EP3562608A1

EP3562608A1 - Method and device for the powder bed-based additive building up of a plurality of identical components

Info

Publication number: EP3562608A1
Application number: EP18704450.8A
Authority: EP
Inventors: Michael Ott
Original assignee: Siemens AG
Current assignee: Siemens Energy Global GmbH and Co KG
Priority date: 2017-02-08
Filing date: 2018-01-25
Publication date: 2019-11-06
Also published as: WO2018145912A1; DE102017201994A1; US20190358755A1; CN110382140A; CN110382140B

Abstract

The invention relates to a method and to device for the powder bed-based additive building up of a plurality of identical components (10), comprising the fixing of each of the components (10) on a base plate (1) by means of a retaining apparatus (2), the adjusting of a vertical position of at least some of the fixed components (10) relative to the base plate (1), such that a structural peak (11) of each component (10) is spaced apart from the base plate (1) within a predetermined tolerance range (TB), providing a powder bed (3) of a building material on the base plate (1) up to a height of the tolerance range (TB) and the layered, additive building up of material on each of the structural peaks (11) of the components (10).

Description

description

Method and device for the powder bed-based additive construction of a plurality of similar components

The present invention relates to a method for or for the powder bed-based, additive production of a plurality of components, in particular the repair of components and a corresponding device.

The components, preferably similar components, are in particular ^¬ special for use in a turbomachine, preferably ^{¬ provided} in the hot gas path of a gas turbine. Vorzugswei ^¬ se is in the components to turbine blades or their blades. Accordingly, the components preferably each comprise or consist of a nickel-based or cobalt-base superalloy. The alloy may be precipitation hardened or precipitation hardenable. The components may alternatively or additionally be worn and / or partially manufactured or constructed components.

Generative or additive manufacturing processes include, for example as powder bed processes, selective laser melting (SLM) or laser sintering (SLS), or electron beam melting (EBM). Also, the laser deposition welding ^¬ SEN (LMD) belongs to the additive process.

A method for selective laser melting is known, for example, from EP 2 601 006 B1.

Additive manufacturing processes (English: "additive manufacturing") have proven to be particularly advantageous for complex or complicated or filigree designed components, for example, labyrinthine structures, cooling structures and / or

Lightweight structures proved. In particular, the additive manufacturing is advantageous by a particularly short chain of Prozessschrit ^¬ th, as a manufacturing or production step of a component can be made directly on the basis of a corresponding CAD file.

Furthermore, the additive manufacturing is particularly advantageous for the development or production of prototypes, which can not or can not be efficiently produced, for example, for cost reasons by means of conventional subtractive or metal-cutting processes or casting technology. Running of gas turbines often require after the scheduled service interval repair the Schaufelblattspit ^¬ ze. This is damaged in the use of the gas turbine by thermal, mechanical and / or corrosive action. To carry out the repair, the damaged area is conventionally removed manually and then with a

Welding process, such as laser cladding, rebuilt. The removal can be done manually or (partially) auto ^¬ matisiert. It is known in the field of turbine blade manufacturing that the parts which are manufactured by vacuum investment casting due to their material composition requirements as well as geometry complexity are subject to variations in their dimensions (range of variation). In particular, the blade length varies due to manufacturing, that is a starting point along the longitudinal axis of the blade or blade ^¬ a nominal airfoil length is precisely defined some tenths of a millimeter only Be ^¬ rich. As well as the described manufacturing variation or "blurring" of the airfoil length, the removal of the airfoil tip or area to prepare for its rebuilding will result in variation or blurring of the remaining airfoil's lay.

Furthermore, it is often desirable to remove only as much as is absolutely necessary from the component since often does not have the requisite or the same material quality or structure as the originally prepared component, for example with regard to its hot crack susceptibility.

The dimensions of the component to be repaired be ^¬ relationship as the component of a certain unavoidable fluctuation or blurring are thus subjected to in terms of its longitudinal extent. In conventional repair methods, for example laser deposition welding or TIG welding, the above-mentioned fluctuation-in contrast to powder-bed-based additive methods-is unproblematic.

