DE102018212019A1 - Process for applying a material - Google Patents

Abstract

The invention relates to a method for applying a material (2), the material (2) being held in a formless or neutral shape and brought in the form of a layer (5) to a support surface (4.1) of a support (4), and the material (2) then solidified in regions by irradiation of the layer (5), characterized in that the carrier (4) is rotated about an axis of rotation (10) and the carrier surface (4.1) faces this axis of rotation (10), so that the Material (2) in the layer (5) due to the rotation a centrifugal force (9) acts in the direction of the support surface (4.1).

Description

Technical field

The present invention relates to a method for applying a material, in particular for the generative construction of a component.

State of the art

Generative manufacturing processes not only allow prototypes to be set up quickly, they can also be used to manufacture components or components with certain material properties that are otherwise difficult to manufacture due to their geometry. The structure takes place, for example, in layers, and it is also possible to generate geometries which, for. B. would not be accessible with a casting process. In the layered structure, layer by layer of a powdery component material is applied sequentially, for example. After applying a layer, it is selectively irradiated, e.g. B. with a laser, and so solidified in a desired area (z. B. by melting or sintering). The next powder layer is then applied and solidified in some areas according to the component geometry to be produced.

Presentation of the invention

The present invention is based on the technical problem of specifying a particularly advantageous method for applying a material.

This is achieved according to the invention with the method according to claim 1. The formless or shape-neutral material is applied to a carrier surface of a carrier as in the prior art in the form of a layer. A special feature, however, is that the carrier is rotated about an axis of rotation. The support surface faces this axis of rotation, so that the material is already held on the support before solidification, namely as a result of the rotation by centrifugal force. The layer of the material therefore forms or is held on the carrier surface with the aid of centrifugal or centrifugal force, and a desired region of the layer can then be solidified by selective irradiation.

The procedure according to the invention, that is to say the use of centrifugal force by a rotating carrier, can particularly advantageously enable the production or processing of rotationally or rotationally symmetrical components. As will become clear in detail below, this can open up interesting applications, particularly in the case of parts or components of an axial turbomachine, such as a gas turbine or an aircraft engine, because many components thereof are subject to such symmetry. For illustration: if you wanted to build a circular ring in a conventional powder bed process, i.e. with powder that lies on a flat, horizontal support surface, this would only be possible in a limited way or in segments due to the overhangs. In addition, the layer boundaries between the individual layers would have a different orientation at different circular positions of the ring. With the procedure according to the invention, however, such a ring can, if required, also be constructed integrally, that is to say coherently, the boundary layers also being rotationally symmetrical in the component.

However, the application and solidification of the material on a rotating carrier can also be used outside of additive manufacturing in layers. The application of material is particularly advantageous on rotationally or rotationally symmetrical geometries and can therefore also be used when balancing a component. This component, which can previously be produced in another way (e.g. by casting and / or milling etc.), then forms the carrier. The material is applied to the surface of the component as a support surface, and the selective consolidation in certain areas enables an imbalance to be removed (by material application instead of removal).

Further preferred embodiments can be found in the dependent claims and the entire disclosure, wherein the representation of the features does not always differentiate in detail between the working method and a corresponding manufacturing method or a device for carrying out these methods; in any case, the disclosure is to be read implicitly with regard to all claim categories. If, for example, certain method steps are described, this should always be read as a disclosure of a device set up to carry it out.

Information such as "axial", "radial" or "circumferential" / "rotating", as well as the associated directions (axial direction etc.) relate in the context of this disclosure to the axis of rotation about which the carrier and rotate the support surface during coating. This axis of rotation preferably coincides with an axis of symmetry of the manufactured or machined component. The carrier rotates in a fixed coordinate system in which the axis of rotation itself preferably rests. In the preferred production of turbomachine or engine parts, the axis of rotation can coincide with a longitudinal axis of the turbomachine (about which the rotor blade rings rotate during operation of the turbomachine, for example).

