EP2493644A2

EP2493644A2 - Method and device for producing a component

Info

Publication number: EP2493644A2
Application number: EP10798475A
Authority: EP
Inventors: Erwin Bayer; Sven-J. Hiller; Karl-Heinz Dusel
Original assignee: MTU Aero Engines GmbH
Current assignee: MTU Aero Engines AG
Priority date: 2009-10-31
Filing date: 2010-10-30
Publication date: 2012-09-05
Also published as: WO2011050791A3; US20120219726A1; WO2011050791A2; DE102009051552A1

Abstract

The invention relates to a method for producing a component (12), especially a hollow structural part for a turbomachine. The method is characterized by the following steps: a) layer-by-layer deposition of at least one powder component material (20a) onto a component platform in the region of a buildup and joining zone (I), b) deposition of at least one liquid component material (20b) onto the powder component material (20a), the liquid component material (20b) comprising at least one metal-containing compound, c) local layer-by-layer fusion or sintering of the component materials (20a, 20b) by means of thermal and/or electromagnetic energy supplied in the region of the buildup and joining zone (I), d) lowering of the component platform by a predefined layer thickness; and e) repetition of steps a) to d) until the component (12) is finished. The invention further relates to a device (10) for producing a component (12) of a turbomachine, especially a hollow structural part for a turbomachine.

Description

Method and device for producing a component

description

The invention relates to a method and a device for producing a component, in particular a hollow component for a turbomachine.

Methods and devices for producing a component, in particular a hollow component of a turbomachine, are known in a wide variety. In particular, generative production methods are known in which the component is built up in layers. The generative production of components made of metal or metal ceramics produces a very fine-grained component structure in the context of rapid manufacturing or rapid prototyping processes. In the case of rapid manufacturing or rapid prototyping of metallic components or of components with metallic bonding, predominantly 5 melting or sintering processes are produced with the aid of electromagnetic radiation. For example, the production is carried out by laser sintering, laser powder deposition welding or electron beam deposition welding.

Three-dimensional components can also be generatively generated from a powder bed by layer-by-layer gluing via a printing process. To bond the powdery shaped component material used in this case, which comprises ceramic or metallic powder, an organic binder is applied to a component platform via a print head. After each partially bonded layer, the component platform is lowered and a new layer of the powdery component material is evenly distributed, smoothed and offset with the binder. The powdered component material is then sintered in layers by the selective action of electromagnetic radiation (laser or electron beam), whereby the binder hardens.

A disadvantage of the known methods and devices, however, is the fact that the components produced thereby have comparatively low heat resistance and low mechanical stability owing to the organic binder. As a result, it is not possible to produce components subject to severe mechanical and thermal stresses, such as, for example, structural components or hollow blades for turbomachines in this way. Object of the present invention is to provide a method and an apparatus of the type mentioned, which allows the production of a component with improved thermal and mechanical strength. The object is achieved by a method having the features of patent claim 1 and by a device having the features of claim 12. Advantageous embodiments of the invention are specified in the respective subclaims, wherein advantageous embodiments of the method are to be regarded as advantageous embodiments of the device and vice versa.

According to the invention, in a method for producing a component, in particular a hollow component for a turbomachine, at least the steps of a) coating at least one powdered component material on a component platform in the region of a buildup and joining zone, b) applying at least one liquid component material c) the layered and local melting and / or sintering of the component materials by means of supplied thermal and / or electromagnetic energy in the region of the assembly and joining zone, d) lowering of the component platform by a predefined layer thickness and e) repeating steps a) to d) until completion of the component. In contrast to the prior art, a liquid component material which comprises a metal-containing compound is thus used in addition to the powdery component material. When supplying thermal and / or electromagnetic energy, the metal-containing compound forms metal bonds between the particles of the powdered component material in addition to fusing and / or sintering of the powdered component material, whereby a component with a significantly increased thermal and mechanical strength is obtained. Under metal-containing compounds are compounds to understand that can release elemental metals at the atomic level under the influence of thermal and / or electromagnetic energy. For this purpose, for example, elemental metals themselves, metal alloys, intermetallic alloys, complexed metals or metal ions, compounds with covalently bonded and / or ionic metal ions and / or any suitable mixtures thereof may be provided. It can be provided in principle that the energy in step c) is supplied in accordance with a layer information of the component to be produced in order to achieve a particularly high manufacturing accuracy. In an advantageous embodiment of the invention, it is provided that in step a) a pulverformiger component material is used, which comprises a metal and / or a metal alloy and / or an intermetallic compound and / or a metal ceramic and / or a silicate. This results in a high degree of design freedom in the manufacture of the component. In addition, the properties of the component can be optimally adapted to its respective application. It can be provided that compound mixtures and / or different compounds are used for different layers of the component. It can create new alloys according commingled pulverfö ^'shaped component materials are produced by the metallic bonding on the atomic level also. Thus, for example, metal powders with oxidic admixtures and / or ceramic powders can be mixed with one another and used as a powdered component material. The metal atoms released from the liquid component material under the influence of the supplied energy can continue to react in situ or in statu nascendi depending on the particular powdery and liquid component materials used and for the targeted formation of alloys, mixed crystals and the like.

