EP3160681A1 - Procédé et dispositif de contrôle de la qualité d'au moins un composant pendant la production de celui-ci au moyen d'au moins un procédé de fabrication additive - Google Patents

Procédé et dispositif de contrôle de la qualité d'au moins un composant pendant la production de celui-ci au moyen d'au moins un procédé de fabrication additive

Info

Publication number
EP3160681A1
EP3160681A1 EP15733608.2A EP15733608A EP3160681A1 EP 3160681 A1 EP3160681 A1 EP 3160681A1 EP 15733608 A EP15733608 A EP 15733608A EP 3160681 A1 EP3160681 A1 EP 3160681A1
Authority
EP
European Patent Office
Prior art keywords
component
layer
crack
heat treatment
energy source
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Withdrawn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
EP15733608.2A
Other languages
German (de)
English (en)
Inventor
Günter Zenzinger
Thomas Hess
Joachim Bamberg
Alexander Ladewig
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 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 MTU Aero Engines AG filed Critical MTU Aero Engines AG
Publication of EP3160681A1 publication Critical patent/EP3160681A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
    • B41J2/435—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by selective application of radiation to a printing material or impression-transfer material
    • B41J2/475—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by selective application of radiation to a printing material or impression-transfer material for heating selectively by radiation or ultrasonic waves
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/364—Process control of energy beam parameters for post-heating, e.g. remelting
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • 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
    • B22F12/00—Apparatus 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
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/03—Observing, e.g. monitoring, the workpiece
    • B23K26/034—Observing the temperature of the workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N25/00—Investigating or analyzing materials by the use of thermal means
    • G01N25/72—Investigating presence of flaws
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/0002—Inspection of images, e.g. flaw detection
    • G06T7/0004—Industrial image inspection
    • G06T7/0008—Industrial image inspection checking presence/absence
    • 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
    • B22F12/00—Apparatus 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
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B22F12/45—Two or more
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/10—Image acquisition modality
    • G06T2207/10048—Infrared image
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/30—Subject of image; Context of image processing
    • G06T2207/30108—Industrial image inspection
    • G06T2207/30164—Workpiece; Machine component
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to a method for quality assurance of at least one component during its production according to the preamble of patent claim 1 and an apparatus for carrying out the method.
  • Laser thermography methods are known from the prior art which are used as non-destructive testing methods (ZFP methods) for detecting cracks in components.
  • ZFP methods non-destructive testing methods
  • the cooling of the surface of the component to be tested is recorded with a laser thermography camera.
  • this is associated with limitations, since the component to be tested must be housed for laser safety reasons. Due to the high energy of the laser, there is a considerable heating of the surface of the component to be tested. For the examination of the component, the manufacturing process must be interrupted in a generative manufacturing process. For the heating of the component, a second energy source is required.
  • the invention is therefore based on the object to provide a method that allows a non-destructive crack test of a metallic component during the manufacturing process (testing by means of an online method) in a generative manufacturing process.
  • the object is achieved in a method for quality assurance of at least one component during its production, the production taking place by means of at least one additive manufacturing method, comprising the following steps:
  • thermographing at least one image of each individual layer applied At least some of the applied layers are subjected before the thermografi recording of the associated image of a controlled heat treatment below the melting temperature of the component material, wherein the heat treatment emanating from the last layer applied thermal radiation causes the occurrence of at least one crack in the layer a characteristic heat history Having crack, wherein the heat history and thus the crack is made visible by means of the associated thermographic recording.
  • a characteristic heat profile at the crack is understood to mean a heat distribution, which arises in particular due to the interruption of the material at the crack.
  • the thermography device is in particular a laser-free or laser-independent thermography device in which no heating of the component takes place by the thermography device.
  • each individual layer is subjected to such a treatment.
  • the controlled heat treatment generates heat radiation in the layer, which lies in the infrared region at the edge of the visible spectrum and in the detection spectrum of a thermography device. It is thus carried out a reduced heat input, which raises the temperature in the layer locally to a level at which heat radiation in the near infrared is emitted, without causing re-melting occurs.
  • the heat radiation comes so close to the edge of the visible spectrum that a high-resolution thermography device can detect the heat distribution.
  • at least one energy source required for the additive manufacturing process in particular a laser, effects the heat treatment. In this case, no further energy source is required except the energy source for the generative manufacturing process.
  • At least one energy source effects the heat treatment, which is independent of the generative manufacturing process.
  • a division of the functions of the generative manufacturing process and the heat treatment takes place.
  • the additive manufacturing process may be a selective laser melting and / or a selective laser sintering. These methods are particularly well suited for the additive production of metallic components.
  • the crack is corrected by reflowing the cracked layer.
  • the quality of the layer is not only tested, but also secured or guaranteed.
  • the images recorded by the thermography device are analyzed and, upon detection of the crack, a signaling device is activated and / or a remelting of the cracked layer is triggered.
  • a signaling device is activated and / or a remelting of the cracked layer is triggered.
  • These method steps can be purely manual, fully automatic or partially automatic or partially manual.
