EP3223980A1

EP3223980A1 - Additive production method using thicker powder layers, and component

Info

Publication number: EP3223980A1
Application number: EP16700568.5A
Authority: EP
Inventors: Christian Brunhuber; Thomas Soller; David Regnery
Original assignee: Siemens AG
Current assignee: Siemens Energy Global GmbH and Co KG
Priority date: 2015-01-30
Filing date: 2016-01-13
Publication date: 2017-10-04
Also published as: CN107206488B; CN107206488A; WO2016120069A1; DE102015201686A1; US20180001424A1

Abstract

The manufacturing rate of selective production methods is increased by using thicker powder layers (7, 10).

Description

Additive manufacturing process using thicker

Powder layers and component

The invention relates to a process or component in the field of additive manufacturing (AM), in which thick powder layers are used to accelerate the manufacturing process.

Beam melting techniques such as Selective Laser Melting (SLM) or Electron Beam Melting (EBM) are currently the technology of choice to fabricate complex gas turbine components, particularly torch parts. Due to the relatively small layer thicknesses of about 0.05 mm, which are due to the desired accuracy, and the time-consuming application of these thin layers by placement by means of a doctor blade or roller, resulting slow Baugeschwindig ^¬ speeds. The low construction speeds (-20 cm ³ / h) are the reason that currently many components can be konven ^¬ tionally cheaper manufactured.

Various technical solutions are proposed to speed up the process. Most manufacturers try to shorten the construction speeds by large laser powers and by integration of several lasers (multi-beam). However, this procedure increases the risk of thermo-mechanically induced stresses and distortions in the component.

It is therefore an object of the invention to solve the above-mentioned problem.

The object is achieved by a method according to claim 1 and a component according to claim 9.

In the dependent claims further advantageous measures are listed, which are combined with each other Kings ^¬ nen to obtain further advantages. Figures 1 to 4 show embodiments of the OF INVENTION ^¬ dung.

The description and figures represent only embodiments of the invention.

The invention is based on the idea to accelerate the time-consuming step of powder deposition. The aim is in addition to the commonly used grain sizes in the range 0.025 0,045mm, which are necessary for the generation of fine structures, preferably also one or more coarser Pulverfrak ^¬ functions, ie come with grain sizes, for example in the range of at least 0.1 mm, are used. In a specific embodiment of the invention contains or contain one or more coarse powder fractions non-spherical, preferably oblate and / or prolate Parti ^¬ angle to obtain a very high packing density and thus bestmög ^¬ Liche heat transfer within the layer.

The one or more coarser powder fractions can be applied by means of a doctor blade, which works perpendicular to the Ra ^¬ angle for the finer powder - the powder deposit would be arranged accordingly. The blasting power of the additive manufacturing process, preferably the SLM process, and the lowering of the build platform are applied as appropriate

Adapted to powder layer thickness.

An inventive step is in particular the use of a second powder (with mono- or multimodal particle size distribution) with larger metal particles in the additive manufacturing process. For components or in portions of construction parts ^¬, in which the contour accuracy allows a coarser Pul ^¬ verauftrag, there was a significant velocity would result keitsvorteil. For a powder with grain sizes in the range of at least 0.1 mm, the powder application would be 2-4 times faster than for powders with grain sizes in the range of 0.025-0.045 mm. Furthermore, by optimizing the morphology and grain size composition of the second powder, a higher

Packing density and thus a faster and poorer defect melting possible what the addition rate and quality to ^¬ additionally improved.

FIG. 1 shows the procedure according to the invention. The component to be produced comprises a substrate 4, on which material in powder form is applied in an application direction 22 ^λ according to an additive manufacturing method. Here, a thick layer of at least 0.1 mm by a plurality of layers 7, 10 is achieved, in which a corresponding squeegee is set gap width or the squeegee travels across several times ^¬ be already known, not yet molten jet Pulverschich ^¬ th.

The powder layers 7, 10 have powders with particle sizes <50 μm. By an adapted melt stream 11, the thick powder layer 7, 10 is melted, wherein the melting is selectively carried out to achieve a certain contour of the manufactured ^¬ part ^¬ 1 ^λ .

Figure 2 shows a further procedure in which ^¬ a thick powder layer 13 is generated in comparison to the same Figure 1 are identical, but one layer powder layer 13 is used here preferably having coarser particles. The larger particles preferably have a minimum grain size of 0.1 mm.

This powder layer 13 with the coarser powder grains is also melted by a melt jet 11 to produce a component 1 ^{λ λ} . Figure 3 shows a component 1 ^{λ λ λ} in cross-section with various ^¬ nen sections, in which in a first end portion 15 ^λ thin powder layers, ie significantly smaller than 0.1mm are used to achieve a certain contour accuracy and in the other end portion 15 ^{λ λ λ} coarser particles or meh ^¬ rere powder layers according to the procedure of Figures 1 and 2 are used, since the contour accuracy in this Ab ^{¬ section} 15 ^{λ λ λ is} not required.

In a middle section 15 ^{λ λ} , which may be present, the procedure according to the section 15 ^λ or 15 ^{λ λ λ is} used or a combination thereof.

Figure 4 shows a plan view of a component 1 in order ^¬ direction 22 ^IV , in which in an outer portion 18 ^{λ λ} higher contour accuracy than in the other section 18 ^{λ is to be} achieved, so that there thin powder layers, ie <50ym be used and in a different range 18 ^{λ λ} the procedure of Figure 1 or Figure 2 is selected.

Claims

claims

1. Procedure

for the production of a component (1 1 ^IV ),

in the layered powder as a powder layer (7, 10,

13) is applied and

is selectively compressed,

in particular selectively melted,

characterized in that

at least partially and at least in layers thick powder ^¬ layers (7, 10, 13) are applied by at least 0.1 mm and

compacted

especially melted,

become.

2. The method according to claim 1,

in which the thick powder layer (7, 10, 13) is obtained by using fine powders with a particle size of <50 μm.

3. The method according to claim 2,

in which the thick powder layer (13) in one operation

(13) is applied.

4. The method according to claim 2,

in which the thick powder layer (7, 10) is achieved by applying a plurality of powder layers (7, 10).

5. The method according to claim 1, 3 or 4,

be used with the grain sizes of at least 0.1mm to achieve the thick powder layer (13).

6. The method according to one or more of the preceding claims,

in which prolate and / or wafer powder particles are used.

7. The method according to one or more of the preceding claims,

characterized in that

the application of the powder layers takes place by means of two doctor blades,

in particular, which are arranged perpendicular to each other.

Method according to one or more of the preceding claims,

in which a powder mixture is used as powder, in particular according to claim 2

and in particular according to claim 5 or 6.

Component (1 \ 1 ^IV )

in particular produced by a method according to one or more of claims 1, 2, 3, 4, 5, 6, 7 or 8, having different regions (15 15 ^{λ λ} , 15 ^{λ λ λ} , 18 18 ^{λ λ} ),

wherein the component (1 1 ^IV ) has at least one area,

the thickness of the compacted,

in particular, to be melted,

Powder layer is different and therefore has a different roughness.