15 same be used.

In a further advantageous embodiment of the invention, it has proved advantageous if a powder size and / or a quantity of powder of pulverfö ^'shaped component material and / or a volume of the liquid component material are selected depending on a to be obtained 20 layer thickness. As a result, the growth of the individual component layers can be precisely controlled. In addition, the property profile of the component can be adapted specifically and optimally to its respective application. When determining the required volume, the concentration of the metallic compound in the liquid component material is preferably taken into account.

25

In a further embodiment, it has proven to be advantageous if in step b) a liquid component material is used which comprises an organometallic compound and / or a metal salt and / or nanoparticles and / or a solvent and / or a suspending agent. When using an organometallic compounds, the organic residue 30 can be split off by the layer-wise feeding of the thermal and / or electromagnetic energy, so that at the point at which the powdered component material was wetted with the liquid, a metallic bond results. Suitable for metallic bonding are, for example, noble metals, which are also known as organometallic compounds in liquid construction. Partial material can be provided. Nanoparticles offer the advantage that their melting or sintering temperature is significantly below that of the powdery component material and thus a particularly reliable bond formation is ensured. In order to be able to optimally adjust the viscosity and wetting property of the liquid component material, the use of a solvent and / or suspending agent has proven to be advantageous.

Further advantages are obtained by using in step b) a liquid component material whose decomposition and / or cleavage and / or sintering and / or melting temperature lies below the melting temperature of the pulverulent component material. As a result, a particularly reliable binding of the powder particles is achieved, since it is ensured that the metal-containing compound of the liquid component material between the particles is released from the powdered component material before the powdered component material melts, conglomerates and / or sinters. By the powdery and / or the liquid component material by means of a print head, in particular a multiple print head, is applied, the relevant component material can be optimally dosed and applied very quickly. When using a multi-printhead, the order speed can be additionally increased, with the further possibility of applying different component materials simultaneously or with a defined spatial distribution.

Further advantages are obtained if, prior to step d), at least steps a) and b) and optionally c) are carried out simultaneously and / or in the reverse order and / or multiple times. As a result, the method can be carried out in a particularly variable manner, so that an optimal adaptability to different component materials is given and targeted layer properties of the component can be represented particularly easily.

In a further advantageous embodiment of the invention, it is provided that the energy in step c) by means of a lamp, in particular an IR lamp and / or a flashlamp and / or a high-energy lamp, and / or a laser, in particular a C0 ₂ - or Nd : YAG laser, and / or a microwave device is supplied. By using strong radiation sources, each component layer can be metallized and bonded in a planar manner, which results in corresponding speed advantages. In addition, excess liquid Components of the Bauteilwerkstoifs be removed by evaporation from the layer. When using organometallic compounds, for example, the organic radical can be easily removed and expelled. By virtue of the method comprising a rapid prototyping and / or rapid manufacturing method, in particular laser deposition welding or electron beam powder coating welding, even geometrically demanding components can be produced particularly quickly and cost-effectively, which allows considerably reduced development and manufacturing costs.

In a further advantageous embodiment of the invention, it is provided that the shape and / or the material structure of the component is determined as a computer-generated model and layer information generated therefrom for controlling and / or regulating at least one of steps a) to e) is used. This enables automated and computer-controlled production processes.

