EP3658316A1 - Method for modifying components using additive manufacturing - Google Patents
Method for modifying components using additive manufacturingInfo
- Publication number
- EP3658316A1 EP3658316A1 EP18793564.8A EP18793564A EP3658316A1 EP 3658316 A1 EP3658316 A1 EP 3658316A1 EP 18793564 A EP18793564 A EP 18793564A EP 3658316 A1 EP3658316 A1 EP 3658316A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- component
- auxiliary plate
- additive manufacturing
- data
- reference mark
- 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.)
- Pending
Links
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- 239000000654 additive Substances 0.000 title claims abstract description 101
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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
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
-
- 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
- B22F3/10—Sintering only
- B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
-
- 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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
-
- 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
- B22F10/10—Formation of a green body
- B22F10/14—Formation of a green body by jetting of binder onto a bed of metal powder
-
- 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
- B22F10/31—Calibration of process steps or apparatus settings, e.g. before or during manufacturing
-
- 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
- B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
-
- 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
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
- B23P6/007—Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
-
- 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
- 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
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/005—Repairing methods or devices
-
- 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
- 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
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
- B22F2007/068—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts repairing articles
-
- 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
- B22F2202/00—Treatment under specific physical conditions
- B22F2202/11—Use of irradiation
-
- 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
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q3/00—Devices holding, supporting, or positioning work or tools, of a kind normally removable from the machine
- B23Q3/02—Devices holding, supporting, or positioning work or tools, of a kind normally removable from the machine for mounting on a work-table, tool-slide, or analogous part
- B23Q3/06—Work-clamping means
- B23Q3/062—Work-clamping means adapted for holding workpieces having a special form or being made from a special material
- B23Q3/063—Work-clamping means adapted for holding workpieces having a special form or being made from a special material for holding turbine blades
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/22—Manufacture essentially without removing material by sintering
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/30—Manufacture with deposition of material
- F05D2230/31—Layer deposition
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/72—Maintenance
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/80—Repairing, retrofitting or upgrading methods
-
- 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 present invention relates to the processing of best ⁇ Henden components using devices for additive manufacturing. Furthermore, the present application relates to an apparatus for additive manufacturing for carrying out this method. Furthermore, the present invention relates to a composite structure which is used in the method according to the invention.
- the additive manufacturing of components is known.
- Example ⁇ example deals with the DE 10 2009 048 665 AI producing ei ⁇ ner turbine blade, a three-dimensional grid that expands is contained in the inside. The interior is surrounded by a wall, wherein holes can be provided in this wall, which connect the interior space with a surface of the turbine blade. As can be seen, for example, from DE 10 2009 033 753 A1, such openings can be used, for example, for transporting cooling gas from the interior of the blade to its surface. In this way, a film cooling of the blade with the cooling gas is possible.
- the additively fabricated structure is built up at a defined location of the space within the device for additive manufacturing from a powder bed.
- this component must be introduced into the powder bed ⁇ the and there high precision on the surface to be machined of the component to the structure of the structure to be started.
- the position and orientation of the existing component is known exactly.
- a high-precision alignment of the component in the system is not always feasible because, for example, too inaccurate, and requires at least a lot of time, in which the device for additive manufacturing can not be used for production.
- a real component may, for example, deviate in shape from the theoretical reference data of its shape. Since, unlike existing methods such as laser welding, a significant excess of material should not be applied, these deviations should also be incorporated into additive manufacturing. Otherwise, no high-precision structures can be applied to the surface of the existing component without the structure having to be removed and rebuilt after fabrication as a result of the deviation.
- the present invention relates to a method for additive manufacturing a structure on at least one surface to be machined of a component in a device for additive manufacturing, wherein the means for additive manufacturing a countertop having umfas ⁇ send the steps of
- upstream in the sense of vorlie ⁇ constricting invention refers to an orientation in which the surface to be processed by the auxiliary plate facing away.
- the abovementioned steps take place in the abovementioned sequence, it also being possible for further intermediate steps mentioned below or not mentioned to occur.