However, one provided additive, and / or powder bed based selective method, such as selective laser ^¬ melt for the reconstruction of the parts would like to use this variation as described would be a committee füh ^¬ reindeer, or decide the parallel repair a plurality of components by a powder bed based method complicated. The reason is that in powder bed-based processes, the position of a build-up tip relative to a substrate or baseplate should be determined to an extent that corresponds to the layer thickness used in the process. Typical layer thicknesses in the range of selective laser melting are approximately between 20 and 80 μm. Consequently, should a tolerance range over which the tips of the parts or components in assembly direction - provided they all are fixed directly on the base plate - of one another variie ^¬ reindeer, are in the range of layer thicknesses so that processing operations no problems, in particular collisions, wherein the individual coating occur.

It is therefore an object of the present invention to provide means with which the additive production of a plurality of components from a powder bed can be simplified or the use of powder-bed-based production technology can be expanded. the can and so do the benefits of additive manufacturing technology ^¬ can be used widely.

This object is solved by the subject matter of the independent patent claims. Advantageous embodiments are subject of the dependent claims ^¬ Ge.

One aspect of the present invention relates to a method for the powder bed-based additive construction of a plurality of components comprising fixing each of the components on a base plate, for example in a system for the corresponding additive production, by means of a holding or fixing device. The method further comprises adjusting a vertical position or height position of at least some of the fixed components (via the holding devices) relative to the base plate, so that a structure of the tip of each component of a predetermined range of tolerance is spaced from the base plate inner ^¬ half. The described adjustment is preferably an individual adjustment of each individual holding device and may comprise a height measurement or distance measurement of the corresponding mounting tips from the surface of the base plate.

With the described height, height position or vertical position, in the present case it is preferable to understand a distance along a construction direction of the components. The method further comprises providing a powder bed of a, in particular pulverulent, build-up material on the base plate up to a height of the tolerance range. In other words, a configuration space is preferably up to a filled to the depth of the powder bed corresponding height which speaks ent ^¬ the distance of the range of tolerance of the base plate with powder. The provision of the powder bed may be provided in the described method equally before and after the step of adjusting the vertical position. Furthermore, the method comprises layer-wise additive build-up, preferably by means of selective laser melting, of material respectively on the construction tip of the components. Said material preferably corresponds to the building material solidified by an energy beam. The components of the advertising preferably parallel or simultaneously additively placed ^¬ builds.

The structure of the tips each preferably have a Aufbauflä ^¬ che which - facing away conveniently from the surface of the base plate ^¬ - through the corresponding fixing on the base plate.

In one embodiment, the adjustment of the vertical position and / or a control of the vertical position is performed after each layer of material has been built up.

A further aspect of the present invention relates to a device for the powder-bed-based additive manufacturing comprising a base plate and a plurality of independently adjustable relative to the base plate and, preferably movable, holding devices, wherein the holding means are each formed, a component (as described above) relative to fix to the base plate. As an advantage, as indicated above, the removal or the subsequent reconstruction of the damaged blade areas can be simplified and carried out using advantageous additive manufacturing technology. In particular, a repair of turbine parts can be carried out more cheaply. Similarly, component repairs can be customized, for example, the ^{Verschleißzu ¬} accordingly. Furthermore, with the method described a plurality of components, in particular the same term components repaired in parallel or put in order ^¬ to.

In one embodiment, the method is a repair or repair method.

In one embodiment, the components are repair components.

In one embodiment, material is removed prior to fixing in each case in a wear region of the components and thus defines the construction tip.

In one embodiment, the components are molded, in particular by precision casting, such as vacuum investment casting, manufactured components.

In one embodiment, the components are forged components. In one embodiment, the components are similar.

In one embodiment, the components are Turbinenlaufschau ^¬ blades, the superstructure tip is a blade tip represents ^¬ . In one embodiment, a nominal layer thickness for the layered additive structure corresponds to a dimension of the tolerance range spaced from the base plate. The tole ^¬ ranzbereich is typically 10 to 80ym, preferably 20 to 30ym. By means of this embodiment, it can be ensured, in particular, that during the production or

Repair process of the components does not cause problems with a coater unit of the additive manufacturing plant, especially not to collisions. If the assembly tips of the components are arranged according to the method described within the tolerance range, they are for the material order or the repair within the layer or layer thickness of a new material order, and a collision with the coater is thus closed from ^¬.

In one embodiment, a distance of each construction tip of the components during the layerwise addition cross ven structure, for example, after each or some of verfes ^¬ saturated layers or plies, measured relative to the base plate and / or rela ^¬ tive to the surface of the powder bed. This Substituted ^¬ staltung is particularly useful to set the vertical position-of the fixed components, such as described in general to be adjusted.

