EP2981381A1 - Method for producing a shell-shaped component and production system suitable for the use of said method - Google Patents

Method for producing a shell-shaped component and production system suitable for the use of said method

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Publication number
EP2981381A1
EP2981381A1 EP14728101.8A EP14728101A EP2981381A1 EP 2981381 A1 EP2981381 A1 EP 2981381A1 EP 14728101 A EP14728101 A EP 14728101A EP 2981381 A1 EP2981381 A1 EP 2981381A1
Authority
EP
European Patent Office
Prior art keywords
component
support body
cold gas
iib
cold
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.)
Granted
Application number
EP14728101.8A
Other languages
German (de)
French (fr)
Other versions
EP2981381B1 (en
Inventor
Christian Doye
Ursus KRÜGER
Oliver Stier
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.)
Siemens AG
Original Assignee
Siemens AG
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 Siemens AG filed Critical Siemens AG
Publication of EP2981381A1 publication Critical patent/EP2981381A1/en
Application granted granted Critical
Publication of EP2981381B1 publication Critical patent/EP2981381B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B22F3/04—Compacting only by applying fluid pressure, e.g. by cold isostatic pressing [CIP]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/115—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by spraying molten metal, i.e. spray sintering, spray casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles

Definitions

  • the invention relates to a method for producing a cup-shaped component with a wall and a recess open to the opening of this component.
  • the invention relates to a manufacturing plant for a component, comprising a cold spray nozzle and a holding device for the component, wherein the cold spray device and the receptacle are movable relative to each other.
  • Cup-shaped components are preferably produced by deep drawing.
  • a sheet is processed via a molding (die) forming technology.
  • components can only be manufactured economically in this way in the case of relatively large quantities since the molds are comparatively expensive to produce and therefore have a negative effect on the unit costs for smaller quantities.
  • This also applies to a production by casting, since in this case molds must be made.
  • machining is also technically possible, for example by milling.
  • machining in the case of shell-shaped components, a large volume has to be removed by machining, which is why this method is not economically justifiable because of the production costs involved.
  • shell-shaped components in the context of the invention, components are to be understood whose shell thickness, ie wall thickness of the wall, is small compared to the overall dimensions of the component.
  • small is meant, for example, a ratio in which the average shell thickness of the component is below 5%, preferably even below 2% and even more preferably even below 0.5%, compared to its longest overall dimension.
  • Such shell components are widely used in the art.
  • DE 10 2010 040 855 AI For example, use of such cup-shaped components in DC particle accelerators is described. These particle accelerators have electrodes which are interlaced and therefore consist of shell-shaped components of different dimensions. These electrodes are therefore produced only in small numbers, with an interest that they can be produced economically. On the one hand, it is therefore an object of the invention to provide a method for producing a cup-shaped component, with which cup-shaped components can be produced economically, even in small quantities.
  • the manufacturing plant mentioned at the outset is also known from the prior art.
  • the cold gas spraying and a suitable plant for the application of this method is described for example in DE 690 164 33 T2.
  • a particle jet is strongly accelerated by a gas under pressure through a convergently-divergent nozzle, which results in deposition of the particles on a suitable substrate.
  • a permissible interval for the spraying angle within which the adhesive strength of the deposited particles reaches maximum values. The zero angle may or may not be included in this interval. The family of permissible spraying angles thus results in a space between two conical surfaces whose tips coincide at the point of impact of the particle beam. If in the
  • Cold gas spraying is a process known per se, in which particles intended for coating are preferably accelerated to supersonic speed by means of a convergent-divergent nozzle, so that they adhere to the surface to be coated on account of their impressed kinetic energy.
  • the kinetic energy of the particles is used, which leads to a plastic deformation of the same, wherein the coating particles are melted on impact only on their surface. Therefore, this method is referred to as cold gas spraying in comparison to other thermal spraying methods, because it is carried out at comparatively low temperatures at which the coating particles remain substantially fixed.
  • cold gas spraying which is also referred to as kinetic spraying, uses a cold gas spraying system which has a gas heating device for heating a gas.
  • a stagnation chamber is connected, which is connected on the output side with the convergent-divergent nozzle, preferably a Laval nozzle.
  • Convergent-divergent nozzles have a converging section and a flared section connected by a nozzle throat.
  • the convergent-divergent nozzle produces on the output side a powder jet in the form of a gas stream with particles therein at high speed, preferably supersonic speed.
  • the cold gas jet layers can be deposited to produce, for example, a tube on a cylindrical Rohrmatrize, as described in DE 10 2010 060362 AI.
  • a further object of the invention is therefore to modify a production plant for cold gas spraying in such a way that the method given in the introduction can be carried out with it. This means that by means of the manufacturing The production of cup-shaped components should advantageously be feasible cost-effective even for small batches.
  • the first object is achieved by the method specified above according to the invention by the following measures.
  • the component is manufactured by cold gas spraying.
  • a support body is provided with a curved surface made of a material on which the particles of the cold gas jet do not adhere.
  • a starting structure on the surface can be temporarily fixed. This fixation must not be followed by an intimate, for example cohesive joining of the starting structure with the support body. But a better possibility is to hold the starting structure by means of a holding device and bring in this way with the support body in contact.
  • the particles of the cold gas jet do not adhere to the material of the support body, this essentially depends on the choice of the spray angle. If the spray angle is 0 °, layers can be deposited on most materials, whereas this is not possible if the spray angle is outside the cold spray cone. In other words, a support body, on which the particles of the cold gas jet remain as little as possible, can advantageously be selected such that the particles to be deposited can only be deposited on the material of the support body in a comparatively sharp cold spray cone or not at all.
  • the component is produced by a material application from the cold gas jet to the seam of the component being formed, wherein the support body and the cold gas jet are moved synchronously such that the cold gas jet at an angle within the cold spray cone of the seam, but impinges on the seam outside of the cold spray cone of the support body.
  • the seam of the component being manufactured will always be be at an angle to the support body, in which the surface of the support body is oriented so that is based on the support body of the cold gas jet outside of the cold spray cone.
  • the orientation of the surface of the seam relative to the surface of the support body is preferably about 90 ° or at least more than 70 ° to 90 °.
  • the supporting body supports the component which is being formed in the point of impact of the cold gas jet. Due to the fact that a production of the component by cold gas spraying always requires support of the component only in the impact area of the cold gas jet, the volume of the support body can advantageously be much smaller than the internal volume of the depression of the shell-shaped component. It is only necessary that with a convex surface of the support body, the radius of curvature at the point of impact of the cold gas jet is just lower than the local radius of curvature of the shell-shaped component on the inside. If a concave support structure is used, the radius of curvature of the component must be smaller on the outside than the radius of curvature of the support structure. Only in this way can it be achieved that the support structure can in each case preferably tangentially cling to the part of the shell-shaped component which is being formed and thereby supports it.
  • the component can be designed like a bowl.
  • the cup-shaped component is rotationally symmetrical and the axis of symmetry is perpendicular to the plane containing the opening.
  • the component can be produced as an electrode shell of a particle accelerator.
  • the support body consists of a hard metal.
  • This material has the advantage that particles can be deposited comparatively poorly on this material by means of cold gas spraying and therefore the supporting effect of a supporting body produced in this way can be well utilized. Besides that is Such a support body exposed only a small amount of wear, so that it rarely needs to be replaced.
  • the support body has a surface which has the shape of a sphere or a sphere section.
  • These shapes of the support bodies belong to the group of support bodies with a convex surface. Spherical support bodies can be advantageously handled easily, since regardless of the positioning of the ball with respect to the originating
  • the support body is formed with a concave surface, wherein also this concave surface can advantageously form the gelgelabsacrificings a.
  • a plurality of support bodies with different radii of curvature are provided on their curved surface. These can then be exchanged in the process, whereby shell-shaped components can advantageously also be produced in this way, in which the radii of curvature of the shell are locally different (that is to say shapes other than spherical shells). It must be taken into account here that the radius of curvature of the support body must not deviate too much from the radius of curvature of the wall which is just to be produced, since otherwise the support effect will be too low. It is particularly advantageous if the cold spray nozzle
  • the cold spray nozzle and the support body are each guided by a robot arm.