- the present method allows the use of ⁇ be stationary devices for additive manufacturing, by a minimal change to the device is made and the measurement is to determine the required data from the apparatus for manufacturing additive is displaced. As a binding point between the reference system of the measuring device
- Step d) and the reference system of the additive manufacturing device is the at least one reference marks, which are defined as a reference point for the reference system of the device. This makes it possible to use the data obtained outside the device in the device.
- the term "reference mark" within the meaning of the present invention relates to a detectable marker of the auxiliary plate, which is a known position in the device for additive manufacturing.
- Such Referenzmarkie ⁇ approximations can be made for example by manufacturing the reference mark in the device for additive manufacturing, so that from the data of production of these reference points a mapping of the position in the device to the location of the reference mark on the auxiliary plate SUC ⁇ gene can.
- indentations may be in the surface of the auxiliary platenecknmo ⁇ ification of the auxiliary plate as markers or body the surface of the auxiliary plate can be used.
- the present OF INVENTION ⁇ dung relates to a device for additive manufacturing including a working plate and an auxiliary plate for carrying out the He ⁇ inventive method, wherein the work plate is suitable the sub-panel releasably Fixed To ⁇ gen to the worktop, and wherein said auxiliary plate at least has a Referenzmar ⁇ cation and is suitable to be releasably connected to the Häplat ⁇ te.
- the present OF INVENTION ⁇ dung relates to a composite structure for use in a method of the invention comprising
- At least one component for machining by additive manufacturing wherein the component is attached to the auxiliary plate, and
- At least one reference mark which is attached to the auxiliary plate, wherein the at least one reference mark is suitable to be used as a reference point for the position determination of the at least one component.
- Figure 1 shows the detail of a schematic side view of an apparatus for additive manufacturing during step f) of the method.
- Figure 2 shows the detail of a schematic side view of an apparatus for additive manufacturing during a later time of step f) of the method.
- Figure 3 shows a schematic representation
- Figure 4 shows the production of an auxiliary plate 3 in the
- the present invention relates to the aforementioned method for additive manufacturing a structure on at least one surface to be machined of a construction ⁇ part in an apparatus for additive manufacturing the component may eg be connected directly to the auxiliary ⁇ plate or by means of fastening elements on the auxiliary plate be attached.
- the component may eg be connected directly to the auxiliary ⁇ plate or by means of fastening elements on the auxiliary plate be attached.
- This is ⁇ geous in particular, since hereby also components can be securely and firmly fixed to the auxiliary plate, for example, have little base surface for contact with the auxiliary plate. Also hereby a component such as a turbine ⁇ scoop between several fasteners are clamped.
- a releasable attachment of the component to optionally present fastening elements is typically preferred here.
- the fastening elements can in this case be fastened releasably or non-detachably to the auxiliary plate.
- a fastener more preferably a plurality of fastening ⁇ elements, releasably secured to the auxiliary plate, for example, screwed to allow a quick and easy attachment of the fastener.
- the worktop is a component preferably detachably connected to the additive manufacturing apparatus, adapted to secure the auxiliary plate thereto. This allows for wear of the fasteners for the auxiliary plate to replace the worktop and thus allow a permanent ⁇ high-precision fastening of the auxiliary plate without noticeable downtime of the device. Further, it is advantageous if the worktop is part of a platform which is suitable to apply the powder bed for the additive manufacturing and gradually lowered rank ⁇ .
- Fabrication in a substantially parallel surface designates a surface which does not differ substantially from a theoretical plane parallel to the working plane
- a substantially parallel surface obtained in step c) gives at most 0.5 mm, more preferably at most 0 , 2 mm, more preferably at most 0.1 mm, particularly preferably at most 0.04 mm, from a theoretical plane parallel to the working plane, which is arranged centrally between the highest and lowest point of the corresponding surface, which in step f) to representing working surface.
- work plane in the sense of the present invention denotes the theoretical level in which a layer is built up in the device for additive manufacturing.
