DE102018201452A1 - Device for the additive production of at least one component region of a component, induction heating device for such a device, method for operating a device and component for a turbomachine - Google Patents

Abstract

The invention relates to a device (10) for the additive production of at least one component region (12) of a component (14), in particular a component (14) of a turbomachine, comprising an induction heating device (20) with at least one induction coil (30) for heating a component material and / or of the component region (12) before, during and / or after the application by means of at least one high-energy beam (50) in an assembly and joining zone (16) of the device (10). The at least one induction coil (30) comprises at least two coil turns (32, 34) which delimit an interior space (40) of the at least one induction coil (30) that tapers at least in regions in the direction of the assembly and joining zone (16), through which the high-energy beam (50) through and on the building and joining zone (16) is emissive. Further aspects of the invention relate to an induction heating device (20) for such a device (10), to a method for operating such a device (10) and to a component (14) for a turbomachine.

Description

The invention relates to a device for the additive production of at least one component region of a component, in particular a component of a turbomachine, comprising an induction heating device with at least one induction coil for heating a component material and / or the component region before, during and / or after the application of at least one high energy beam in a building and joining zone of the device. Further aspects of the invention relate to an induction heating device for a device, a method for operating a device and a component for a turbomachine.

Devices having at least one induction heating device and methods of operating such devices are known in a wide variety. In particular, these are also used in so-called additive or additive manufacturing processes (so-called rapid manufacturing or rapid prototyping processes). In additive manufacturing processes, the component, which may be, for example, a component of a turbomachine or of an aircraft engine, is built up in layers. Predominantly metallic components can be produced, for example, by laser or electron beam melting methods. In this case, at least one powdered component material is initially applied in layers in the region of a buildup and joining zone, in order to form a powder layer. Subsequently, the component material is locally solidified by supplying energy to the component material in the region of the assembly and joining zone by means of at least one high-energy beam, whereby the component material melts or sinters and forms a component layer. In this case, the high-energy beam is usually controlled as a function of 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 of the molten component material, a construction platform is lowered in layers by a predefined layer thickness. Thereafter, the said steps are repeated until the final completion of the desired component area or the entire component. The component region or the component can in principle be produced on a construction platform or on an already produced part of the component or component region. The advantages of this additive manufacturing are, in particular, the possibility of being able to produce very complex component geometries with cavities, undercuts and the like within the scope of a single method.

The object of the present invention is to provide a device for the additive production of at least one component region of a component, an induction heating device for such a device and a method for operating such a device, in which production of particularly large component regions is made possible with uniform heating of these component regions. Another object of the invention is to provide a correspondingly manufactured component with improved quality.

These objects are achieved by a device having the features of claim 1, by an induction heating with the features of claim 9, by a method having the features of claim 10 and by a component having the features of claim 13. Advantageous embodiments with expedient developments of the invention are specified in the respective subclaims, wherein advantageous embodiments of each invention aspect are to be regarded as advantageous embodiments of the respective other aspects of the invention.

A first aspect of the invention relates to a device for the additive production of at least one component region of a component, in particular a component of a turbomachine, comprising an induction heating device with at least one induction coil for heating a component material and / or the component region before, during and / or after the application by means of at least a high energy beam in a building and joining zone of the device.

In order to enable the production of particularly large component areas of a component with uniform heating of these component areas, it is provided according to the invention that the at least one induction coil comprises at least two coil windings which delimit an interior of the at least one induction coil which tapers at least in regions in the direction of the buildup and joining zone through which the high-energy beam can be emitted through and onto the assembly and joining zone. The interior forms a through opening extending through the at least one induction coil, which tapers in the direction of the assembly and joining zone. Through this passage opening of the high-energy beam is through and emit the assembly and joining zone.

A first coil turn of the at least two coil turns can have a larger distance to the build-up and joining zone than a second coil turn of the at least two coil turns. Accordingly, the first coil turn can be further removed from a landing surface of the build and join zone upon which the high energy beam may strike for additive fabrication be, as the second coil turn. The first coil turn can thus be referred to as a zone-distant coil turn with respect to the build-up and joining zone, whereas the second coil turn can be referred to as zone-near coil turn.

The first coil turn may, at least in some areas, have a first distance between a first turn inner side of the first coil turn facing the inner space, and a central axis extending through the at least one induction coil. The second coil turn may, at least in regions, have a second distance between a second turn inside side of the second coil turn facing the interior and the center axis. The at least partially in the direction of the building and joining zone tapered interior can be formed in that the first distance is greater than the second distance.