  • the cold spray nozzle and the support body can advantageously optimally be aligned with each other, which increases the variety of manufacturable shapes of bowl-shaped components.
  • the robot arm can advantageously each have at least three axes. Of course, more degrees of freedom increase the geometric flexibility of the entire system.
  • a further embodiment of the invention is obtained when the starting structure used is an annularly closed structure which defines the edge of the opening of the cup-shaped component, the wall of the component being constructed starting from the starting structure.
  • the structure must be ring-shaped so that it forms a border of the opening of the cup-shaped component. However, this does not mean that this opening must be circular.
  • ring-shaped closure is merely to be understood as meaning that the starting structure is elongate and has no beginning and no end.
  • the starting structure can also be produced as an annularly closed structure on a base by cold gas spraying. This then forms the edge of the opening of the cup-shaped component and the wall is constructed starting from the starting structure by cold gas spraying.
  • the object directed to the production plant specified at the outset is achieved according to the invention in that the production plant has a support body which has a convexly or concavely curved surface and is movable relative to the receptacle.
  • the advantages associated with the use of such a support body are associated with already mentioned above.
  • the free mobility of the support body and the cold spray nozzle ensure that the movement of these two elements can be synchronized to locally support the deposition of particles on the seam of the component being manufactured.
  • the relative mobility between the holding device for the component to be manufactured, the cold spray nozzle and the support body can not necessarily be accomplished by a movement of cold spray nozzle and support body alone, but also by a movement of the component in the holding device ,
  • the cold spray nozzle and the support body have to perform only pivotal movements in a plane.
  • this simplification is paid for by the lower geometric flexibility of the manu- facturing plant.
  • a technical compromise must be found.
  • the support body can be attached to a robot arm.
  • the cold spray nozzle can be attached to a robot arm.
  • FIGS. 1 and 2 show selected steps of an embodiment of the method according to the invention in a sectional representation
  • Figure 6 shows another embodiment of the method according to the invention in a sectional view
  • Figure 7 shows a schematic embodiment of the manufacturing plant according to the invention in a schematic section.
  • FIG. 1 shows how the method according to the invention is started.
  • a starting structure IIa is provided, which is of annular design and forms the edge of an opening 12 to be produced of a cup-shaped component which is not yet to be recognized.
  • the starting structure IIa is fixed with a holding device 13.
  • a cold spray nozzle 14 which is fastened to a robot arm 15, is directed onto the edge of the starting structure IIa.
  • a spherical support body 16 from the other side with a further robot arm 15 b to the edge of the
  • FIG. 2 it can be seen in section how a wall 18 of the component 19 to be produced arises. It can be seen that the support body 16 is tracked in such a way that it is always located at the point of impact of the cold gas jet 17. This is directed to the seam 20 of the wall 18 being produced and, in the variant shown in FIG. 2, strikes the seam 20 exactly at an angle of 90 °. The spraying angle is therefore 0 °. However, this can, as indicated by the cold spray cone 21, also deviate from the illustrated 0 °, as long as it is within the cold spray cone 21.
  • the support body 16 conforms to the concave inner side of the wall 18 in such a way that in the region of the seam 20 a tangential contact of the wall 18 with the surface of the support body 16 takes place.
  • the orientation of the seam with respect to a standing on the surface of the support body 16 normal 22 is inclined by the angle ß, the angle ß is chosen low enough so that an alignment of the cold jet 17 outside of
  • spray cone on the surface of the support body is (ß can also be zero). This avoids that particles are deposited on the surface of the support body.
  • FIG. 3 shows how a starting structure IIb is produced on a base 24 in the form of a flat table.
  • the cold gas jet 17 is directed onto this base 24 and thus produces the annular starting structure.
  • This advantageously consists preferably of the same material as the wall to be produced.
  • a hole 25 is provided, through which the support structure 16 (see Figure 5) can be inserted into the recess 26 of the cup-shaped member 19.
  • FIG. 4 It can be seen in FIG. 4 that the support structure 16 used there has the shape of a hemisphere so that it can be brought to the seam 20 without the pad 24 disturbs. Otherwise, the wall according to FIG. 4 is produced in the manner already described for FIG. 2. In Figure 5 it can be seen how the component 19 is made shortly before its final completion.
  • FIG. 6 shows a concave supporting body 16, which is guided from the outside against the wall 18 of the component to be produced which is not shown in any more detail. It can be seen that the radius of curvature of the concave support body 16 can only be so great that the cold gas jet 17 can still be brought to the seam 20 of the component. Therefore, a concave support body is preferably suitable for the production of large radii, which would be made difficult by an approach of the support body from the inside.
  • the manufacturing plant has a housing 27 so that it can be filled with a protective gas.
  • two robots 28a, 28b are arranged, which have the robot arms 15a, 15b.
  • Attached to the robot arm 15a is the cold spray nozzle 14, which is connected to a cold spray system 30 via a flexible conduit 29.
  • the holding device 13 allows the inclusion of a starting structure (not shown). This can be supported in a production of the wall according to the methods already described on the support structure 16, which is tracked by means of the robot 28b in a suitable manner. If the component to be manufactured ranges differently Have diameter, so more support body 16 are provided in a magazine 31. This magazine 31 can be approached by the robot arm 15b, so that the support body 16 can be replaced.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

The invention relates to a method for producing a shell-shaped component (18). The invention further relates to a production system that is suitable for producing such a component (18). According to the invention, the component (18) is produced by a cold gas stream (17) by means of cold gas spraying. The particles of the cold gas stream (17) are applied to the edge (20) of the component (18) being produced, wherein simultaneously a supporting body (16) is used, which, according to the invention, supports the component only at the point of incidence of the cold gas stream (17). In this way, the form of the component (18) can be shaped by suitably moving the supporting body (16) and the cold spray nozzle, without having to produce a core that fills the entire volume of the shell-shaped component (18). Thus, the method according to the invention is advantageously especially economical for small quantities, because the supporting body (16) can be used universally for components of different geometries. According to the invention, the production system therefore has a movable supporting body in addition to the cold spray nozzle.

Description

Beschreibung description
Verfahren zum Erzeugen eines schalenförmigen Bauteils sowie zur Anwendung dieses Verfahrens geeignete Herstellungsanlage Method for producing a cup-shaped component and production plant suitable for the use of this method
Die Erfindung betrifft ein Verfahren zum Erzeugen eines schalenförmigen Bauteils mit einer Wandung und einer zur Öffnung dieses Bauteils hin offenen Vertiefung. Außerdem betrifft die Erfindung eine Herstellungsanlage für ein Bauteil, aufweisend eine Kaltspritzdüse und eine Haltevorrichtung für das Bauteil, wobei die Kaltspritzeinrichtung und die Aufnahme relativ zueinander beweglich sind. The invention relates to a method for producing a cup-shaped component with a wall and a recess open to the opening of this component. In addition, the invention relates to a manufacturing plant for a component, comprising a cold spray nozzle and a holding device for the component, wherein the cold spray device and the receptacle are movable relative to each other.