- the generated work data includes data required for the additive manufacturing apparatus to produce a desired final shape of the component.
- the reference marks serve as reference points, so that the device for additive manufacturing the necessary steps for
- the present invention relates to a method, wherein the working data after step d) are generated based on the spatial arrangement of the surface to be processed to the at least one reference mark, wherein the additive manufacturing device based on these working data in step f) the additive Fer ⁇ account the structure controls such that the structure adjoins the surface to be machined and is firmly connected to the component.
- the auxiliary plate serves as a basis for being able to transmit the relations of component and reference marking, which are determined in the measuring device, to one another in the apparatus for additive production.
- the work data also include the data of the structure to be fabricated.
- the summary of the data required for processing for example, reduces the risk of confusion in the indust ⁇ -material processing a large number of components.
- auxiliary plate with a machine-readable marking such as a barcode.
- the present invention relates to a method, wherein after step d) measured data of the component are compared with reference data of the component, deviations between the measured data of the component and the reference data of the component are determined, the need ⁇ tion of an adaptation of reference data of the structure is determined and possibly adjusted based on the deviations ⁇ conditions of the measured data of the component, the reference data of the structure and working data are created with data of an adapted structure.
- reference data that can be used here are the CAD data that illustrate example, the original CAD data of the component ⁇ or CAD data that have been modified with respect to the structures to be applied.
- the present invention relates to a method, wherein the auxiliary plate is fixed in step e) at a predetermined position with a predetermined orientation on the worktop. Due to the possibility, the auxiliary plate is detachably fastened at a predetermined position with a predetermined orientation on the worktop a simple yet accurate way created, the data from the measurement in step d) to the vibrationssys ⁇ system of the device for additive manufacturing to be transmitted.
- This makes it possible in particular to use existing devices for ad ⁇ ditive manufacturing without additional measurement technology in the interior, with high-precision structures can be applied to any components. Given the prices of Vorrich ⁇ obligations and the flexibility of the disclosed in the present invention way the efficiency of the use of existing plants can be increased dramatically.
- the present invention relates to a method, wherein the exact position and orientation of the auxiliary plate by a detection method after attachment to the worktop is determined.
- a determination of the exact position and orientation can also be made, for example, by detecting the position of different reference points of the auxiliary plate or of the at least one reference mark.
- the position of a defined side of the auxiliary plate by ei ⁇ ner measuring device can be determined for example, the analog of a dial gauge, in particular digital dial gauge, or analogous to a probe, digital or analog, is working or a dial gauge, preferably digital dial indicator, and / or a sensor, preferably a digital sensor. In this case, it is necessary for a corresponding measurement technology to be integrated in the interior of the device for additive production. However, because only a few points of the defined
- Auxiliary plate must be determined, this is a very simple a ⁇ measurement technique sufficient and quickly perform the measurement ⁇ .
- the actual high-precision measurement of the exact position and / or shape of the component is nevertheless shifted to step d) and thus out of the device for additive production.
- the present invention relates to a method wherein the at least one reference mark comprises 3-dimensional bodies attached to the auxiliary plate.
- Such reference markings can typically be measured very well with the conventional measuring methods in step d), so that preferably also the position of at least one reference mark can be determined simultaneously with the position of the component. This can avoid, for example, the position of a Referenzmarkie ⁇ tion and of the component are determined separately on the auxiliary plate, which is calculated therefrom indirectly the position of the component in Re ⁇ lation to the reference marking. Rather, the exact position of a component in relation to at least one reference mark can be obtained directly, which serves as a link to the reference system of the device for additive production.
- 3-dimensional body is typically advantageous that at least one edge more before ⁇ Trains t 2 edges have.
- cylinders are on the auxiliary plate with a circular base area, where ⁇ provides an edge for simplifying the measurement in the upper circular area.
- the 3-dimensional body has a height of at least 0.5 cm, preferably at least 1 cm.
- the present invention relates to a method wherein the at least one reference mark is measured with the same method as the component.