In one embodiment, the predetermined Toleranzbe ^¬ rich, for example, measured along a mounting direction, 10 to 80ym, preferably 20 to 30ym.

In one embodiment, each holding device, for example, via a guide in the base plate, designed to be height adjustable.

In one embodiment, each holder device has a carrier and / or a clamping device. About the support or the clamping device (s), in particular clamping jaws or those comprising, the components are expedient fi ^¬ xed.

In one embodiment, the carrier, the clamping device and / or the holding device is designed to be movable and / or height-adjustable relative to the base plate by means of hydraulic, pneumatic, electromechanical or piezoelectric means.

In one embodiment, the device has at least four holding devices. Accordingly, for example, four components can be constructed in parallel additive layers or

be repaired. In one embodiment, the device has more than four retaining devices, for example six, eight or ten Hal ^¬ teeinrichtungen.

Embodiments, features and / or advantages relating in the present case to the method may also relate to the device or vice versa.

Further details of the invention are described below with reference to the figures.

1 shows a schematic perspective view ei ^¬ ner apparatus of the present invention.

Figure 2 shows a schematic sectional or side view of at least a portion of the device.

Figure 3 shows a schematic sectional view of the Vorrich ^¬ tung in operation and implies an inventive method.

FIG. 4 indicates, with reference to a schematic view, method steps of the method.

FIG. 5 shows a schematic flow diagram of method steps of the method according to the invention.

In the exemplary embodiments and figures, identical or similar elements in each case with the same Bezugszei ^¬ surfaces may be provided. The illustrated elements and their proportions with each other are basically not to be regarded as true to scale, but individual elements, for better representation and / or better understanding exaggerated be shown thick or large.

Figure 1 shows a perspective view of a device 100. The device 100 is preferably provided for the Use in a plant for powder-bed-based additive production, preferably by selective laser melting (SLM). The device 100 has a base plate 1. The base plate is expediently a base plate for the additive production of metallic components, in particular turbine components.

The base plate 1 may be a construction platform similar to a construction platform of a conventional additive manufacturing installation, for example a steel base plate and / or low-distortion base plate.

The base plate 1 has a square or rectangular main surface. The device 100 furthermore has a plurality of holding devices 2. Four retaining devices 2 are arranged or fastened by way of example on the surface mentioned.

The holder devices 2 are provided, for example in order to be repaired or refurbished to be set, in particular ver ^¬ schlissene components on the support means 2 relative to the base 1 to fix.

The holding devices 2 each have clamping devices 4, in particular clamping jaws to clamp a fixated ^¬ compo nent or a corresponding component, and to fix it that way.

The holding devices 2 are furthermore designed to be height-adjustable independently of one another (compare FIG. 2) in order to adjust the components for the powder-bed-based additive production in the device 100 in the powder bed at the same level or the same height along a mounting direction (vertical Z direction). This may be necessary to suitably carry out the additive process, in particular the powder coating. FIG. 2 shows at least part of the device 100 in an enlarged view. In particular, a guide 6 of the device 100 is further shown in FIG. The guide 6 is preferably carried out through a bore or opening of the base plate 1 and connected to the holding device 2. Furthermore, the clamping jaws 4 described above are shown in an enlarged view. Per holding device 2, two clamping jaws or a Spannba ^¬ pair of blocks are preferably provided. Holding or fixing surfaces of the clamping jaws can be configured like a Christmas tree around one

Shovel foot, preferably a turbine blade, purpose ^{¬ tionally} to grab and fix.

Preferably, at least one of the clamping jaws of each holding device 2 is movable in order to fix the component (not explicitly shown in FIG. 2). In the present case is indicated by the hori zontal ^¬ arrow of the right jaw in Figure 2 that this can be pressed, for example, for fixing the component 10 against the left jaw. This can be done by measures known to those skilled in the art.

The device 100 further comprises a carrier 7. The carrier 7 preferably connects the clamping jaws 4 with the guide 6 or couples them.

The device 100 further comprises means 5 to the Hal ^¬ teeinrichtung 2 and / or the carrier 7 form height adjustable, ie, for example adjustable along a mounting direction (see vertical arrow on the right side in Figure 2). For this purpose, a thread 8 can be used.