Ein Verfahren der eingangs angegebenen Art ist allgemein be- kannt . Schalenförmige Bauteile werden bevorzugt durch Tiefziehen hergestellt. Hierbei wird ein Blech über einen Formkörper (Matrize) umformtechnisch bearbeitet. Allerdings können Bauteile auf diese Weise nur bei größeren Stückzahlen wirtschaftlich hergestellt werden, da die Formwerkzeuge ver- gleichsweise teuer in der Herstellung sind und bei kleineren Stückzahlen die Stückkosten daher negativ beeinflussen. Dies gilt auch für eine Herstellung durch Gießen, da in diesem Fall Gussformen hergestellt werden müssen. Grundsätzlich technisch möglich ist auch eine spanende Bearbeitung, bei- spielsweise durch Fräsen. Allerdings ist bei schalenförmigen Bauteilen ein großes Volumen spanend abzuheben, weswegen dieses Verfahren wegen des anfallenden Fertigungsaufwandes wirtschaftlich nicht vertretbar ist. Als schalenförmige Bauteile im Sinne der Erfindung sollen Bauteile verstanden werden, deren Schalendicke, d. h. Wandstärke der Wandung, klein gegenüber den Gesamtabmessungen des Bauteils ist. Unter klein ist beispielsweise ein Verhältnis zu verstehen, bei dem die mittlere Schalendicke des Bauteils im Vergleich zu seiner längsten Gesamtabmessung unter 5 %, bevorzugt sogar unter 2 % und noch bevorzugter sogar unter 0,5 %, beträgt. Derartige Schalenbauteile finden in der Technik mannigfache Verwendung. Gemäß der DE 10 2010 040 855 AI ist beispielsweise eine Verwendung solcher schalenförmiger Bauteile in Gleichspannungs-Teilchenbeschleunigern beschrieben. Diese Teilchenbeschleuniger weisen Elektroden auf, welche ineinander verschachtelt werden und daher aus schalenför- migen Bauteilen unterschiedlicher Abmessungen bestehen. Diese Elektroden werden daher nur in geringer Stückzahl hergestellt, wobei ein Interesse daran besteht, dass diese wirtschaftlich hergestellt werden können. Die Aufgabe der Erfindung besteht daher einerseits darin, ein Verfahren zum Erzeu- gen eines schalenförmigen Bauteils anzugeben, mit dem sich schalenförmige Bauteile auch in kleinen Stückzahlen wirtschaftlich herstellen lassen. A method of the type described above is generally known. Cup-shaped components are preferably produced by deep drawing. In this case, a sheet is processed via a molding (die) forming technology. However, components can only be manufactured economically in this way in the case of relatively large quantities since the molds are comparatively expensive to produce and therefore have a negative effect on the unit costs for smaller quantities. This also applies to a production by casting, since in this case molds must be made. In principle, machining is also technically possible, for example by milling. However, in the case of shell-shaped components, a large volume has to be removed by machining, which is why this method is not economically justifiable because of the production costs involved. As shell-shaped components in the context of the invention, components are to be understood whose shell thickness, ie wall thickness of the wall, is small compared to the overall dimensions of the component. By "small" is meant, for example, a ratio in which the average shell thickness of the component is below 5%, preferably even below 2% and even more preferably even below 0.5%, compared to its longest overall dimension. Such shell components are widely used in the art. According to DE 10 2010 040 855 AI For example, use of such cup-shaped components in DC particle accelerators is described. These particle accelerators have electrodes which are interlaced and therefore consist of shell-shaped components of different dimensions. These electrodes are therefore produced only in small numbers, with an interest that they can be produced economically. On the one hand, it is therefore an object of the invention to provide a method for producing a cup-shaped component, with which cup-shaped components can be produced economically, even in small quantities.
Die eingangs angegebene Herstellungsanlage ist aus dem Stand der Technik ebenfalls bekannt. Das Kaltgasspritzen sowie eine zur Anwendung dieses Verfahrens geeignete Anlage ist beispielsweise in der DE 690 164 33 T2 beschrieben. Dabei wird ein Partikelstrahl durch ein unter Druck stehendes Gas durch eine konvergent -divergent ausgeführte Düse stark beschleu- nigt, wodurch es zu einer Abscheidung der Partikel auf einem geeigneten Substrat kommt . The manufacturing plant mentioned at the outset is also known from the prior art. The cold gas spraying and a suitable plant for the application of this method is described for example in DE 690 164 33 T2. In the process, a particle jet is strongly accelerated by a gas under pressure through a convergently-divergent nozzle, which results in deposition of the particles on a suitable substrate.
Idealerweise wird der Partikelstrahl mit einem Spritzwinkel = 0° eingestellt (d. h., dass die Strahlachse des Kaltgas- Strahls senkrecht auf der zu beschichtenden Oberfläche steht) . Jede davon abweichende Orientierung der Strahlachse führt zu einem positiven Wert des Spritzwinkels . Abhängig von den Randbedingungen wie verarbeitete Partikel, Oberflächenmaterial und Spritzparameter gibt es ein zulässiges In- tervall für den Spritzwinkel, innerhalb dessen die Haftfestigkeit der abgeschiedenen Partikel maximale Werte erreichen. Der Nullwinkel kann in diesem Intervall enthalten sein oder nicht. Die Schar aller zulässigen Spritzwinkel ergibt damit einen Raum zwischen zwei Kegelflächen, deren Spitzen im Auf- treffpunkt des Partikelstrahls zusammenfallen. Wenn in demIdeally, the particle beam is set at a spray angle = 0 ° (that is, the beam axis of the cold gas jet is perpendicular to the surface to be coated). Any deviating orientation of the beam axis leads to a positive value of the spray angle. Depending on the boundary conditions such as processed particles, surface material and spray parameters, there is a permissible interval for the spraying angle within which the adhesive strength of the deposited particles reaches maximum values. The zero angle may or may not be included in this interval. The family of permissible spraying angles thus results in a space between two conical surfaces whose tips coincide at the point of impact of the particle beam. If in the
Intervall der Nullwinkel enthalten ist (was normalerweise der Fall ist) , benötigt man zur Beschreibung des Spritzwinkelin- tervalls nur einen Kegel, den sogenannten Kaltspritzkegel, der in der beschriebenen Weise ausgerichtet ist. Interval of the zero angle is included (which is usually the case), one needs to describe the injection angle tervalls only one cone, the so-called cold spray cone, which is aligned in the manner described.
Das Kaltgasspritzen ist ein an sich bekanntes Verfahren, bei dem für die Beschichtung vorgesehene Partikel mittels einer konvergent-divergenten Düse vorzugsweise auf Überschallgeschwindigkeit beschleunigt werden, damit diese aufgrund ihrer eingeprägten kinetischen Energie auf der zu beschichtenden Oberfläche haften bleiben. Hierbei wird die kinetische Ener- gie der Teilchen genutzt, welche zu einer plastischen Verformung derselben führt, wobei die Beschichtungspartikel beim Auftreffen lediglich an ihrer Oberfläche aufgeschmolzen werden. Deshalb wird dieses Verfahren im Vergleich zu anderen thermischen Spritzverfahren als Kaltgasspritzen bezeichnet, weil es bei vergleichsweise tiefen Temperaturen durchgeführt wird, bei denen die Beschichtungspartikel im Wesentlichen festbleiben. Vorzugsweise wird zum Kaltgasspritzen, welches auch als kinetisches Spritzen bezeichnet wird, eine Kaltgasspritzanlage verwendet, die eine Gasheizeinrichtung zum Er- hitzen eines Gases aufweist. An die Gasheizeinrichtung wird eine Stagnationskammer angeschlossen, die ausgangsseitig mit der konvergent-divergenten Düse, vorzugsweise einer Lavaldüse verbunden wird. Konvergent-divergente Düsen weisen einen zusammenlaufenden Teilabschnitt sowie einen sich aufweitenden Teilabschnitt auf, die durch einen Düsenhals verbunden sind. Die konvergent-divergente Düse erzeugt ausgangsseitig einen Pulverstrahl in Form eines Gasstroms mit darin befindlichen Partikeln mit hoher Geschwindigkeit, vorzugsweise Überschallgeschwindigkeit. Mit dem Kaltgasstrahl lassen sich Schichten abscheiden, um zum Beispiel ein Rohr auf einer zylindrischen Rohrmatrize herzustellen, wie in der DE 10 2010 060362 AI beschrieben . Cold gas spraying is a process known per se, in which particles intended for coating are preferably accelerated to supersonic speed by means of a convergent-divergent nozzle, so that they adhere to the surface to be coated on account of their impressed kinetic energy. Here, the kinetic energy of the particles is used, which leads to a plastic deformation of the same, wherein the coating particles are melted on impact only on their surface. Therefore, this method is referred to as cold gas spraying in comparison to other thermal spraying methods, because it is carried out at comparatively low temperatures at which the coating particles remain substantially fixed. Preferably, cold gas spraying, which is also referred to as kinetic spraying, uses a cold gas spraying system which has a gas heating device for heating a gas. To the gas heater a stagnation chamber is connected, which is connected on the output side with the convergent-divergent nozzle, preferably a Laval nozzle. Convergent-divergent nozzles have a converging section and a flared section connected by a nozzle throat. The convergent-divergent nozzle produces on the output side a powder jet in the form of a gas stream with particles therein at high speed, preferably supersonic speed. With the cold gas jet layers can be deposited to produce, for example, a tube on a cylindrical Rohrmatrize, as described in DE 10 2010 060362 AI.
