EP2493644A2 - Procédé et dispositif de fabrication d'un élément - Google Patents

Procédé et dispositif de fabrication d'un élément

Info

Publication number
EP2493644A2
EP2493644A2 EP10798475A EP10798475A EP2493644A2 EP 2493644 A2 EP2493644 A2 EP 2493644A2 EP 10798475 A EP10798475 A EP 10798475A EP 10798475 A EP10798475 A EP 10798475A EP 2493644 A2 EP2493644 A2 EP 2493644A2
Authority
EP
European Patent Office
Prior art keywords
component
component material
liquid
metal
joining zone
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP10798475A
Other languages
German (de)
English (en)
Inventor
Erwin Bayer
Sven-J. Hiller
Karl-Heinz Dusel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MTU Aero Engines AG
Original Assignee
MTU Aero Engines GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by MTU Aero Engines GmbH filed Critical MTU Aero Engines GmbH
Publication of EP2493644A2 publication Critical patent/EP2493644A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20Direct sintering or melting
    • B22F10/25Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/30Platforms or substrates
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40Radiation means
    • B22F12/41Radiation means characterised by the type, e.g. laser or electron beam
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50Means for feeding of material, e.g. heads
    • B22F12/53Nozzles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50Means for feeding of material, e.g. heads
    • B22F12/55Two or more means for feeding material
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

Definitions

  • 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 are known in a wide variety.
  • 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.
  • 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.
  • 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.
  • 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 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.
  • 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.
  • a liquid component material which comprises a metal-containing compound is thus used in addition to the powdery component material.
  • the metal-containing compound 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.
  • 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.
  • 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.
  • step c) 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the growth of the individual component layers can be precisely controlled.
  • the property profile of the component can be adapted specifically and optimally to its respective application.
  • the concentration of the metallic compound in the liquid component material is preferably taken into account.
  • a liquid component material which comprises an organometallic compound and / or a metal salt and / or nanoparticles and / or a solvent and / or a suspending agent.
  • 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.
  • the use of a solvent and / or suspending agent has proven to be advantageous.
  • 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.
  • 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.
  • 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.
  • 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.
  • a lamp in particular an IR lamp and / or a flashlamp and / or a high-energy lamp
  • a laser in particular a C0 2 - or Nd : YAG laser
  • microwave device a microwave device
  • 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.
  • a hollow blade for a turbine or for a compressor of a thermal gas turbine is produced as a component.
  • 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.
  • a liquid component material which comprises a metal-containing compound.
  • 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.
  • 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.
  • the powder and the liquid supply are integrated in a component of the device.
  • 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.
  • 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.
  • the energy source is a lamp and / or a laser and / or an electron beam device and / or a microwave device.
  • each component layer can be metallized and bonded in a planar manner, which results in corresponding speed advantages.
  • excess liquid components of the component material can be removed by evaporation from the layer.
  • organometallic compounds moreover, the organic radical can be easily removed and expelled.
  • the liquid supply comprises a print head for applying the liquid component material.
  • 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.
  • the liquid supply comprises at least one nozzle through which the liquid component material is to be applied to the component platform.
  • a plurality of nozzles may be provided.
  • the component material can be applied simultaneously in several places.
  • different component materials can be applied simultaneously in several places.
  • 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.
  • 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.
  • the 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.
  • 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.
  • a control and / or control device to enable automated process execution.
  • 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.
  • 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 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
  • liquid component material 20b applied by means of the liquid supply 18.
  • the liquid component material 20b used is an organometallic compound taken up in a solvent.
  • a suspension of a liquid suspending agent and nanoparticles may also be used. The use of nanoparticles offers the advantage that their sintering
  • the component materials 20a, 20b are fused in layers and locally in step c) or sintered.
  • 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.
  • the metal is released from the liquid component material 20b, which 5 connects to the surrounding powder at the atomic level.
  • the eliminated organic radical and the solvent or suspending agent are expelled by the supplied energy E.
  • 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.
  • step d) 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.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un élément (12), notamment d'un élément creux d'une turbomachine, comprenant au moins les étapes suivantes: a) appliquer par couches au moins un matériau d'élément (20a) pulvérulent sur une plate-forme de l'élément dans une zone de construction et d'assemblage (I), b) répandre au moins un matériau d'élément (20b) liquide sur le matériau d'élément (20a) pulvérulent, le matériau d'élément (20b) liquide contenant au moins un composé métallique, c) fondre et/ou fritter les matériaux d'élément (20a, 20b) localement et par couches, par apport d'énergie (E) thermique et/ou électromagnétique dans la zone de construction et d'assemblage (I), d) abaisser la plate-forme de l'élément d'une épaisseur de couche prédéterminée, et e) répéter les étapes a) à d) jusqu'à l'achèvement de l'élément (12). L'invention porte également sur un dispositif (10) de fabrication d'un élément (12) de turbomachine, notamment d'un élément creux de turbomachine.
EP10798475A 2009-10-31 2010-10-30 Procédé et dispositif de fabrication d'un élément Withdrawn EP2493644A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102009051552A DE102009051552A1 (de) 2009-10-31 2009-10-31 Verfahren und Vorrichtung zur Herstellung eines Bauteils
PCT/DE2010/001276 WO2011050791A2 (fr) 2009-10-31 2010-10-30 Procédé et dispositif de fabrication d'un élément