The means 5 may be, for example, electromechanical means, such as stepper motors. Wei ^¬ terhin a height adjustment of the holding device by hydraulic, pneumatic or similar mechanical means, or even piezoelectric can be accomplished. The described means for height adjustment, in particular stepper motors, are furthermore arranged below the base plate, al ^¬ so outside a powder space during operation of the device 100. Furthermore, the guide 6 against the powder bed, which is arranged in the operation of the device 100 above the base ^¬ plate 1, for example, sealed by the skilled person known means.

Figure 3 shows a schematic sectional view of the Vorrich- processing 100 which is used in a system 200 for additive Her ^¬ position. The device 100 is preferential ^¬, in a process for the manufacture of additive (see Figure 5 below) was used. Figure 3 indicates wei ^¬ terhin at some steps of the method described.

By way of example, three holding devices 2 are shown, which are numbered via the curly brackets for the sake of clarity. Each of the holding devices 2 fixes or holds a component 100, expediently via the clamping jaws, as described in FIGS. 1 and 2.

The components are preferably turbine blades, in particular turbine blades. The components 10 can accordingly be cast components 10, in particular produced by fine casting, such as vacuum precision casting. In particular, the components 10 are preferably similar, in particular wear parts for the same power plant or industrial plant. During operation, the components 10 are preferably exposed to heavy wear, for example due to corrosive or mechanical influences, which is why they have to be repaired or repaired after ^certain operating intervals. For this purpose, preferably a Schaufelblattspit ^¬ ze machined and removed material, thereby defining a building tip or mounting surface 11.

Each of the component 10 accordingly has the tip 11 (construction tip), on which with the described method In a later step, material is built up and the construction part is to be ^repaired again. The structure of the tips 11 of the members 10 shown as an example are shown in the pre ^¬ direction 100 at a different height (vertical polyvinyl sition). This is because the part or blade length is subject to some variation.

The method presented now comprises individual A ^¬ or adjusting the heights of the components 10 by the holding means or the means described, relative to the base plate so that the construction of the tips 11 are arranged within a predetermined tolerance range TB and spaced from the base plate 1 / become. The predetermined tol ^¬ ranzbereich TB is measured along the mounting direction, 10 to 80ym, preferably 20 to 30ym.

Preferably, a readjustment or Kontrollie ^¬ ren the height or vertical position of the components after each in a later step is structured or solidified

Layer of building material, in particular from the hardened alloy suitable for the blades.

To adjust the height to adjust (individually) in accordance with, the method comprising a height measurement within the forward direction 100 or 200 this comprehensive system, preferably ^¬ by means of laser distance measurement, when the components are already covered with powder. The height measurement may be relative to the baseplate and / or relative to a surface of the powder bed.

The filling or provision of the powder 3 (powder bed) or building material can basically be done before or after adjusting the height or vertical position. In particular, is shown in Figure 3 that the structure with the number 1 ^λ (see left side) is set such that the corresponding component or its structure tip 11 in ^¬ nerhalb, more specifically at the upper limit of the tolerance range, is arranged. The structure shown in point 3 ^λ (see right side) is adjusted in terms of height such that the construction of tip 11 of the right component 10 in approximately the unte ^¬ ren limit of the tolerance range TB (see Distance A) is arranged arrival. Only the structure of the central component (see reference numeral 2 ^λ ) is arranged, for example due to its state of wear far outside the powder bed and the tolerance range TB, so that an adjustment of the position is required. Would not be made according to the process described this setting, a coater unit would drive (not explicitly present Darge ^¬ provides) for the additive built-up against the tip of mittle ^¬ ren component 10 and cause under certain circumstances by a collision damage to the plant 200th

Preferably, the position is set in such a way or the tolerance range TB is selected such that it corresponds to a predetermined layer thickness D of the powder to be applied. By virtue of this configuration, it is precisely the damage to the installation described above and, at the same time, reliable construction of the material on the construction tips 11 or corresponding construction areas that can be ensured.

Figure 4 shows parts of the apparatus shown in Figure 3 100 and system 200, where, using the beschrie ^¬ surrounded method, a height or vertical position of the "on ^¬ construction", comprising the central holding member 2 together with the fixed member 10, corrected, or such is set, that the corresponding mounting tip 11 with respect to its height or its distance from the building board 1 is within the tolerance range TB.