In a further advantageous embodiment of the invention, it is provided that a hollow blade for a turbine or for a compressor of a thermal gas turbine is produced as a component. In particular, in the production of such finely structured components - for example, hollow structural components or rotor blades of a turbine or a compressor of a turbomachine - the various advantages of the method according to the invention in terms of speed, cost and quality of the finished component particularly come into play. Another aspect of the invention relates to a device for producing a component of a turbomachine, in particular a hollow component for a turbomachine, wherein the production of a component with improved thermal and mechanical load capacity according to the invention is made possible by the fact that the device at least one powder feed for applying at least one powdery component material on a component platform in the region of a building and joining zone, at least one liquid supply for applying a liquid component material, which comprises at least one metal-containing compound on the component platform in the assembly and joining zone and at least one energy source for layered and local fusing and / or sintering of the component materials by means of supplied thermal and / or electromagnetic energy in the field of building and joining zone comprises. In contrast to the prior art, therefore, in addition to the powdery component material, a liquid component material is used which comprises a metal-containing compound. When supplying thermal and / or electromagnetic energy by means of the energy source, the metal-containing compound in addition to fusing and / or sintering of the powdered component material form metal bonds between the particles of the powdered component material, whereby a component with a significantly increased thermal and mechanical strength can be produced , Under metal-containing compounds are to be understood compounds that can release elemental metal atoms under the influence of thermal and / or electromagnetic energy. For this purpose, for example, elemental metals, metal alloys, intermetallic alloys, complexed metals or metal ions, compounds with covalently bonded and / or ionic metal ions and / or any suitable mixtures thereof may be provided. It can be provided that the powder and the liquid supply are integrated in a component of the device. Likewise it can be provided that the device comprises at least one coupled to the powder and / or the liquid supply storage container, in which at least one of the component materials is added. Furthermore, it can be provided that the device is designed to carry out a generative manufacturing process, such as, for example, a rapid prototyping or rapid manufacturing process, in particular laser deposition welding or electron beam (EB) powder coating welding. Further advantages can be found in the preceding descriptions, wherein advantageous embodiments of the method according to the invention are to be regarded as advantageous embodiments of the device and vice versa.

In an advantageous embodiment of the invention it is provided that the energy source is a lamp and / or a laser and / or an electron beam device and / or a microwave device. By using strong radiation sources, each component layer can be metallized and bonded in a planar manner, which results in corresponding speed advantages. In addition, excess liquid components of the component material can be removed by evaporation from the layer. When using organometallic compounds, moreover, the organic radical can be easily removed and expelled. A particularly simple, precise and rapid application of the liquid component material is made possible in a further embodiment in that the liquid supply comprises a print head for applying the liquid component material. When using a multi-printhead, the order speed can be additionally increased, with the further possibility of applying different component materials simultaneously or with a defined spatial distribution.

A particularly uniform distribution of the liquid component material is achieved in a further embodiment in that the liquid supply comprises at least one nozzle through which the liquid component material is to be applied to the component platform. In particular, in combination with the printhead technology mentioned above, a plurality of nozzles may be provided. As a result, the component material can be applied simultaneously in several places. Alternatively or additionally, different component materials can be applied simultaneously in several places.

Further features of the invention will become apparent from the claims, the exemplary embodiment and with reference to the drawing. The features and combinations of features mentioned above in the description as well as the features and combinations of features mentioned below in the exemplary embodiment can be used not only in the respectively specified combination but also in other combinations or alone, without departing from the scope of the invention. The single figure shows a schematic representation of an apparatus for producing a component of a turbomachine.

The single FIGURE shows a schematic representation of a device 10 for producing a component 12 of a turbomachine. The component 12 is in the illustrated embodiment, a blade of a high-pressure turbine. The device 10 is used for the generative production of the component 10 and comprises a Pulverzuf supply 14 for applying at least one powdered component material 20a on a in a powder container 16 movably arranged component platform (not visible) in the region of a build-up and joining zone I. The powdered component material 20a includes a metallic, ceramic and / or intermetallic compound. Furthermore, the device 10 has a liquid feed 18 for applying a liquid component material 20b to the component platform in the region of the assembly and joining zone I, wherein the liquid component material 20b has at least one metal halide. tiger compound includes. The liquid supply 18 is designed as a print head and brings the liquid component material 20b via several nozzles (not visible) on the powdered component material 20a and on the assembly and joining zone I. It can also be provided that the powder feed 14 and the liquid feed 18 are integrated in a common component of the device 10.

For layered and local fusing and / or sintering of the component materials 20a, 20b, an energy source 22 is provided by means of which the component 12 in the assembly and joining zone I thermal and / or electromagnetic energy E is supplied. The oil source 22 may be formed, for example, as a microwave source, flash lamp, IR lamp and / or high-energy lamp.

The device 10 may be further coupled to a control and / or control device to enable automated process execution. In this case, first the desired shape and / or the desired material structure of the component 12 is determined as a computer-generated model and layer information generated therefrom for controlling and / or regulating the device 10 is used.