- the reference marking it possible that additional steps are vermie ⁇ .
- the transfer of the supported component into another measuring device requires additional time.
- the risk of an accident eliminates the transfer between the measuring devices, thereby changing the location of at least one component and therefore needs to be ⁇ measure again. Furthermore, this prevents the misallocation of measured data of different auxiliary plates.
- a component optionally a plurality of components, and at least one reference mark are measured simultaneously. Further, measurement can be carried out, for example, first, the data of at least one component and min ⁇ least be obtained a reference mark. Subsequently, for example, in the case of a plurality of components on the auxiliary plate, the relation also can be measured from component to component in order indirectly to obtain a reference to the at least one reference mark.
- the present invention relates to a method, wherein the component is a component of a ner turbine, more preferably a gas turbine, is.
- the component is a component of a ner turbine, more preferably a gas turbine, is.
- Such components particularly benefit from the possibilities of the method according to the invention. So various structures can be built on loading stationary components given the flexib ⁇ len manufacturing capabilities. This is particularly advantageous for turbine components, in particular gas turbine components , whose price makes the repair sensible and in which adjustments are to be carried out as part of an upgrade for the further optimization of the existing system. Furthermore, it is also possible to apply directly additively manufactured structures to new conventionally produced components in order to be able to offer more cost-effective new components with additively manufactured components. This also makes possible the direct repair of additively manufactured components which, on the one hand, have an increased significance in these areas and, on the other hand, can at least in part not be repaired by conventional methods.
- the at least one component is a blade such as a vane or blade or a heat shield as it is present in the blade area or in the region of the combustion chamber.
- the method has proven particularly advantageous for structures on blades. For example, in structures at the ends of the blades in this case the respective component at the other end must be clamped ⁇ in a holder ⁇ , the attachment can be done so far best case with great effort in predefined high-precision orientation.
- the present invention relates to a method, wherein in step b) at least two components, more preferably at least four components, even more preferably at least eight components, each with at least one surface to be machined on the auxiliary plate fortified.
- a plurality of components can also be applied to the auxiliary plate, the measurement data providing sufficient information for processing.
- the remaining visible region of the components in United ⁇ bond is sufficiently with the possibility of high-precision measurements in order to obtain the necessary data to create the Häda- th.
- additive manufacturing refers to the production methods customary to the person skilled in the art, in which a component is constructed from an informal material such as liquids, gels or powders or shape-neutral materials such as band-shaped, wire-shaped or sheet-shaped materials based on a data model such as CAD data are hereby shapeless form or neutral substances from metals, Metalllegie ⁇ stanchions and ceramic materials, preferably metals and metal alloys selected.
- a typically preferred example of the additive manufacturing procedures are 3D printing process.
- SLM selective laser melting
- EBM electron beam melting
- SLS selective laser sintering
- binder jetting from which in a further embodiment the additive manufacturing method is preferably selected.
- SLM selective laser melting
- EBM electron beam melting
- SLS selective laser sintering
- binder jetting from which in a further embodiment the additive manufacturing method is preferably selected.
- the selective laser melting, electron beam melting and selective laser sintering are particularly preferred.
- Such methods proved to be particularly suitable for use in the method according to the invention.
- flexible 3D flexible 3D
- Structures can be built on high-priced components with high precision and reliability.
- insbesonde ⁇ re additive manufacturing processes such as selective laser sintering and Binder jetting, in particular proved selective laser sintering to be advantageous.
- the binder jetting has proved to be advantageous if, for example, high quantities are to be processed at low cost.
- the present invention relates to a method wherein the structure on the component is made of a metal, a metal alloy or a ceramic material, preferably a metal or a metal alloy.
- a high temperature metal or a high temperature metal alloy is used, such as a nickel superalloy.
- the present invention relates to a method, wherein the measurement in step d) takes place by means of an optical detection method, more preferably with an optical 3D scanner, even more preferably with a blue light scanner.
- an optical detection method more preferably with an optical 3D scanner, even more preferably with a blue light scanner.