Eine weitere Aufgabe der Erfindung besteht damit darin, eine Herstellungsanlage zum Kaltgasspritzen so zu modifizieren, dass sich das eingangs angegebene Verfahren mit dieser durchführen lässt. Dies bedeutet, dass mittels der Herstellungsan- läge die Herstellung von schalenförmigen Bauteilen auch bei Kleinserien vorteilhaft kostengünstig durchführbar sein soll. A further object of the invention is therefore to modify a production plant for cold gas spraying in such a way that the method given in the introduction can be carried out with it. This means that by means of the manufacturing The production of cup-shaped components should advantageously be feasible cost-effective even for small batches.
Die erstgenannte Aufgabe wird durch das eingangs angegebene Verfahren erfindungsgemäß durch folgende Maßnahmen gelöst. Das Bauteil wird durch Kaltgasspritzen hergestellt. Hierbei wird ein Stützkörper mit einer gekrümmten Oberfläche aus einem Material zur Verfügung gestellt, auf dem die Partikel des Kaltgasstrahls nicht haften bleiben. Auf diesem Stützkörper kann eine Startstruktur auf der Oberfläche temporär fixiert werden. Diese Fixierung darf nicht durch ein inniges, beispielsweise Stoffschlüssiges Verbinden der Startstruktur mit dem Stützkörper folgen. Eine bessere Möglichkeit besteht aber darin, die Startstruktur mittels einer Haltevorrichtung zu halten und auf diesem Wege mit dem Stützkörper in Kontakt zu bringen . The first object is achieved by the method specified above according to the invention by the following measures. The component is manufactured by cold gas spraying. Here, a support body is provided with a curved surface made of a material on which the particles of the cold gas jet do not adhere. On this support body, a starting structure on the surface can be temporarily fixed. This fixation must not be followed by an intimate, for example cohesive joining of the starting structure with the support body. But a better possibility is to hold the starting structure by means of a holding device and bring in this way with the support body in contact.
Wenn im Zusammenhang mit der Erfindung davon die Rede ist, dass die Partikel des Kaltgasstrahls nicht an dem Material des Stützkörpers haften bleiben, so hängt dies wesentlich von der Wahl des Spritzwinkels ab. Beträgt der Spritzwinkel 0°, so lassen sich auf den meisten Materialien Schichten abscheiden, während dies nicht möglich ist, wenn der Spritzwinkel außerhalb des Kaltspritzkegels liegt. Mit anderen Worten lässt sich ein Stützkörper, auf dem die Partikel des Kaltgasstrahls möglichst wenig haften bleiben, vorteilhaft dadurch auswählen, dass die abzuscheidenden Partikel auf dem Material des Stützkörpers nur in einem vergleichsweise spitzen Kaltspritzkegel oder gar nicht abgeschieden werden können. If, in connection with the invention, it is said that the particles of the cold gas jet do not adhere to the material of the support body, this essentially depends on the choice of the spray angle. If the spray angle is 0 °, layers can be deposited on most materials, whereas this is not possible if the spray angle is outside the cold spray cone. In other words, a support body, on which the particles of the cold gas jet remain as little as possible, can advantageously be selected such that the particles to be deposited can only be deposited on the material of the support body in a comparatively sharp cold spray cone or not at all.
Erfindungsgemäß ist außerdem vorgesehen, dass das Bauteil durch einen Materialauftrag aus dem Kaltgasstrahl jeweils an den Saum des in Entstehung befindlichen Bauteils hergestellt wird, wobei der Stützkörper und der Kaltgasstrahl synchron derart bewegt werden, dass der Kaltgasstrahl in einem Winkel innerhalb des Kaltspritzkegels des Saumes, aber außerhalb des Kaltspritzkegels des Stützkörpers auf den Saum auftrifft. Der Saum des in Herstellung befindlichen Bauteils wird sich immer in einem Winkel zu dem Stützkörper befinden, bei dem die Oberfläche des Stützkörpers so ausgerichtet ist, dass sich bezogen auf den Stützkörper der Kaltgasstrahl außerhalb des Kaltspritzkegels befindet. Bevorzugt beträgt die Ausrichtung der Oberfläche des Saums gegenüber der Oberfläche des Stütz - körpers ca. 90° oder wenigstens mehr als 70° bis 90°. Hierdurch kommt der erfindungsgemäße Effekt zustande, dass der Stützkörper das in Entstehung befindliche Bauteil im Auf- treffpunkt des Kaltgasstrahls stützt. Dadurch, dass eine Her- Stellung des Bauteils durch Kaltgasspritzen eine Stützung des Bauteils immer nur im Auftreffbereich des Kaltgasstrahls erfordert, kann das Volumen des Stützkörpers vorteilhaft sehr viel kleiner als das Innenvolumen der Vertiefung des schalenförmigen Bauteils sein. Erforderlich ist es nur, dass bei ei- ner konvexen Oberfläche des Stützkörpers der Krümmungsradius an der Auftreffstelle des Kaltgasstrahls gerade geringer ausfällt, als der lokale Krümmungsradius des schalenförmigen Bauteils auf der Innenseite. Wird eine konkave Stützstruktur verwendet, dann muss der Krümmungsradius des Bauteils außen geringer sein als der Krümmungsradius der Stützstruktur. Nur so kann erreicht werden, dass sich die Stützstruktur jeweils an die in Entstehung befindliche Partie des schalenförmigen Bauteils bevorzugt tangential anschmiegen kann und diese dadurch stützt. According to the invention, it is also provided that the component is produced by a material application from the cold gas jet to the seam of the component being formed, wherein the support body and the cold gas jet are moved synchronously such that the cold gas jet at an angle within the cold spray cone of the seam, but impinges on the seam outside of the cold spray cone of the support body. The seam of the component being manufactured will always be be at an angle to the support body, in which the surface of the support body is oriented so that is based on the support body of the cold gas jet outside of the cold spray cone. The orientation of the surface of the seam relative to the surface of the support body is preferably about 90 ° or at least more than 70 ° to 90 °. As a result, the effect according to the invention is achieved that the supporting body supports the component which is being formed in the point of impact of the cold gas jet. Due to the fact that a production of the component by cold gas spraying always requires support of the component only in the impact area of the cold gas jet, the volume of the support body can advantageously be much smaller than the internal volume of the depression of the shell-shaped component. It is only necessary that with a convex surface of the support body, the radius of curvature at the point of impact of the cold gas jet is just lower than the local radius of curvature of the shell-shaped component on the inside. If a concave support structure is used, the radius of curvature of the component must be smaller on the outside than the radius of curvature of the support structure. Only in this way can it be achieved that the support structure can in each case preferably tangentially cling to the part of the shell-shaped component which is being formed and thereby supports it.
Vorteilhaft kann das Bauteil schüsseiförmig ausgebildet sein. Hiermit ist gemeint, dass das schalenförmige Bauteil rotationssymmetrisch ist und die Symmetrieachse senkrecht auf der die Öffnung enthaltenden Ebene steht. Besonders bevorzugt kann das Bauteil als Elektrodenschale eines Teilchenbeschleunigers hergestellt werden. Advantageously, the component can be designed like a bowl. By this is meant that the cup-shaped component is rotationally symmetrical and the axis of symmetry is perpendicular to the plane containing the opening. Particularly preferably, the component can be produced as an electrode shell of a particle accelerator.