The invention is based on the finding that a better efficiency in heating the component material or the component region can be achieved by an increased number of coil turns, that is, by a plurality of coil turns of the induction coil. Furthermore, the invention is based on the finding that when conventional induction coils are used, in which a plurality of coil windings form a cylindrical interior, additive production using the high-energy beam and the induction coil is made possible only in a narrow space. This can be explained by the fact that, when the induction coil moves relative to the assembly and joining zone and relative to a radiation source emitting the high-energy beam, an undesired collision of the high-energy beam with a zone-distant coil turn of the conventional induction coil can occur.

As a result of the inner space tapering in the direction of the assembly and joining zone, the at least two coil windings of the induction coil form an opening angle which permits a larger lateral offset between the induction coil and the radiation source than with a conventional induction coil, without causing a collision of the high-energy beam the first coil turn of the at least two coil turns comes.

By means of the interior which tapers in the direction of the assembly and joining zone, a collision of the high-energy beam with the induction coil can also be avoided if the component region is particularly large, that is to say has a particularly large component surface to be formed by the additive production. At the same time, an improved power input with high efficiency and uniform heating of the component region on the basis of the induction coil can be achieved by the at least two coil windings.

In an advantageous embodiment of the invention, the interior is funnel-shaped, in particular frusto-conical, tapered in the direction of the assembly and joining zone. This is advantageous because a collision of the high-energy beam with the induction coil can be particularly effectively prevented by a funnel-shaped taper.

Preferably, the interior is frustoconically tapered in the direction of the building and joining zone. As a result, the additive production of the component region without collision of the high-energy beam with the induction coil is also made possible if the component region has a particularly large and, for example, rotationally symmetrical surface.

In a further advantageous development of the invention, the at least one induction coil is movable relative to the assembly and joining zone by means of at least one associated drive means. This allows a simple, precise and process-safe positioning of the induction coil and a correspondingly reliable and precise inductive heating of the desired range.

The at least one drive means may be associated with the induction heater. Alternatively, the at least one drive means may be associated with the device.

In a further advantageous development of the invention, the at least one induction coil is translationally movable along at least one axis by means of the at least one drive means and additionally or alternatively rotatively about the at least one axis. This allows a particularly targeted, selective heating of a selected area.

In a further advantageous development of the invention, the device comprises at least one adjusting means, by means of which the high-energy beam is adjustable relative to the assembly and joining zone, in particular pivotable. This is advantageous since the high-energy beam can be deflected or deflected by means of the adjustment means with particularly little effort, for example, without having to move a radiation source emitting the high-energy beam. For this purpose, the adjusting means may comprise at least one movable mirror and additionally or alternatively at least one lens. The adjusting means can also be generally referred to as optics.

In a further advantageous embodiment of the invention, the device comprises a radiation source for generating the at least one high-energy beam. This is advantageous since the device thereby forms a functional unit for the additive production of the at least one component region. In particular, this makes it possible to dispense with the use of external radiation sources.

In a further advantageous development of the invention, the device comprises at least one temperature measuring device for measuring the temperature of the component material and / or the component region at least in the region of the assembly and joining zone of the device. By the temperature measuring device, the temperature can be controlled within the assembly and joining zone in an advantageous manner. In the event of deviations, for example, an intensity of an inductive heating field generated by means of the induction coil can be varied and adjusted by a movement of the at least one induction coil relative to the assembly and joining zone and / or by the activation, deactivation or variation of the current supply of the induction coil. This allows a particularly precise and situation-specific expression of the inductive heating field during the entire additive production.

In a further advantageous development of the invention, the device has a control device, which is designed to position and / or close the at least one induction coil as a function of at least one parameter from the group of component geometry, type of component material, temperature of the component material and temperature of the component region operate. As a result, the location and intensity of an inductive heating can be optimally adapted to the particular individual case and a concrete construction situation, as a result of which particularly high-quality components can be produced.

A second aspect of the invention relates to an induction heating device for a device according to the first aspect of the invention. By means of such an induction heating device, it is possible to produce particularly large component regions of a component while uniformly heating these component regions by means of the at least one induction coil of the induction heating device.

The induction heating device in this case comprises the at least one induction coil for heating the component material and / or the component region before, during and / or after the application by means of the at least one high-energy beam in the assembly and joining zone of the device. The induction coil comprises the at least two coil windings which delimit the inner space of the at least one induction coil which tapers at least in regions in the direction of the buildup and joining zone, through which the high energy beam can be emitted and onto the buildup and joining zone. The resulting features and their advantages can be found in the descriptions of the first aspect of the invention, with advantageous embodiments of the first aspect of the invention to be regarded as advantageous embodiments of the second aspect of the invention and vice versa.