The manufacture of the component 12 is described below by way of example:

20

In a first step a), the powdery component material 20 is applied in layers to the component platform in the region of the assembly and joining zone I with the aid of the powder feed 14. Parameters such as powder size and powder quantity can be used to control the growth of the individual component layers. Subsequently and / or simultaneously in step b) the

25 liquid component material 20b applied by means of the liquid supply 18. In the present exemplary embodiment, the liquid component material 20b used is an organometallic compound taken up in a solvent. Alternatively or additionally, for example, a suspension of a liquid suspending agent and nanoparticles may also be used. The use of nanoparticles offers the advantage that their sintering

30 temperature significantly lower than that of the solid or powdered component material 20a decreases. Subsequently, the component materials 20a, 20b are fused in layers and locally in step c) or sintered. For this purpose, thermal energy and / or electromagnetic energy E in the region of the assembly and joining zone I is supplied to the component 12 with the aid of the energy source 22. As a result, the metal is released from the liquid component material 20b, which 5 connects to the surrounding powder at the atomic level. This results in crosslinking of the powdery component material 20a with the metal released from the organometallic compound of the liquid component material 20b. The eliminated organic radical and the solvent or suspending agent are expelled by the supplied energy E. In contrast, when using elemental metals, metal alloys or nanoparticles, only the solvent or suspending agent is expelled by the action of energy, wherein the liberated metal or the liberated alloy is fused or sintered with the powdered component material 20a.

After this step, the component platform is lowered in a following step d) according to arrow II by 15 a predefined layer thickness, after which in step e) the preceding steps a) to d) are repeated until the completion of the component 12.

Claims

claims

1. A method for producing a component (12), in particular a hollow component for a turbomachine, characterized in that at least the following steps are carried out:

a) layered application of at least one powdered component material (20a) on a component platform in the region of a building and joining zone (I); b) applying at least one liquid component material (20b) to the powdery component material (20a), wherein the liquid component material (20b) comprises at least one metal-containing compound;

c) layer-by-layer and local melting and / or sintering of the component materials (20a, 20b) by means of supplied thermal and / or electromagnetic energy (E) in the region of the assembly and joining zone (I);

d) lowering the component platform by a predefined layer thickness; and e) repeating steps a) to d) until completion of the component (12).

2. The method according to claim 1, characterized in that in step a) a pulverulent component material component (20a) is used, which is a metal and / or a metal alloy and / or an intermetallic compound and / or a metal ceramic and / or a silicate includes.

3. The method according to claim 1 or 2, characterized in that a powder size

and / or a powder quantity of the pulverulent component material (20a) and / or a volume of the liquid component material (20b) are selected as a function of a layer thickness to be achieved.

4. The method according to any one of claims 1 to 3, characterized in that in step b) a liquid component material (20b) is used, which is an organometallic compound and / or a metal salt and / or nanoparticles and / or a solvent and / or a Suspending agent includes.

5. The method according to any one of claims 1 to 4, characterized in that in step b) a liquid component material (20b) is used whose decomposition and / or Abspaltungs- and / or sintering and / or melting temperature below the melting temperature of the powdery Component material (20a) is located.

6. The method according to any one of claims 1 to 5, characterized in that the powdered and / or the liquid component material (20a, 20b) by means of a print head, in particular a multiple print head, is applied.

7. The method according to any one of claims 1 to 6, characterized in that before step d) at least steps a) and b) and optionally c) are carried out simultaneously and / or in reverse order and / or multiple times.

8. The method according to any one of claims 1 to 7, characterized in that the energy (E) in step c) by means of a lamp, in particular an IR lamp and / or a flash lamp and / or a high-energy lamp, and / or a laser, in particular a C0 ₂ - or Nd: YAG laser, and / or a microwave device is supplied.

9. The method according to any one of claims 1 to 8, characterized in that the method comprises a rapid prototyping and / or rapid-manufacturing method, in particular a laser deposition welding or an electron beam powder deposition welding.

10. The method according to any one of claims 1 to 9, characterized in that the shape and / or the material structure of the component (12) is determined as a computer-generated model and generated therefrom layer information for controlling and / or regulating at least one of the steps a) to e ) is used.

11. The method according to any one of claims 1 to 10, characterized in that as a component (12) a hollow blade for a turbine or for a compressor of a thermal gas turbine is produced.

12. Device (10) for producing a component (12) of a turbomachine, in particular a hollow component for a turbomachine, characterized in that the device comprises at least one powder feed (14) for applying at least one powdered component material (20a) to a component platform in the region of a buildup and joining zone (I), at least one liquid feed (18) for applying a liquid component material (20b), which at least one metal-containing compound comprises, on the component platform in the region of the assembly and joining zone (I) and at least one energy source (22) for layered and local fusing and / or United of the component materials (20a, 20b) by means of supplied thermal and / or electromagnetic energy (E ) in the region of the assembly and joining zone (I).

13. Device (10) according to claim 12, characterized in that the energy source (22) is a lamp and / or a laser and / or an electron beam device and / or a microwave device.

14. Device (10) according to claim 12 or 13, characterized in that the liquid keitszufuhrung (18) comprises a printhead for applying the liquid component material (20b).

15. Device (10) according to any one of claims 12 to 14, characterized in that the liquid supply (18) comprises at least one nozzle through which the liquid component material (20b) is to be applied to the component platform.