Gemäß einer weiteren Ausführung der Erfindung ist vorgesehen, dass der Stützkörper aus einem Hartmetall besteht. Dieses Ma- terial hat den Vorteil, dass sich Partikel mittels Kaltgasspritzen vergleichsweise schlecht auf diesem Material abscheiden lassen und daher die Stützwirkung eines so hergestellten Stützkörpers gut genutzt werden kann. Außerdem ist ein solcher Stützkörper nur einem geringen Verschleiß ausgesetzt, so dass dieser selten ausgetauscht werden muss. According to a further embodiment of the invention it is provided that the support body consists of a hard metal. This material has the advantage that particles can be deposited comparatively poorly on this material by means of cold gas spraying and therefore the supporting effect of a supporting body produced in this way can be well utilized. Besides that is Such a support body exposed only a small amount of wear, so that it rarely needs to be replaced.
Gemäß einer anderen Ausgestaltung der Erfindung ist vorgese- hen, dass der Stützkörper eine Oberfläche aufweist, die die Form einer Kugel oder eines Kugelabschnitts hat. Diese Formen der Stützkörper gehören zur Gruppe der Stützkörper mit konvexer Oberfläche. Kugelförmige Stützkörper lassen sich dabei vorteilhaft einfach handhaben, da unabhängig von der Positio- nierung der Kugel gegenüber der in Entstehung befindlichenAccording to another embodiment of the invention, it is provided that the support body has a surface which has the shape of a sphere or a sphere section. These shapes of the support bodies belong to the group of support bodies with a convex surface. Spherical support bodies can be advantageously handled easily, since regardless of the positioning of the ball with respect to the originating
Wandung des Bauteils immer derselbe Krümmungsradius zur Stützung zur Verfügung steht. Gemäß einer anderen Ausgestaltung ist der Stützkörper mit konkaver Oberfläche ausgebildet, wobei auch diese konkave Oberfläche vorteilhaft die eines Ku- gelabschnitts bilden kann. Wall of the component always the same radius of curvature is available for support. According to another embodiment, the support body is formed with a concave surface, wherein also this concave surface can advantageously form the gelgelabschnitts a.
Auch an sich schwierig zu verarbeitende Materialien wie Titan und Tantal lassen sich vorteilhaft erfindungsgemäß mit dem Verfahren abscheiden. Dadurch können vorteilhaft auch diese Materialien einer breiteren Anwendung zugeführt werden. Even difficult to process materials such as titanium and tantalum can advantageously be deposited according to the invention with the method. As a result, these materials can advantageously also be supplied to a broader application.
Gemäß einer besonderen Ausgestaltung des Verfahrens ist vorgesehen, dass mehrere Stützkörper mit unterschiedlichen Krümmungsradien ihrer gekrümmten Oberfläche zur Verfügung ge- stellt werden. Diese können in dem Verfahren dann ausgewechselt werden, wobei sich vorteilhaft auf diesem Wege auch schalenförmige Bauteile herstellen lassen, bei denen die Krümmungradien der Schale lokal unterschiedlich sind (d. h. andere Formen als Kugelschalen) . Hierbei muss berücksichtigt werden, dass der Krümmungsradius des Stützkörpers nicht zu stark von dem gerade herzustellenden Krümmungsradius der Wandung abweichen darf, da der Stützeffekt ansonsten zu gering ausfällt . Besonders vorteilhaft ist es, wenn die Kaltspritzdüse According to a particular embodiment of the method, it is provided that a plurality of support bodies with different radii of curvature are provided on their curved surface. These can then be exchanged in the process, whereby shell-shaped components can advantageously also be produced in this way, in which the radii of curvature of the shell are locally different (that is to say shapes other than spherical shells). It must be taken into account here that the radius of curvature of the support body must not deviate too much from the radius of curvature of the wall which is just to be produced, since otherwise the support effect will be too low. It is particularly advantageous if the cold spray nozzle
und/oder der Stützkörper jeweils durch einen Roboterarm geführt werden. Durch Führung mittels eines Roboterarms können die Kaltspritzdüse sowie der Stützkörper vorteilhaft optimal gegeneinander ausgerichtet werden, wodurch sich die Vielfalt der herstellbaren Formen von schüsseiförmigen Bauteilen erhöht. Um eine möglichst raumunabhängige Führungsmöglichkeit für die Kaltspritzdüse und/oder den Stützkörper zu erreichen, kann der Roboterarm vorteilhaft jeweils mindestens drei Achsen aufweisen. Mehr Freiheitsgrade erhöhen selbstverständlich die geometrische Flexibilität des gesamten Systems. and / or the support body are each guided by a robot arm. By guiding by means of a robot arm, the cold spray nozzle and the support body can advantageously optimally be aligned with each other, which increases the variety of manufacturable shapes of bowl-shaped components. In order to achieve a space-independent possible guidance for Kaltspritzdüse and / or the support body, the robot arm can advantageously each have at least three axes. Of course, more degrees of freedom increase the geometric flexibility of the entire system.
Eine weitere Ausgestaltung der Erfindung erhält man, wenn als Startstruktur eine ringförmig geschlossene Struktur verwendet wird, die den Rand der Öffnung des schalenförmigen Bauteils definiert, wobei die Wandung des Bauteils ausgehend von der Startstruktur aufgebaut wird. Ringförmig geschlossen muss die Struktur deswegen sein, damit sie eine Umrandung der Öffnung des schalenförmigen Bauteils darstellt. Dies bedeutet jedoch nicht, dass diese Öffnung kreisringförmig sein muss. Unter ringförmig geschlossen ist im Sinne der Erfindung lediglich zu verstehen, dass die Startstruktur länglich ausgebildet ist und keinen Anfang und kein Ende aufweist. A further embodiment of the invention is obtained when the starting structure used is an annularly closed structure which defines the edge of the opening of the cup-shaped component, the wall of the component being constructed starting from the starting structure. The structure must be ring-shaped so that it forms a border of the opening of the cup-shaped component. However, this does not mean that this opening must be circular. For the purposes of the invention, ring-shaped closure is merely to be understood as meaning that the starting structure is elongate and has no beginning and no end.
Vorteilhaft kann die Startstruktur auch als ringförmig geschlossene Struktur auf einer Unterlage durch Kaltgasspritzen hergestellt werden. Diese bildet dann den Rand der Öffnung des schalenförmigen Bauteils und die Wandung wird ausgehend von der Startstruktur durch Kaltgasspritzen aufgebaut. Die hiermit verbundenen Vorteile sind vorstehend bereits beschrieben worden. Zusätzlich ergibt sich der Vorteil, dass die Unterlage besser zur Abscheidung von Material durch Kaltgasspritzen geeignet ist, als der Stützkörper, der an sich schwer zu beschichten ist, damit die Partikel beim Stützen der herzustellenden Wandung nicht an diesem haften bleiben. Advantageously, the starting structure can also be produced as an annularly closed structure on a base by cold gas spraying. This then forms the edge of the opening of the cup-shaped component and the wall is constructed starting from the starting structure by cold gas spraying. The associated advantages have already been described above. In addition, there is the advantage that the pad is better suited for the separation of material by cold gas spraying, as the support body, which is difficult to coat in itself, so that the particles do not adhere to the supporting the wall to be produced on this.