• - Positionieren der wenigstens einen Induktionsspule im Bereich der Aufbau- und Fügezone der Vorrichtung; und
• - Aktivieren der wenigstens einen Induktionsspule zum induktiven Erwärmen des Bauteilwerkstoffs und/oder des zumindest einen Bauteilbereichs vor, während und/oder nach der Beaufschlagung des Bauteilbereichs und/oder des Bauteilwerkstoffs mit dem Hochenergiestrahl.

A third aspect of the invention relates to a method for operating a device according to the first aspect of the invention, comprising at least the following steps:

• - Positioning the at least one induction coil in the region of the assembly and joining zone of the device; and
• Activating the at least one induction coil for inductively heating the component material and / or the at least one component region before, during and / or after the application of the component region and / or the component material to the high-energy beam.

The resulting features and their advantages can be found in the descriptions of the first and second aspect of the invention, with advantageous embodiments of the first and second aspects of the invention are to be regarded as advantageous embodiments of the third aspect of the invention and vice versa.

In an advantageous development of the invention, the at least one induction coil for inductive heating is displaced relative to a radiation source of the device in such a way that the at least one high-energy beam emitted by the radiation source arranged above the at least one induction coil with respect to the construction and joining zone of the device , collision-free through the interior of the at least one induction coil is emitted through and hits the assembly and joining zone. This is advantageous since, when displacing the induction coil, it is thus ensured that the high-energy beam passes through the interior of the induction coil unhindered, ie without colliding with one of the coil turns, and hits the assembly and joining zone. As a result, it can always be ensured in an advantageous manner that both heating by means of the high-energy beam and by means of the induction coil can take place in the region of the assembly and joining zone at which the induction coil is currently located. This allows a particularly uniform heating.

In a further advantageous development of the invention, the at least one induction coil is dependent on at least one parameter from the group component geometry, type of component material, temperature of the component material and temperature of the component area positioned and / or operated. As a result, the location and intensity of the inductive heating can be optimally adapted to the particular case and the concrete construction situation, which qualitatively very high quality components are obtained.

A fourth aspect of the invention relates to a component for a turbomachine, in particular compressor or turbine component, wherein a high surface quality of the component is ensured according to the invention that the component at least partially or completely by means of a device according to the first aspect of the invention and / or using an induction heating device according to the second aspect of the invention and / or obtained by a method according to the third aspect of the invention. The resulting features and their advantages will become apparent from the description of the first, second and third aspects of the invention, with advantageous embodiments of the first, second and third aspect of the invention to be regarded as advantageous embodiments of the fourth aspect of the invention and vice versa.

Further features of the invention will become apparent from the claims, the figures and the description of the figures. The features and combinations of features 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 indicated 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.

• 1 eine schematische Seitenansicht einer Vorrichtung zur additiven Herstellung zumindest eines Bauteilbereichs eines Bauteils mit einer Induktionsheizvorrichtung;
• 2 eine schematische Schnittdarstellung einer Induktionsspule der Induktionsheizvorrichtung; und
• 3 eine schematische Schnittdarstellung einer aus dem Stand der Technik bekannten Induktionsspule.

Showing:

• 1 a schematic side view of an apparatus for the additive production of at least one component region of a component with an induction heating device;
• 2 a schematic sectional view of an induction coil of the induction heater; and
• 3 a schematic sectional view of an induction coil known from the prior art.

1 shows a schematic side view of a device 10 for the additive production of at least one component area 12 a component 14 and is described below in synopsis with 2 which illustrates a schematic sectional view of an induction coil 30 an induction heater 20 the device 10 shows. The device 10 is here designed as a selective laser melting or laser sintering device (Selective Laser Melting, SLM) and includes a radiation source 60 , by means of which a high energy beam 50 generated in the form of a laser and can be emitted with it. The high energy beam 50 applies to an additive surface on an impact surface 18 in the area of a construction and joining zone 16 the device 10 on to one in the construction and joining zone 16 existing, in this case powdered component material of the component 14 solidify selectively and in layers. In the component 14 For example, it may be a compressor or turbine component of a gas turbine or an aircraft engine.