  • the activation of the signaling device may alert an operator when a crack is detected. The operator can then interrupt the generative production of the component and set the energy source for the generative manufacturing process so that the cracked layer is remelted again. Alternatively, the remelting of the cracked layer can be triggered automatically. In addition, an alarm signal can be generated.
  • the device comprises at least one energy source, by means of which the controlled heat treatment of each individual layer is feasible.
  • the energy source must be specially designed for it to perform the controlled heat treatment. This feature enables quality assurance.
  • the energy source of the generative manufacturing device is at the same time the energy source for the controlled heat treatment. For example, can be used for the heat treatment of the already existing in the generative manufacturing device laser, so that a further energy source is not required. This achieves a thermography test without additional integration of further energy sources and recording systems in the generative manufacturing facility.
  • the energy source of the generative manufacturing device is independent of the energy source for the controlled heat treatment. This makes the easy retrofitting of existing systems possible.
  • thermography device comprises a high-resolution image recording device and / or an image recording device sensitive to infrared rays, which is based in particular on CCD, CMOS or sCMOS sensors.
  • image pickup devices are well suited for thermographic recording. This achieves a fast, extremely high-resolution thermography test with all the advantages of this test technique.
  • the component may be arranged without housing in the generative manufacturing device. This only allows the execution of the component inspection in an online process.
  • the component to be tested must be housed for laser safety reasons.
  • the high laser energy leads to an uncontrolled and undesired strong heating of the test surface.
  • the device comprises at least one display device, at least one
  • Evaluation device at least one signaling device for reporting a crack and at least at least one control of the power source of the generative manufacturing device.
  • the recordings recorded by the thermography device can be displayed optically on the display device.
  • the evaluation device is used for data processing.
  • the signaling device may alert an operator when a crack is detected. The operator can then interrupt the generative production of the component and control the energy source for the generative manufacturing process in such a way that the cracked layer is remelted again. Alternatively, the remelting of the layer by means of the control of the energy source for the generative manufacturing process can be triggered automatically by the evaluation device.
  • the signaling device can be activated.
  • FIG. 1 is a perspective view of a detail of a device according to the invention
  • Fig. 2 is a schematic side view of the device according to the invention shown in FIG. 1,
  • FIG. 3 shows a thermographic image of the respective uppermost layer of several components during the implementation of the method according to the invention
  • FIG. 4 shows a perspective enlargement of the detail IV
  • FIG. 4 shows a perspective enlargement of the detail IV
  • Fig. 5 is a schematic diagram of the device according to the invention.
  • FIG. 1 shows a perspective view of a section of a device 10 according to the invention, which comprises a generative production device 12 for producing a component 14.
  • a generative production device 12 for producing a component 14.
  • Fig. 1 will be explained below in conjunction with Fig. 2, in which a schematic side view of the device 10 according to the invention shown in FIG. 1 is shown.
  • the device 10 serves to carry out a method for quality assurance of a component 14 during its manufacture.
  • the generative production device 12 itself is designed as a selective laser melting system (SLM) known per se, ie a laser 22 is the energy source for the melting process. The laser is directed downwards, so that the component 14 can be produced from the bottom to the top in layers to be applied one above the other.
  • a thermography device 18 is arranged outside a construction space 16 (FIG.
  • thermography device 18 is directed onto the respectively uppermost layer of the component 14, wherein the detection angle of the thermography device 18 covers the installation space 16 so that the entire uppermost layer of the component 14 can be detected.
  • the thermography device is arranged in a vertical plane, which in this case corresponds to the image plane in FIG. 2, between the laser 22 and the outer boundaries of the installation space 16. As a result, an optical distortion that might arise in a too inclined thermography device avoided.
  • a laser protection glass 20 (FIG.
  • thermography device 18 is arranged in order to prevent damage to a sCMOS sensor of the camera by a laser 22 of the generative production device 12.
  • the thermography device 18 is thus located above the installation space 16 and outside the beam path II of the laser 22 of the generative production device 12. This ensures that the thermography device 18 is not located in the beam path II and that the laser 22 accordingly no energy losses through optical elements like semitransparent mirrors, grids or the like. Furthermore, the thermography device 18 does not affect the manufacturing process of the component 14 and is also easily replaceable or retrofittable.
  • the thermography device 18 here comprises an IR-sensitive sMOS camera with 5.5 megapixels and a refresh rate of 100 Hz.
  • a color sensor or a sensor with a broad spectral range provides comparatively more information, which allows a correspondingly more accurate assessment of the uppermost layer of the component 14.
  • thin powder layers of a high-temperature-resistant metal alloy are applied in a manner known per se to a platform (not shown) of the generative production device 12, locally melted by means of the laser 22 and solidified by cooling. Subsequently, the platform is lowered, applied a further powder layer and solidified again. This cycle is repeated until the component 14 is produced.
  • An exemplary component 14 consists of up to 2000 component layers and has a total layer height of 40 mm. The finished component 14 can then be further processed or used immediately.
  • the respectively uppermost layer of the component 14 is subjected to a heat treatment below the melting temperature of the component material.
  • This heat treatment causes thermal radiation emanating from the uppermost layer, which can be detected by means of a thermography device 18.
  • the heat radiation of the uppermost layer is adjusted so that it lies in the infrared region at the edge of the visible spectrum and also in the sensitivity range of the thermography device 18.
  • the energy source e.g.
  • the heat generated in the uppermost layer of the component 14 by the laser 22 or an additional energy source is determined in the form of a slice image 24 (see FIG.