In a preferred embodiment, the carrier surface on which the layer is applied is rotationally symmetrical. In general, a certain eccentricity is also conceivable, but the axis of rotation about which the carrier rotates preferably coincides with the axis of symmetry. In other words, the carrier surface is a rotation or jacket surface (an inner jacket surface of the carrier).

In general, for example, a conical or otherwise inclined / curved support surface is also conceivable (viewed in an axial section), but in a preferred embodiment a cylindrical surface is provided. The carrier as a whole can have, for example, a hollow cylindrical shape, at least apart from suspension and bearing elements etc. The inner wall surface of the hollow cylinder forms the support surface.

In a preferred embodiment, the thickness of the layer applied to the carrier is adjusted by first applying the shapeless or neutral material in excess and then partially removing it again. The excess part is braced with a stripping unit, the stripping edge of which defines the layer. A blade, for example a doctor blade, can preferably be provided as the stripping unit.

In a preferred embodiment, the scraper unit is radially adjustable, that is to say the scraper edge can be arranged in different radial positions. This can be of interest even if only a single layer is applied, for example during balancing, in order to be able to adjust its thickness if necessary. In the case of layer-by-layer construction, ie if the component successively "grows" radially inwards, the scraper edge can be shifted radially inwards from layer to layer in accordance with the construction height.

As already mentioned, the material is preferably applied in powder form. In general, a metallic material is preferred, ie metal particles form the layer. In the irradiated areas, the metal is melted in some areas and thus solidified. In general, a particulate material could also be applied, for example, in the form of a suspension (the liquid component can evaporate, for example, when irradiated).

In general, an application unit with which the material is applied to the carrier surface is arranged radially within the carrier surface. In a preferred embodiment, the application unit is oriented such that the material leaves the application unit with a directional component that coincides with the direction of the solder. The plumb direction is the direction of the acceleration of gravity, it points down to the earth's surface (and is perpendicular to the level surfaces of the earth's gravity field). The material is thus applied in such a way that it reaches the support surface, supported by gravity. Metaphorically speaking, a powder can drizzle down or a suspension can run down or drip down. The axis of rotation is preferably oriented horizontally.

In a preferred embodiment, the application unit is radially adjustable. The application opening at which the material, for example the powder, is dispensed can thus be arranged in different radial positions. When building up in layers, the application unit can then be successively displaced radially inwards.

For solidification, the material is preferably irradiated with a laser beam, ie a laser is provided as the radiation source. This can be made up of a single or even a plurality of individual emitters, for example as a laser diode array. In general, however, as an alternative to a laser, an electron beam source, ie an electron beam, can also be irradiated.

In a preferred embodiment, the beam, preferably the laser beam, is deflected axially. For example, the beam source itself can be tilted and / or the beam can be guided over a deflection means, for example a tiltable / oscillating mirror. With the axial deflection of the beam, components with a correspondingly large axial extension can also be processed or manufactured.

In a preferred embodiment, the radiation source has a plurality of individual emitters, for example laser diodes, which are arranged axially offset. Alternatively or in combination with the deflection of the The beam or beams can thus also be irradiated at different axial positions and thus solidified. This can increase the accessible axial depth.

As already mentioned at the beginning, in a preferred embodiment the component is built up generatively from a multiplicity of layers. The carrier can remain as part of the device if several components are successively produced on the same machine; several components are thus built up in succession on the same carrier.

In the alternative preferred balancing, however, the component is placed in the machine as a carrier. One or more layers, if necessary, are then applied to compensate for the imbalance, after which the component is removed again (and another component is used). Generally, "balancing" means eliminating an imbalance, which in the present case takes place by applying material. In contrast to balancing through material removal, the component can advantageously be originally manufactured to a nominal size, and the balancing mass is applied. In the original component shape, there is no need to maintain or take into account mass due to oversize, which can help to optimize the overall weight. The area to be consolidated can be dimensioned, for example, using calculations after a measurement of the component. For balancing, material can be applied that has the same or even better properties than the base material.

Regardless of whether the component is manufactured or balanced generatively, a preferred embodiment is part of a turbomachine. The component is preferably at least rotationally symmetrical about the axis of rotation, sometimes also rotationally symmetrical. In the direction of rotation or rotation, the component is preferably integral, that is, coherent (not segmented).