By means of the induction coil 30 the induction heater 20 is a heating of the component material and additionally or alternatively the component area 12 before, during and additionally or alternatively after the application of the high-energy beam 50 in the assembly and joining zone 16 the device 10 allows. In other words, by means of the induction coil 30 a preheating of the component material and additionally or alternatively the component area 12 , a simultaneous heating of the component material and additionally or alternatively the component area 12 and heating by the induction coil 30 after processing (application) by the high energy beam 50 respectively. The induction coil 30 in the present case comprises two coil turns 32 . 34 in the form of a first coil turn 32 or a second coil turn 34 , The two coil turns 32 . 34 limit yourself at least partially in the direction of the construction and joining zone 16 tapered interior 40 the induction coil 30 through which the high energy beam 50 for additive production through and on the assembly and joining zone 16 is emitted.

2 shows particularly clearly that the interior 40 in the present case, frustoconical in the direction of the assembly and joining zone 16 rejuvenated. In other words, the interior 40 frusto-conical towards the assembly and joining zone 16 formed tapering, with the interior 40 against an arrow direction of an axis z one in 1 and 2 tapered coordinate system shown rejuvenated. The axis z corresponds here to a central axis 31 the induction coil 30 ,

The induction heater 20 comprises at least one drive means 22 , by means of which the induction coil 30 relative to the construction and joint zone 16 is movable. By means of the drive means 22 , which may be configured for example as a linear motor, is the induction coil 30 translationally for example in a plane and thus parallel to respective axes x . y as well as parallel to the axis z movable. In addition, the induction coil 30 around the respective axes x . y . z rotationally movable, ie about the axes x . y . z pivotable. This is the induction coil 30 with regard to their movement, particularly precisely a component geometry of the component 14 feasible.

The device 10 comprises at least one adjusting means 52 , by means of which the high-energy beam 50 relative to the assembly and joining zone 16 adjustable while being pivotable. The adjusting means 52 can be configured as an adjustable mirror, as in 1 is indicated. The device further comprises at least one temperature measuring device 70 for measuring the temperature of the component material and additionally or alternatively the component area 12 at least in the area of the assembly and joining zone 16 the device 10 , Furthermore, the device comprises 10 a control device 80 , which is adapted to the induction coil 30 as a function of at least one parameter from the group of component geometry, type of component material, temperature of the component material and temperature of the component region 12 to position and operate additionally or alternatively. The control device 80 is present signal transmitting with the drive means 22 , the adjusting means 52 , the radiation source 60 as well as with the temperature measuring device 70 coupled. This allows the controller 80 the induction coil 30 relative to the respective axes x . y . z move and synchronously to the adjustment 52 (here: mirror) adjust to the high energy beam 50 with the induction coil 30 to take along, so that the high-energy beam 50 during additive manufacturing through the interior 40 passes through and on the assembly and joining zone 16 or the impact area 18 incident.

2 shows that the first coil turn 32 , which may also be referred to as a zone-distant coil turn, a first turn inside 33 which is at a first distance 36 from the central axis 31 the induction coil is arranged. The second coil turn 34 , which may also be referred to as a zone-near coil turn, has a second turn inside 35 on which at a second distance 38 to the central axis 31 is arranged. The frustoconical or funnel-shaped interior 40 results from the fact that the first distance 36 is greater than the second distance 38 , The induction coil 30 , which can be configured generally as Vorwärmspule, thus widens in the arrow direction of the axis z and thus of the assembly and joining zone 16 away, or from the second coil turn 34 towards the first coil turn 32 on. In other words, the induction coil opens 30 from the second coil turn 34 towards the first coil turn 32 ,

2 shows a tangent 42 , which at the respective Windungsinnenseiten 33 . 35 is applied. The tangent 42 runs parallel to one, a first wind center 44 the first coil turn 32 , with a second mean of the wind 46 the second coil turn 34 connecting straight line 48 , Straight 48 closes - as well as the tangent 42 - An opening angle α with the central axis 31 a, like in 2 can be seen. During the high energy beam 50 between the central axis 31 and the tangent 42 collision-free in the interior 40 enter and through the interior 40 in the direction of the assembly and joining zone 16 can pass through, this is at one, in 3 schematically shown in a sectional view, conventional induction coil 100 not possible. The conventional induction coil 100 includes two equidistant to a central axis 102 the induction coil 100 arranged turns 106 . 108 , In other words, the turns form 106 . 108 a hollow cylinder, so that it is at an incidence of a laser beam 104 below the opening angle α to a collision 110 of the laser beam 104 with the winding 106 comes.