  • the heat profile in the uppermost layer of the component 14 and optionally further information derived therefrom is subsequently visualized in a spatially resolved manner and coded, for example, via brightness values and / or colors by means of a display device 32 (FIG. 5).
  • thermography device 18 has no influence on the heat flow in the component 14 either during the additive production or during the examination of the component 14.
  • the optical thermography not only provides geometric information, but also information about the local temperature distribution in the relevant component layer. It can be provided in principle that the layer image 24 is composed of several individual images.
  • the layer image 24 depending on the surface of the space 16 be composed of up to 1000 individual images or more per component layer or from individual images, each of which between 0, 1 cm 2 and 1, 0 cm of the individual component layer image.
  • the exposure time per image is required between 1 ms and 5000 ms, preferably between 50 ms and 500 ms.
  • the distance covered by the laser beam per individual image is between 10 mm and 120 mm, for example 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 1 10 mm or 120 mm.
  • each layer image 24 is determined within 2 minutes in order to avoid excessive cooling of the component layers and a concomitant loss of information.
  • FIG. 3 shows, by way of example, a layer image 24 of a plurality of components 14, which are produced together in the installation space 16 of the production device 12 and are represented here as rotor blades for an aircraft engine, which are constructed in layers in a direction perpendicular to their longitudinal extent.
  • the layer image can be displayed, for example, on at least one display device 32 (FIG. 5). It can be seen that the layer image 24 images the entire space 16 without overlapping. From each component 14 as many detail sections can be increased. The maximum magnification of the detail sections depends on the resolution of the thermography device 18.
  • the reference numeral III a detail and the associated enlargement of this detail of one of the components 14 are characterized, wherein the corresponding component 14 has a schematically illustrated crack 30 in its uppermost layer.
  • the crack 30 may be a hot crack or a segmentation crack.
  • the reference numeral IV denotes a special section of the detail III, wherein the cutout IV includes the crack 30.
  • FIG. 4 shows an additional enlargement of the section IV in a schematic perspective detail view.
  • three layers 26, 28 of the component 14 are shown here.
  • the component 14 may also include more or fewer layers 26 depending on the current manufacturing state.
  • the two layers 26 shown here are crack-free layers whose cracks are detected by means of the thermography device 18 could, so that the manufacturing process was continued.
  • the uppermost layer of the component 14 is a cracked layer 28.
  • the course and the shape of the crack 30 are shown here only schematically. In the layer 28, more than one crack 30 may occur.
  • the crack can take any random form.
  • the length and width of the crack 30 may vary and be in the range of a few microns. These small dimensions can only be detected by means of the thermography device 18.
  • cracks 30 of this magnitude can only be brought into the optical detection range of the thermography device by the corresponding heat treatment described above.
  • the generative production can be continued. However, if the limits are reached or exceeded, the manufacturing process for the corresponding component 14 is prematurely terminated or the cracked layer 28 of the component 14 is corrected by reflow.
  • each layer 26, 28 is optically detected by means of the thermography device 18 and displayed on the display device 32.
  • the thermography device is in operative connection with at least one evaluation device 34 so that the recorded images can be sorted and stored there and, if necessary, an instruction for interrupting the generative production process of one or more components 14 having cracks can be triggered.
  • the evaluation device 34 is configured such that it can detect the crack 30 in the uppermost layer 28 of the component 14 with the aid of an algorithm.
  • these processes can also be carried out manually by evaluating the images or images of the thermography device 18 on the pointing device 32 by an operator.
  • the generative production process can be interrupted and the cracked layer 28 corrected by reflowing.
  • the remelting of the cracked layer 28 takes place, for example, in that the
  • Evaluation device 34 upon automatic detection of a crack 30 of the controller 38 of the Sers 22 gives a corresponding command for interrupting the generative manufacturing process and remelting.
  • the generative manufacturing process for a single or multiple cracked components 14 may be terminated prematurely. This is done by a command, which is triggered manually or by the evaluation device 34, to the controller 38 of the laser 22.
  • the premature termination of the generative manufacturing process is preferably carried out when the component 14 has only a small number of layers 26, 28. If the component 14 is already almost finished, the interruption and re-melting of the layer 28 is preferred.
  • the evaluation device 34 can also trigger an alarm in the form of acoustic or optical signals by means of a signal device 36, e.g. in the form of a warning message on the display device 32 or another computing device (not shown) connected to the generative manufacturing device 12. Then it can be decided by an operator whether and how the generative production of the components 14 is continued.
  • the evaluation device 34 and the signal device 36 including the required signal lines between the thermography device 18, the evaluation device, the signal device 36 and the controller 38 of the laser 22 generative manufacturing device 12 are components of the device 10th
  • the invention relates to a method for quality assurance of at least one component during its production, wherein the production takes place by means of at least one additive manufacturing method, comprising the following steps:
  • thermographing at least one image of each individual layer applied In order to enable a non-destructive crack test of a metallic component during the manufacturing process (testing by means of an on-line method), at least some of the applied layers are subjected to a controlled heat treatment below the melting temperature of the component material prior to the thermographic recording of the associated image, wherein the heat treatment a heat emanating from the last applied layer Radiation causes the occurrence of at least one crack in the layer has a characteristic heat history at the crack, the heat history and thus the crack is made visible by means of the associated thermographic recording.
  • each applied layer is subjected to such a treatment.