Die auf die eingangs angegebene Herstellungsanlage gerichtete Aufgabe wird erfindungsgemäß dadurch gelöst, dass die Her- Stellungsanlage einen Stützkörper aufweist, der eine konvex oder konkav gekrümmte Oberfläche aufweist und relativ zur Aufnahme beweglich ist. Die mit der Anwendung eines solchen Stützkörpers verbundenen Vorteile sind im Zusammenhang mit dem oben beschriebenen Verfahren bereits erwähnt worden. Die freie Beweglichkeit des Stützkörpers sowie der Kaltspritzdüse stellen sicher, dass die Bewegung dieser beiden Elemente synchronisiert werden kann, um lokal den Auftrag von Partikeln auf den Saum des in Herstellung befindlichen Bauteils zu stützen. Zu bemerken ist im Zusammenhang mit der Herstellungsanlage, dass die relative Beweglichkeit zwischen der Haltevorrichtung für das herzustellende Bauteil, der Kaltspritzdüse sowie des Stützkörpers nicht unbedingt durch eine Bewegung von Kaltspritzdüse und Stützkörper alleine, sondern auch durch eine Bewegung des Bauteils in der Haltevorrichtung bewerkstelligt werden kann. Insbesondere bei rotationssymmetrischen Bauteilen bietet sich beispielsweise an, dass das schüsseiförmige Bauteil um seine Rotationsachse gedreht wird. Dann müssen die Kaltspritzdüse sowie der Stützkörper nur noch Schwenkbewegungen in einer Ebene ausführen. Abhängig vom Anwendungsfall kann die Konstruktion der Herstellungsanlage also vereinfacht werden. Erkauft wird diese Vereinfachung aber durch eine geringere geometrische Flexibilität der Herstel- lungsanlage. Hierbei muss ein technischer Kompromiss gefunden werden . The object directed to the production plant specified at the outset is achieved according to the invention in that the production plant has a support body which has a convexly or concavely curved surface and is movable relative to the receptacle. The advantages associated with the use of such a support body are associated with already mentioned above. The free mobility of the support body and the cold spray nozzle ensure that the movement of these two elements can be synchronized to locally support the deposition of particles on the seam of the component being manufactured. It should be noted in connection with the manufacturing plant, that the relative mobility between the holding device for the component to be manufactured, the cold spray nozzle and the support body can not necessarily be accomplished by a movement of cold spray nozzle and support body alone, but also by a movement of the component in the holding device , In particular, in the case of rotationally symmetrical components, it is, for example, advisable for the bowl-shaped component to be rotated about its axis of rotation. Then the cold spray nozzle and the support body have to perform only pivotal movements in a plane. Depending on the application, the construction of the manufacturing plant can thus be simplified. However, this simplification is paid for by the lower geometric flexibility of the manu- facturing plant. Here, a technical compromise must be found.
Gemäß einer vorteilhaften Ausgestaltung der erfindungsgemäßen Herstellungsanlage kann der Stützkörper an einem Roboterarm befestigt werden. Genauso kann gemäß einer anderen Ausgestaltung dieser Herstellungsanlage die Kaltspritzdüse an einem Roboterarm befestigt werden. Hierdurch lässt sich vorteilhaft eine vergleichsweise hohe Flexibilität der Herstellungsanlage erreichen. Insbesondere, wenn die Roboterarme mehrere According to an advantageous embodiment of the manufacturing plant according to the invention, the support body can be attached to a robot arm. Likewise, according to another embodiment of this manufacturing plant, the cold spray nozzle can be attached to a robot arm. As a result, a comparatively high flexibility of the production plant can advantageously be achieved. In particular, if the robot arms more
rotatorische Freiheitsgrade haben (3 oder mehr) , kann einehave rotational degrees of freedom (3 or more), one can
Freiformfläche beliebiger Geometrie vorteilhaft ohne größeren Rüstaufwand der Herstellungsanlage hergestellt werden. Freiformfläche arbitrary geometry can be advantageously produced without major setup effort of the manufacturing plant.
Weitere Einzelheiten der Erfindung werden nachfolgend anhand der Zeichnung beschrieben. Gleiche oder sich entsprechende Zeichnungselemente sind jeweils mit den gleichen Bezugszeichen versehen und werden nur insoweit mehrfach erläutert, wie sich Unterschiede zwischen den einzelnen Figuren ergeben. Es zeigen : Further details of the invention are described below with reference to the drawing. Identical or corresponding drawing elements are each provided with the same reference numerals and will only be explained several times as far as There are differences between the individual figures. Show it :
Figur 1 und 2 ausgewählte Schritte eines Ausführungsbei - spiels des erfindungsgemäßen Verfahrens in geschnittener Darstellung, FIGS. 1 and 2 show selected steps of an embodiment of the method according to the invention in a sectional representation,
Figur 3 bis 5 ausgewählte Fertigungsschritte eines anderen Figure 3 to 5 selected production steps of another
Ausführungsbeispiels des erfindungsgemäßen Verfahrens, teilweise in dreidimensionaler und teilweise in geschnittener Darstellung,  Embodiment of the method according to the invention, partly in three-dimensional and partially in section,
Figur 6 ein weiteres Ausführungsbeispiel des erfindungsgemäßen Verfahrens in Schnittdarstellung und Figure 6 shows another embodiment of the method according to the invention in a sectional view and
Figur 7 ein schematisches Ausführungsbeispiel der erfindungsgemäßen Herstellungsanlage im schema- tischem Schnitt. Figure 7 shows a schematic embodiment of the manufacturing plant according to the invention in a schematic section.
In Figur 1 ist zu erkennen, wie das erfindungsgemäße Verfahren gestartet wird. Zu diesem Zweck ist eine Startstruktur IIa vorgesehen, die ringförmig ausgebildet ist und den Rand einer herzustellenden Öffnung 12 eines noch nicht zu erken- nenden, herzustellenden schalenförmigen Bauteils bildet. Die Startstruktur IIa ist mit einer Haltevorrichtung 13 fixiert. FIG. 1 shows how the method according to the invention is started. For this purpose, a starting structure IIa is provided, which is of annular design and forms the edge of an opening 12 to be produced of a cup-shaped component which is not yet to be recognized. The starting structure IIa is fixed with a holding device 13.
Um die Wandung des herzustellenden Bauteils zu erzeugen, wird eine Kaltspritzdüse 14, die an einem Roboterarm 15 befestigt ist, auf den Rand der Startstruktur IIa gerichtet. Gleichzeitig wird ein kugelförmiger Stützkörper 16 von der anderen Seite mit einem weiteren Roboterarm 15b an den Rand der To create the wall of the component to be manufactured, a cold spray nozzle 14, which is fastened to a robot arm 15, is directed onto the edge of the starting structure IIa. At the same time a spherical support body 16 from the other side with a further robot arm 15 b to the edge of the
Startstruktur IIa herangeführt. Hierdurch wird lokal eine Stützung der im Aufbau befindlichen Wandung des herzustellen- den Bauteils erreicht, und zwar genau an der Auftreffstelle eines Kaltgasstrahls 17, der die von der Kaltspritzdüse 14 beschleunigten Partikel enthält. In Figur 2 ist ausschnitthaft zu erkennen, wie eine Wandung 18 des herzustellenden Bauteils 19 entsteht. Es ist zu erkennen, dass der Stützkörper 16 derart nachgeführt wird, dass er sich immer an der Auftreffstelle des Kaltgasstrahls 17 befin- det . Dieser wird auf den Saum 20 der in Herstellung befindlichen Wandung 18 gerichtet und trifft in der in Figur 2 dargestellten Variante genau in einem Winkel von 90° auf den Saum 20. Der Spritzwinkel liegt insofern bei 0°. Allerdings kann dieser, wie durch den Kaltspritzkegel 21 angedeutet, auch von den dargestellten 0° abweichen, solange dieser innerhalb des Kaltspritzkegels 21 liegt. Starting structure IIa introduced. As a result, local support for the wall of the component to be produced is achieved, specifically at the point of impact of a cold gas jet 17, which contains the particles accelerated by the cold spray nozzle 14. In FIG. 2 it can be seen in section how a wall 18 of the component 19 to be produced arises. It can be seen that the support body 16 is tracked in such a way that it is always located at the point of impact of the cold gas jet 17. This is directed to the seam 20 of the wall 18 being produced and, in the variant shown in FIG. 2, strikes the seam 20 exactly at an angle of 90 °. The spraying angle is therefore 0 °. However, this can, as indicated by the cold spray cone 21, also deviate from the illustrated 0 °, as long as it is within the cold spray cone 21.