By synopsis of 2 and 3 it can be seen that by means of the induction coil 30 a larger area of the assembly and joining zone 16 without colliding with the high-energy beam 50 can be traversed than using the conventional induction coil 100 , Especially in each corner of the construction and joining zone 16 , which can also be referred to as a construction field, falls the high-energy beam 50 (here: laser beam) off-center and thus laterally into the interior 40 so that by the opening design of the coil turns 32 . 34 in other words, through the tapered interior 40 a collision between the high energy beam 50 and the induction coil 30 at least largely avoided.

Although in 1 and 2 with the coil turns 32 . 34 only two coil turns 32 . 34 the induction coil 30 are shown, it is clear that the induction coil 30 even further, so for example, a third coil turn, a fourth coil turn, a fifth coil turn, etc. may have.

In general, all coil turns are preferred 32 . 34 along the straight line 48 or the tangent 42 aligned, causing a collision with the high energy beam 40 can be effectively prevented.

LIST OF REFERENCE NUMBERS

10

device

12

component area

14

component

16

Assembly and joining zone

18

incident

20

induction heating

22

drive means

30

induction coil

31

central axis

32

first coil turn

33

first turn inside

34

second coil turn

35

second winding inside

36

first distance

38

second distance

40

inner space

42

tangent

44

first wind center

46

second wind center

48

Just

50

High energy beam

52

adjustment

60

radiation source

70

Temperature measuring device

80

control device

100

induction coil

102

central axis

104

laser beam

106

convolution

108

convolution

110

collision

α

opening angle

x

axis

y

axis

z

axis

Claims (13)

Device (10) for the additive production of at least one component region (12) of a component (14), in particular a component (14) of a turbomachine, comprising an induction heating device (20) with at least one induction coil (30) for heating a component material and / or the component region (12) before, during and / or after the application of at least one high energy beam (50) in a construction and joining zone (16) of the device (10), characterized in that the at least one induction coil (30) at least two coil turns (32 , 34), which delimit an at least partially in the direction of the building and joining zone (16) tapered interior (40) of the at least one induction coil (30) through which the high energy beam (50) and through the assembly and joining zone ( 16) is emissive. Device (10) according to Claim 1 , characterized in that the interior (40) is funnel-shaped, in particular frusto-conical, in the direction of the building and joining zone (16) is tapered. Device (10) according to Claim 1 or 2 , characterized in that the at least one induction coil (30) by means of at least one associated drive means (22) relative to the assembly and joining zone (16) is movable. Device (10) according to Claim 3 , characterized in that the at least one induction coil (30) by means of the at least one drive means (22) translationally along at least one axis (x, y, z) and / or rotationally about the at least one axis (x, y, z) is movable , Device (10) according to any one of the preceding claims, characterized in that the device (10) comprises at least one adjusting means (52) by means of which the high energy beam (50) relative to the assembly and joining zone (16) adjustable, in particular pivotable , Device (10) according to one of the preceding claims, characterized in that the device (10) comprises a radiation source (60) for generating the at least one high-energy beam (50). Device (10) according to one of the preceding claims, characterized in that the device (10) at least one temperature measuring device (70) for measuring the temperature of the component material and / or the component region (12) at least in the region of the assembly and joining zone (16) of the device (10). Device (10) according to any one of the preceding claims, characterized in that the device (10) comprises a control device (80) which is adapted to at least an induction coil (30) in response to at least one parameter from the group component geometry, type of component material, temperature of the component material and temperature of the component region (12) to position and / or operate. Induction heating device (20) for a device (10) according to one of Claims 1 to 8th , Method for operating a device (10) according to one of Claims 1 to 8th comprising at least the following steps: - positioning the at least one induction coil (30) in the region of the assembly and joining zone (16) of the device (10); and - activating the at least one induction coil (30) for inductively heating the component material and / or the at least one component region (12) before, during and / or after applying the high-energy beam (50) to the component region (12) and / or the component material. , Method according to Claim 10 characterized in that the at least one inductive heating induction coil (30) is displaced relative to a radiation source (60) of the apparatus (10) such that the at least one high energy beam (50) passing through the assembly and joining zones (16) of the device (10) is emitted above the at least one induction coil (30) arranged radiation source (60) collision-free through the interior (40) of the at least one induction coil (30) through and on the building and joining zone (16 ) meets. Method according to one of Claims 10 or 11 , characterized in that the at least one induction coil (30) is positioned and / or operated as a function of at least one parameter from the group component geometry, type of component material, temperature of the component material and temperature of the component area. Component (14) for a turbomachine, in particular compressor or turbine component, characterized in that the component (14) at least partially or completely by means of a device (10) according to one of Claims 1 to 8th and / or using an induction heating device (20) according to Claim 9 and / or by a method according to any one of Claims 10 to 12 is obtained.

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