Abstract

L'invention concerne un procédé de contrôle de la qualité d'au moins un composant (14) pendant la production de celui-ci, la production étant effectuée au moyen d'au moins un procédé de fabrication additive qui comprend les étapes consistant à : élaborer le composant (14) par couches et effectuer un enregistrement thermographique d'au moins une image de chaque couche déposée. Pour effectuer un contrôle non destructif d'une pièce métallique (14) pour rechercher des fissures pendant le processus de fabrication (contrôle au moyen d'un processus en ligne), on soumet au moins certaines couches déposées, avant l'enregistrement thermographique de l'image associée, à un traitement thermique commandé au-dessous de la température de fusion du matériau du composant, le traitement thermique générant un rayonnement thermique émanant de la dernière couche déposée qui, lors de l'apparition d'au moins une fissure dans la couche, présente un profil thermique caractéristique au niveau de la fissure, le profil thermique, et donc la fissure, étant rendu visible au moyen de l'enregistrement thermographique associé. De préférence, chaque couche déposée est soumise à un tel traitement.
EP15733608.2A 2014-06-26 2015-04-29 Procédé et dispositif de contrôle de la qualité d'au moins un composant pendant la production de celui-ci au moyen d'au moins un procédé de fabrication additive Withdrawn EP3160681A1 (fr)

Applications Claiming Priority (2)

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DE102014212246.5A DE102014212246B3 (de) 2014-06-26 2014-06-26 Verfahren und Vorrichtung zur Qualitätssicherung
PCT/DE2015/000205 WO2015197038A1 (fr) 2014-06-26 2015-04-29 Procédé et dispositif de contrôle de la qualité d'au moins un composant pendant la production de celui-ci au moyen d'au moins un procédé de fabrication additive

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EP3160681A1 true EP3160681A1 (fr) 2017-05-03

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US (1) US20170136574A1 (fr)
EP (1) EP3160681A1 (fr)
DE (1) DE102014212246B3 (fr)
WO (1) WO2015197038A1 (fr)

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