The component can be, for example, a blade ring, an entire blade ring can also be produced integrally, for example a moving blade ring (BLISK). Of course, segments of it can also be produced according to the invention and here the advantages come to bear. The production of a housing part can also be advantageous. Seals can also be constructed, for example honeycomb geometries. The seals can also be provided integrally with housing parts. The manufacture of turbine housings or housing parts can be of particular interest.

The invention also relates to a device for applying a shapeless or shape-neutral material by applying and solidifying a layer in some areas. This device has an application unit, a radiation source and a rotating unit with which the carrier and thus the carrier surface can be rotated about an axis of rotation. With regard to further possible configurations, reference is expressly made to the above disclosure.

list of figures

The invention is explained in more detail below on the basis of an exemplary embodiment, the individual features within the framework of the subordinate claims also being essential to the invention in other combinations and furthermore not being distinguished in detail between the different claim categories.

• 1 in schematischer Darstellung eine Vorrichtung zur Illustration des erfindungsgemäßen Verfahrens;
• 2 in schematischer Darstellung ein erfindungsgemäß hergestelltes Bauteil, nämlich einen Laufschaufelkranz eines Triebwerks;
• 3 ein Triebwerk in einem Axialschnitt zur Illustration möglicher Anwendungen.

In detail shows

• 1 in a schematic representation an apparatus for illustrating the method according to the invention;
• 2 a schematic representation of a component manufactured according to the invention, namely a rotor blade ring of an engine;
• 3 an engine in an axial section to illustrate possible applications.

Preferred embodiment of the invention

1 shows a device 1 for applying a material according to the invention 2 , namely a metal powder. This is held in a reservoir (not shown) and with an application unit 3 on a carrier 4 applied, specifically on its support surface 4.1 , The carrier 4 has a hollow cylindrical shape, the support surface 4.1 represents an inner surface of the cylinder. The material 2 forms on the support surface 4.1 a layer 5 , This comes with a beam 6 a radiation source 7 , in the present case a laser beam, selectively irradiated and thus solidified in some areas (in the areas 5.1 shown schematically). With generative A further layer is then applied and solidified in some areas so that a component can be built up successively layer by layer.

A special feature here is that the carrier 4 with a turntable 8th is rotated. The speed of rotation (rpm) is chosen so that the material 2 in the shift 5 by centrifugal force 9 , perpendicular to the axis of rotation 10 outwards, on the support surface 4.1 is held. The turntable 8th can the carrier 4 For example, drive over a roller, this and a suspension are not shown in detail.

The application unit 3 specifically their application opening 3.1 on which the material 2 is given in such a way that the material 2 trickles. Based on a final layer thickness 11 becomes the material 2 applied in excess, with an excess portion 12 with a stripping unit 13 is removed. Their scraper edge 13.1 defines the layer thickness 11 , The stripping unit 13 is the application unit 3 related to the direction of rotation 14 downstream. Both the application unit 3 as well as the stripping unit 13 are radially adjustable (see the introduction to the description in detail).

2 shows a in the device according to 1 manufactured component 20 in a schematic representation, namely a moving blade ring. This has an inner cover tape 21 and an outside shroud 22 on, the blades extend in between 23 , These are about the axis of rotation 10 arranged rotationally symmetrical. With the method according to the invention, this blade ring can be produced integrally. As an alternative to complete production by building up in layers, the application and consolidation of the material in areas can also be used for balancing, cf. the introduction to the description in detail. The blade ring would then serve as the carrier, the carrier surface 4.1 would be, for example, on an inner wall surface of the inner cover tape 21 educated. In some areas, material is selectively applied to compensate for an imbalance.

3 shows a turbomachine 30 , specifically a turbofan engine, in an axial section (the section plane contains the longitudinal axis 31 ). The fluid machine is functionally structured 30 in compressor 32 , Combustion chamber 33 and turbine 34 , being in the compressor 32 sucked air is compressed. In the combustion chamber 33 it is burned with added kerosene, the hot gas generated is in the turbine 34 expanded. Both the compressor 32 so the turbine 34 are built up in several stages. The component 20 according to 2 can, for example, as a rotor in the compressor 32 or also in the turbine 34 Find application. Parts of the housing can also be removed 35 produce with the inventive method.