FIG. 5 shows a schematic flow diagram of method ^steps according to the invention. As described above, the method is a method for the powder-bed-based, additive construction of a majority of the components described. According to method steps a), the method may comprise the removal of material in a wear region of the components, in particular in such a way that an ^assembly recess 11 of the components is defined in this way.

Furthermore, the method according to method steps b) comprises fixing each of the components 10 on a base plate 1 by means of a holding device 2. According to method steps c), the method comprises measuring a distance of each assembly tip 11 of the components 10 relative to the base plate 1 during the actual additive up ^¬ construction (see step f) below). In accordance with process steps d), the method comprises a ^¬ represent a vertical position of at least some of the fixed parts 10 relative to the base plate 1, so that a structure tip 11 of each member 10 is spaced within a vorbestimm ^¬ th tolerance range TB of the base plate. 1

According to method steps e), the method comprises ^providing a powder bed 3 of the building material on the base plate 1 up to a height of the tolerance range TB.

The arrow in the flowchart of FIG. 5 indicates that this method step (provision) can be carried out before or after the setting step (method step d)), so that the sequence of steps d) and e) can be interchanged.

According to method step f), the method comprises

additively wiederherzu provide ^¬ layerwise additive build-up of material on each of the tip 11 structure, in particular a worn area of the components 10 (see FIG. 11 structure peak) or repaired. Instead, as described above, to fill the entire powder space (not explicitly marked) with powder or to provide a fully ^¬ constant powder bed, can also be vorgese ^¬ hen to place or arrange only a frame or sealing template to each of the individual to be built components or blade tips so that the entire space can not be filled with powder, and building materials can be saved. Such components may, for example, be connected to the base plate 1 by means of a silicone gasket around the components 10 or holding devices 2.

The invention is not limited by the description based on the embodiments of these, but includes each new feature and any combination of features. This includes in particular any combination of features in the patent claims, even if this feature or combination itself is not explicitly stated in the patent claims or exemplary embodiments.

Claims

claims

A method for the powder bed-based additive construction of a plurality of components (10) comprising the following steps:

Fixing each of the components (10) on a base plate (1) by means of a holding device (2),

- Setting a vertical position of at least some of the fixed components (10) relative to the base plate (1), so that a mounting tip (11) of each component (10) within a predetermined tolerance range (TB) from the base ^¬ plate (1) spaced is

- Providing a powder bed (3) of a building material on the base plate (1) up to a height of the tolerance range (TB), and

Layer-by-layer additive build-up of material on the construction tip (11) of the components (10).

2. The method according to claim 1, wherein the adjustment of the vertical position and / or a control of the same is carried out after each built-up layer of material.

3. The method according to claim 1 or 2, wherein the components (10) are repair components and wherein prior to fixing in each case in a wear region of the components (10) material removed and so the assembly tip (11) is defined.

4. The method according to any one of the preceding claims, wherein the components (10) cast, in particular by investment casting, such as vacuum investment casting, manufactured components (10).

5. The method according to any one of the preceding claims, wherein the components (10) are similar, in particular Turbi ^¬ nenlaufschaufeln and the construction tip (11) represents a blade blade tip.

6. Method according to one of the preceding claims, wherein a nominal layer thickness (D) for the layered ad- ditive structure corresponds to a dimension of the base plate (1) spaced tolerance range (TB).

7. The method according to any one of the preceding claims, wherein during the layered additive structure, a distance of each assembly tip (11) of the components (10) relative to the base plate (1) and / or relative to the surface of the powder ^¬ verbettes, for example by means a laser is measured.

8. The method according to any one of the preceding claims, wherein the predetermined tolerance range (TB), measured along a mounting direction, 10ym to 80ym, preferably 20ym to 30ym.

9. Device (100) for the powder bed-based additive manufacturing comprising a base plate (1) and a plurality of relative to the base plate (1) independently height-adjustable holding means (2), wherein the holding means (2) are each formed, a component (2) to fix relative to the base plate (1).

10. Device (100) according to claim 9, wherein each holding device (2) is height-adjustable via a guide in the base plate.

11. Device (100) according to claim 9 or 10, wherein each holder device (2) comprises a carrier and / or a clamping device (4), and wherein the holding device (2) via hydraulic, pneumatic, electromechanical or piezoelectric means (5) relative is formed height adjustable to the base plate (1).

12. Device (100) according to one of claims 9 to 11, which has at least four holding devices (2).