Weiterhin ist zu erkennen, dass sich der Stützkörper 16 derart an die konkave Innenseite der Wandung 18 anschmiegt, dass im Bereich des Saums 20 eine tangentiale Berührung der Wandung 18 mit der Oberfläche des Stützkörpers 16 erfolgt. Dabei ist die Ausrichtung des Saums in Bezug auf eine auf der Oberfläche des Stützkörpers 16 stehenden Normalen 22 um den Winkel ß geneigt, wobei der Winkel ß gering genug gewählt wird, damit eine Ausrichtung des Kaltstrahls 17 außerhalb des Furthermore, it can be seen that the support body 16 conforms to the concave inner side of the wall 18 in such a way that in the region of the seam 20 a tangential contact of the wall 18 with the surface of the support body 16 takes place. In this case, the orientation of the seam with respect to a standing on the surface of the support body 16 normal 22 is inclined by the angle ß, the angle ß is chosen low enough so that an alignment of the cold jet 17 outside of
(nicht dargestellten) Spritzkegels auf der Oberfläche des Stützkörpers liegt ( ß kann auch Null betragen) . Damit wird vermieden, dass Partikel auf der Oberfläche des Stützkörpers abgeschieden werden.  (not shown) spray cone on the surface of the support body is (ß can also be zero). This avoids that particles are deposited on the surface of the support body.
In Figur 3 ist zu erkennen, wie eine Startstruktur IIb auf einer Unterlage 24 in Form eines flachen Tisches hergestellt wird. Hierbei wird der Kaltgasstrahl 17 auf diese Unterlage 24 gerichtet und so die ringförmige Startstruktur herge- stellt. Diese besteht vorteilhaft bevorzugt aus demselben Material wie die herzustellende Wandung. In der Mitte der Unterlage ist ein Loch 25 vorgesehen, durch das die Stützstruktur 16 (vgl. Figur 5) in die Vertiefung 26 des schalenförmigen Bauteils 19 eingeführt werden kann. FIG. 3 shows how a starting structure IIb is produced on a base 24 in the form of a flat table. In this case, the cold gas jet 17 is directed onto this base 24 and thus produces the annular starting structure. This advantageously consists preferably of the same material as the wall to be produced. In the middle of the base, a hole 25 is provided, through which the support structure 16 (see Figure 5) can be inserted into the recess 26 of the cup-shaped member 19.
In Figur 4 ist zu erkennen, dass die dort zur Anwendung kommende Stützstruktur 16 die Form einer Halbkugel aufweist, damit diese an den Saum 20 herangeführt werden kann, ohne dass die Unterlage 24 dabei stört. Ansonsten erfolgt die Herstellung der Wandung gemäß Figur 4 in der zu Figur 2 bereits beschriebenen Weise. In Figur 5 ist zu erkennen, wie das Bauteil 19 kurz vor dessen endgültiger Fertigstellung hergestellt wird. Die WandungIt can be seen in FIG. 4 that the support structure 16 used there has the shape of a hemisphere so that it can be brought to the seam 20 without the pad 24 disturbs. Otherwise, the wall according to FIG. 4 is produced in the manner already described for FIG. 2. In Figure 5 it can be seen how the component 19 is made shortly before its final completion. The wall
18 ist bereits fast geschlossen, wobei der Stützkörper 16 mit dem Roboterarm 15b durch das Loch 25 an die letzte offene Stelle der Wandung herangeführt wird. Die Stützstruktur 16 vermag das verbleibende offene Areal der Wandung komplett zu verschließen, so dass mittels des Kaltgasstrahls 17 dieses Loch geschlossen werden kann. Anschließend kann das Bauteil18 is already almost closed, wherein the support body 16 is brought with the robot arm 15b through the hole 25 to the last open position of the wall. The support structure 16 is able to completely close the remaining open area of the wall, so that this hole can be closed by means of the cold gas jet 17. Then the component can
19 in nicht dargestellter Weise beispielsweise durch Drahterodieren von der Unterlage 24 getrennt werden. 19 are separated in a manner not shown, for example, by wire erosion of the pad 24.
In Figur 6 ist ein konkaver Stützkörper 16 dargestellt, der von außen an die Wandung 18 des nicht näher dargestellten herzustellenden Bauteils herangeführt wird. Es ist zu erkennen, dass der Krümmungsradius des konkaven Stützkörpers 16 nur so groß sein kann, dass der Kaltgasstrahl 17 noch an den Saum 20 des Bauteils herangeführt werden kann. Daher eignet sich ein konkaver Stützkörper bevorzugt für die Herstellung großer Radien, die durch eine Heranführung des Stützkörpers von innen erschwert werden würde . FIG. 6 shows a concave supporting body 16, which is guided from the outside against the wall 18 of the component to be produced which is not shown in any more detail. It can be seen that the radius of curvature of the concave support body 16 can only be so great that the cold gas jet 17 can still be brought to the seam 20 of the component. Therefore, a concave support body is preferably suitable for the production of large radii, which would be made difficult by an approach of the support body from the inside.
In Figur 7 lässt sich das Ausführungsbeispiel der erfindungsgemäßen Herstellungsanlage erkennen. Die Herstellungsanlage weist ein Gehäuse 27 auf, damit diese mit einem Schutzgas befüllt werden kann. In dem Gehäuseraum sind zwei Roboter 28a, 28b angeordnet, die die Roboterarme 15a, 15b aufweisen. An dem Roboterarm 15a ist die Kaltspritzdüse 14 befestigt, die über eine flexible Leitung 29 mit einer Kaltspritzanlage 30 verbunden ist. Die Haltevorrichtung 13 ermöglicht die Aufnahme einer Startstruktur (nicht dargestellt) . Diese kann bei einer Herstellung der Wandung gemäß den bereits beschriebenen Verfahren über die Stützstruktur 16 gestützt werden, die mittels des Roboters 28b in geeigneter Weise nachgeführt wird. Sollte das herzustellende Bauteil Bereiche unterschiedlicher Durchmesser aufweisen, so sind weitere Stützkörper 16 in einem Magazin 31 vorgesehen. Dieses Magazin 31 kann von dem Roboterarm 15b angefahren werden, damit die Stützkörper 16 ausgewechselt werden können. In Figure 7, the embodiment of the manufacturing plant according to the invention can be seen. The manufacturing plant has a housing 27 so that it can be filled with a protective gas. In the housing space, two robots 28a, 28b are arranged, which have the robot arms 15a, 15b. Attached to the robot arm 15a is the cold spray nozzle 14, which is connected to a cold spray system 30 via a flexible conduit 29. The holding device 13 allows the inclusion of a starting structure (not shown). This can be supported in a production of the wall according to the methods already described on the support structure 16, which is tracked by means of the robot 28b in a suitable manner. If the component to be manufactured ranges differently Have diameter, so more support body 16 are provided in a magazine 31. This magazine 31 can be approached by the robot arm 15b, so that the support body 16 can be replaced.

Claims

Patentansprüche claims
1. Verfahren zum Erzeugen eines schalenförmigen Bauteils (19) mit einer Wandung (18) und einer zu einer Öffnung (12) hin offenen Vertiefung, 1. A method for producing a cup-shaped component (19) having a wall (18) and a recess open to an opening (12),
d a d u r c h g e k e n n z e i c h n e t, characterized,
dass dieses Bauteil (19) durch Kaltgasspritzen hergestellt wird, wobei that this component (19) is produced by cold gas spraying, wherein
- ein Stützkörper (16) mit einer gekrümmten Oberfläche aus einem Material zur Verfügung gestellt wird, auf dem die Partikel des Kaltgasstahls (17) nicht haften bleiben, a support body (16) having a curved surface made of a material is provided on which the particles of the cold gas steel (17) do not adhere,
- eine Startstruktur (IIb) auf der Oberfläche temporär fixiert wird, a temporary structure (IIb) is temporarily fixed on the surface,
- das Bauteil durch einen Materialauftag aus dem Kaltgasstrahl (17) jeweils an den Saum (20) des in Entstehung befindlichen Bauteils (19) hergestellt wird, wobei der Stützkörper (IIa, IIb) und der Kaltgasstrahl (21) synchron derart bewegt werden, dass der Kaltgasstrahl (17) in einem Winkel innerhalb des Kaltspritzkegels (21) auf den Saum (20) auftrifft und der Stützkörper (IIa, IIb) das in Entstehung befindliche Bauteil (19) im Auftreffpunkt des Kaltgasstrahls (17) stützt.  - The component is produced by a Materialauftag from the cold gas jet (17) respectively to the seam (20) of the component (19) being formed, wherein the support body (IIa, IIb) and the cold gas jet (21) are moved synchronously such that the cold gas jet (17) strikes the seam (20) at an angle within the cold spray cone (21), and the support body (IIa, IIb) supports the component (19) being formed at the point of impact of the cold gas jet (17).