LIST OF REFERENCE NUMBERS

contraption 1 material 2 application unit 3 Applizieröffnung 3.1 carrier 4 support surface 4.1 layer 5 Solidified areas 5.1 beam 6 radiation source 7 rotary unit 8th centrifugal 9 axis of rotation 10 layer thickness 11 Excess part 12 scraper 13 stripping 13.1 direction of rotation 14 component 20 Inner shroud 21 Outer shroud 22 shovel 23 flow machine 30 longitudinal axis 31 compressor 32 combustion chamber 33 turbine 34 casing 35

Claims (15)

Method for applying a material (2), the material (2) being held in a formless or shape-neutral manner and brought in the form of a layer (5) to a support surface (4.1) of a support (4), and the material (2) then being passed through region-by-region irradiation of the layer (5) is solidified in regions, characterized in that the carrier (4) is rotated about an axis of rotation (10) and the carrier surface (4.1) faces this axis of rotation (10) so that the material (2) in a centrifugal force (9) acts on the layer (5) as a result of the rotation in the direction of the support surface (4.1). Procedure according to Claim 1 , in which the support surface (4.1) is rotationally symmetrical about the axis of rotation (10) as an axis of symmetry. Procedure according to Claim 1 or 2 , in which the support surface (4.1) is a cylindrical surface. Method according to one of the preceding claims, in which the material (2) for setting a layer thickness (11) is brought to the carrier (4) in an excess, based on the layer thickness (11), and an excess part (12) of the material (2) is removed again with a stripping unit (13). Procedure according to Claim 4 , in which the stripping unit (13) is adjusted radially with respect to the axis of rotation (10), that is, a stripping edge (13.1) of the stripping unit (13) is arranged at different radial positions. Method according to one of the preceding claims, in which the material (2) is brought to the carrier surface (4.1) in the form of a powder. Method according to one of the preceding claims, in which an application unit (3) with which the material (2) is brought to the carrier surface (4.1) is oriented such that the material (2) leaves at least one when leaving the application unit (3) Directional component that coincides with the perpendicular direction. Method according to one of the preceding claims, in which an application unit (3) with which the material (2) is brought to the support surface (4.1) is adjusted radially, that is to say an application opening (3.1) of the application unit (3) is arranged at different radial positions becomes. Method according to one of the preceding claims, in which a beam emitted by a radiation source (7) and falling on the layer (5) for solidification is deflected axially with respect to the axis of rotation (10). Method according to one of the preceding claims, in which a radiation source (7) with which the layer (5) is irradiated has a plurality of individual emitters which are axially offset from one another with respect to the axis of rotation (10). Method for producing a component (20), the component (20) being constructed from a multiplicity of layers (5) made of a material (2) on a carrier surface (4.1) of a carrier (4), wherein the material (2) per layer (5) is applied in a method according to one of the preceding claims. Method for balancing a component (20) by applying a material (2), the material (2) in a method according to one of the Claims 1 to 10 is applied to the component (20) as a carrier (4), that is to say to a surface of the component (20) as a carrier surface (4.1). Method according to one of the preceding claims, in which the component (20) is a component of a turbomachine (30), in particular a blade ring module or a housing part. Procedure according to Claim 13 , in which the component (20) is at least rotationally symmetrical about the axis of rotation (10) as an axis of symmetry. Device (1) for applying an informally or form-neutral material (2) to a carrier (4), which device (1) has: - an application unit (3) to apply the formless or form-neutral material (2) in the form of a layer ( 5) to a support surface (4.1) of the support (4), - a radiation source (7) for irradiation and thus solidification of the material (2) in areas in the layer (5), and - a rotating unit (8) for rotating the Carrier (4) and thus the carrier surface (4.1) about an axis of rotation (10), the device (1) for carrying out a method according to one of the Claims 1 to 14 is set up.

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