Publications (1)

Publication Number Publication Date
EP2493644A2 true EP2493644A2 (fr) 2012-09-05

Family

ID=43828817

Family Applications (1)

Application Number Title Priority Date Filing Date
EP10798475A Withdrawn EP2493644A2 (fr) 2009-10-31 2010-10-30 Procédé et dispositif de fabrication d'un élément

Country Status (4)

Country Link
US (1) US20120219726A1 (fr)
EP (1) EP2493644A2 (fr)
DE (1) DE102009051552A1 (fr)
WO (1) WO2011050791A2 (fr)

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DE102012107297A1 (de) * 2012-08-08 2014-06-18 Ralph Stelzer Arbeitsverfahren und Vorrichtung zum Auftragen, Aushärten und Oberflächenbearbeitung von pulverförmigen Werkstoffen auf Bauflächen
EP2787178B1 (fr) * 2013-04-03 2016-03-02 MTU Aero Engines AG Ensemble d'aube directrice
EP2851180A1 (fr) * 2013-09-20 2015-03-25 Rolls-Royce Corporation Procédé et appareil pour former des articles en trois dimensions
US10124531B2 (en) 2013-12-30 2018-11-13 Ut-Battelle, Llc Rapid non-contact energy transfer for additive manufacturing driven high intensity electromagnetic fields
US9650537B2 (en) 2014-04-14 2017-05-16 Ut-Battelle, Llc Reactive polymer fused deposition manufacturing
US10072506B2 (en) * 2014-06-30 2018-09-11 Rolls-Royce Corporation Coated gas turbine engine components
WO2016053312A1 (fr) 2014-09-30 2016-04-07 Hewlett-Packard Development Company, L.P. Création d'un objet tridimensionnel
DE102016201838A1 (de) * 2016-02-08 2017-08-10 Siemens Aktiengesellschaft Verfahren zur Herstellung eines Bauteils und Vorrichtung
CN106041060B (zh) * 2016-05-31 2018-02-16 华中科技大学 一种在液相中采用激光焊接制备纳米复合材料的方法
DE102018102753A1 (de) * 2018-02-07 2019-08-08 Exone Gmbh 3d-drucker und generatives fertigungsverfahren

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US6742456B1 (en) * 2002-11-14 2004-06-01 Hewlett-Packard Development Company, L.P. Rapid prototyping material systems
US7220380B2 (en) * 2003-10-14 2007-05-22 Hewlett-Packard Development Company, L.P. System and method for fabricating a three-dimensional metal object using solid free-form fabrication
DE102004012682A1 (de) * 2004-03-16 2005-10-06 Degussa Ag Verfahren zur Herstellung von dreidimensionalen Objekten mittels Lasertechnik und Auftragen eines Absorbers per Inkjet-Verfahren
WO2007114895A2 (fr) * 2006-04-06 2007-10-11 Z Corporation production d'éléments tridimensionnels au moyen de radiations électromagnétiques
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Also Published As

Publication number Publication date
DE102009051552A1 (de) 2011-05-05
WO2011050791A2 (fr) 2011-05-05
US20120219726A1 (en) 2012-08-30
WO2011050791A3 (fr) 2011-06-23

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