2. Verfahren nach Anspruch 1, 2. The method according to claim 1,
d a d u r c h g e k e n n z e i c h n e t, characterized,
dass ein schüsseiförmiges Bauteil (19) hergestellt wird. a bowl-shaped component (19) is produced.
3. Verfahren nach einem der voranstehenden Ansprüche, 3. Method according to one of the preceding claims,
d a d u r c h g e k e n n z e i c h n e t, characterized,
dass als Bauteil (19) eine Elektrodenschale eines Teilchenbeschleunigers hergestellt wird. in that as component (19) an electrode shell of a particle accelerator is produced.
4. Verfahren nach einem der voranstehenden Ansprüche, 4. Method according to one of the preceding claims,
d a d u r c h g e k e n n z e i c h n e t, characterized,
dass der Stützkörper (IIa, IIb) aus einem Hartmetall besteht. that the supporting body (IIa, IIb) consists of a hard metal.
5. Verfahren nach einem der voranstehenden Ansprüche, 5. The method according to any one of the preceding claims,
d a d u r c h g e k e n n z e i c h n e t, dass der Stützkörper (IIa, IIb) eine Oberfläche aufweist, die die Form einer Kugel oder eines Kugelabschnittes aufweist. characterized, in that the support body (IIa, IIb) has a surface which has the shape of a sphere or a sphere section.
6. Verfahren nach einem der voranstehenden Ansprüche, d a d u r c h g e k e n n z e i c h n e t, 6. The method according to one of the preceding claims, d a d u c h e c e n e c e n e,
dass das der Stützkörper (16) konkav ausgebildet ist. in that the support body (16) is concave.
7. Verfahren nach einem der voranstehenden Ansprüche, d a d u r c h g e k e n n z e i c h n e t, 7. Method according to one of the preceding claims, characterized in that
dass als Material Titan oder Tantal verarbeitet wird. that as material titanium or tantalum is processed.
8. Verfahren nach einem der voranstehenden Ansprüche, d a d u r c h g e k e n n z e i c h n e t, 8. Method according to one of the preceding claims, characterized in that
dass mehrere Stützkörper (16) mit unterschiedlichen Krüm- mungsradien ihrer gekrümmten Oberfläche zur Verfügung gestellt werden. that a plurality of support bodies (16) with different curvature radii are provided on their curved surface.
9. Verfahren nach einem der voranstehenden Ansprüche, d a d u r c h g e k e n n z e i c h n e t, 9. Method according to one of the preceding claims, characterized in that
dass die Kaltspritzdüse (14) und/oder der Stützkörper (16) jeweils durch einen Roboterarm (15a, 15b) geführt werden. in that the cold spray nozzle (14) and / or the support body (16) are each guided by a robot arm (15a, 15b).
10. Verfahren nach einem der voranstehenden Ansprüche, d a d u r c h g e k e n n z e i c h n e t, 10. The method according to one of the preceding claims, d a d u c h e c e n e c e n e,
dass als Startstruktur (IIa, IIb) eine ringförmig geschlossene Struktur verwendet wird, die den Rand der Öffnung (12) des schalenförmigen Bauteils (19) definiert und dass die Wandung (18) des Bauteils (19) ausgehend von der Startstruktur (IIa, IIb) aufgebaut wird. in that the starting structure (IIa, IIb) used is an annularly closed structure which defines the edge of the opening (12) of the cup-shaped component (19) and in that the wall (18) of the component (19) starts from the starting structure (IIa, IIb ) is constructed.
11. Verfahren nach einem der Ansprüche 1 bis 9, 11. The method according to any one of claims 1 to 9,
d a d u r c h g e k e n n z e i c h n e t, characterized,
dass die Startstruktur (IIb) als ringförmig geschlossene Struktur auf einer Unterlage (24) durch Kaltgasspritzen her- gestellt wird und den Rand der Öffnung (12) des schalenförmigen Bauteils (19) definiert und dass die Wandung (18) des Bauteils (19) ausgehend von der Startstruktur (IIa, IIb) aufgebaut wird. the starting structure (IIb) is produced as an annularly closed structure on a base (24) by cold gas spraying and defines the edge of the opening (12) of the cup-shaped component (19) and that the wall (18) of the component (19) starts from the start structure (IIa, IIb) is established.
12. Herstellungsanlage für ein Bauteil, aufweisend eine Kalt spritzdüse (14) , und eine Haltevorrichtung (13) für das Bauteil, wobei die Kaltspritzeinrichtung und die Aufnahme relativ zueinander beweglich sind, 12. A production line for a component, comprising a cold spray nozzle (14), and a holding device (13) for the component, wherein the cold spray device and the receptacle are movable relative to each other,
d a d u r c h g e k e n n z e i c h n e t, characterized,
dass die Herstellungsanlage außerdem einen Stützkörper aufweist, der eine konvex oder konkav gekrümmte Oberfläche aufweist und relativ zur Aufnahme beweglich ist. that the manufacturing plant also comprises a support body having a convexly or concavely curved surface and movable relative to the receptacle.
13. Herstellungsanlage nach Anspruch 12 13. Production plant according to claim 12
d a d u r c h g e k e n n z e i c h n e t, characterized,
dass der Stützköper (16) an einem Roboterarm (15a, 15b) befestigt ist. in that the supporting body (16) is fastened to a robot arm (15a, 15b).
14. Herstellungsanlage nach einem der Ansprüche 12 oder 13, d a d u r c h g e k e n n z e i c h n e t, 14. Manufacturing plant according to one of claims 12 or 13, d a d e r c h e c e n e c e n e,
dass die Kaltspritzdüse (14) an einem Roboterarm (15a, 15b) befestigt ist. in that the cold spray nozzle (14) is fastened to a robot arm (15a, 15b).
EP14728101.8A 2013-05-22 2014-05-12 Method for producing a shell-shaped component and production system suitable for the use of said method Active EP2981381B1 (en)

Applications Claiming Priority (3)

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DE102013209477 2013-05-22
DE102013216439.4A DE102013216439A1 (en) 2013-05-22 2013-08-20 Method for producing a cup-shaped component and production plant suitable for the use of this method
PCT/EP2014/059612 WO2014187688A1 (en) 2013-05-22 2014-05-12 Method for producing a shell-shaped component and production system suitable for the use of said method

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DE102013216439A1 (en) 2013-05-22 2014-11-27 Siemens Aktiengesellschaft Method for producing a cup-shaped component and production plant suitable for the use of this method
BR112017025844A2 (en) * 2015-06-11 2018-08-14 Effusiontech Pty Ltd apparatus for forming a 3d object from dust and its use
WO2017210718A1 (en) * 2016-06-06 2017-12-14 Effusiontech Pty Ltd Apparatus for forming 3d objects
WO2018068082A1 (en) * 2016-10-11 2018-04-19 Effusiontech Pty Ltd A method of forming 3d objects.
WO2020038927A1 (en) * 2018-08-21 2020-02-27 Sascha Larch Method for producing a light-weight pressure container forming a light-weight pressure tank, and light-weight pressure container

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US20160107231A1 (en) 2016-04-21
EP2981381B1 (en) 2019-03-13

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