers in the work area (2). Device after Claim 11 , characterized in that the means for providing material layers at least one in particular laterally of the working area (2) arranged and / or height adjustable cassette (8, 9, 10, 11) for holding sheets (12), the feed means for conveying films (12) from the cassette (8, 9, 10, 11) are assigned to the work area (2). Device after Claim 12 , characterized in that two or more cassettes (8, 9, 10, 11) are provided with these respectively assigned feed means, wherein in particular on two opposite sides of the working area (2) in each case at least one cassette (8, 9, 10, 11) is arranged and / or each cassette (8, 9, 10, 11) associated catchment means each comprise at least one roller (14) for conveying foils (12). Device after Claim 12 or 13 , characterized in that a plurality of superposed cassettes (8, 9, 10, 11) are provided. Device according to one of Claims 11 to 14 , characterized in that one for performing the method according to one of Claims 1 to 10 trained and established control device (15) is provided.

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