- Such systems are based on the prior ⁇ preferably fringe projection to means reconnectsequen- zen the 3-dimensional detection of the surface of the Scanned ⁇ th objects to be determined.
- These methods are particularly geous before ⁇ since hereby with very high accuracy and high speed Ge ⁇ the measurements in step d) can be performed. This is particularly necessary for maintenance work, which within a narrow time window example ⁇ as complete Turbinenschaufei engines a gas turbine over ⁇ works must be.
- the present invention relates to a method, wherein the at least one reference mark is at least partially applied by means of additive manufacturing on the auxiliary plate.
- the at least partial application of the reference mark by means of additive manufacturing makes it possible in a simple manner to connect the spatial reference system within the device for additive manufacturing with the coordinate system of a measuring device used in step d).
- Minim ⁇ least completely, more preferably completely all reference marks are applied by means of additive manufacturing and subsequently only takes place a reference mark an optional processing step by removal of material before the measurement in step d).
- This requires a larger Zeitbe ⁇ may in the apparatus for additive manufacturing, but avoids, for example, an additional process step, in which based on the location of partially applied reference mark more material is applied.
- the abovementioned material removal can be done, for example, by cutting. In this case, for example, one or more edges can be generated in particular.
- auxiliary plates comprising identical reference markings are produced at identical points with high precision, for example by means of cutting processes.
- Standard processes are those known to the person skilled in the manufacturing process, preferably not the selective laser melting, electric nenstrahlschmelzen or selective laser sintering include.
- a combination of at least one material- applying method such as build-up welding, for example laser deposition welding
- at least one material-removing method such as a machining operation.
- At least one reference point for exact alignment of a subsequently constructed reference body is applied by means of additive manufacturing. This has the time interpreting ⁇ Lich reduced in the sub-panel has to be processed in the Vorrich ⁇ processing for additive manufacturing, which is typically the time-limiting factor the advantage.
- a derar ⁇ tiger reference point can be done for example on a dummy body.
- the term "dummy-body" in the sense of the present invention refers to a body that the at least one reference mark is mounted on the auxiliary plate to the destination and having a larger volume than are required by ⁇ following reference mark.
- the inaccurate plate-cation and orientation of the reference bodies is subsequently compensated by the fact that on the pressure applied by means of additi ⁇ ver manufacturing reference point material is based removed from the blank body, preferably by machining, so that the reference body with a defined placement, shape and orien- tation results on the auxiliary plate. Additionally or al ⁇ ternatively this If desired, at least one reference body can be set up at a distance from it, in other embodiments it is preferred that during step e) at least one centering element of the work surface is connected to a counterpart of the auxiliary plate or at least one centering element of the auxiliary plate with a counterpart of the Ar beitsplatte be combined.
- the Zentrierele ⁇ ment can be selected for example from known zero-point clamping systems.
- each ⁇ bib elements is protruding from the surface of each ⁇ ilia elements At the very least partially towards its end taper.
- the plate having the centering element ist ⁇ turned side is considered.
- such a centering element preferably has at its end a slope or curvature, which steers the auxiliary plate to the exact position when connecting the worktop and auxiliary plate.
- the Ge ⁇ gene fragment of each other plate in this case provides a Publ ⁇ represents voltage, which is engaged by the centering and thus setting a defined orientation.
- the work plate has at least such a cen- rierelement.
- step a) comprises the following steps
- the present OF INVENTION ⁇ dung relates to the aforementioned apparatus for additive manufacturing including a working plate and an auxiliary plate for imple ⁇ out the method according to the invention.
- the countertop is releasably connected to the additive manufacturing apparatus. This facilitates the replacement when Abnut ⁇ tion of fasteners for the auxiliary plate.
- the worktop can be permanently installed in the device for additive manufacturing.
- modifying a fixed worktop although typically wisely increases the times required during maintenance. However, this can typically achieve even greater accuracy in positioning the worktop and thus the auxiliary panel attached thereto.
- the additive manufacturing apparatus preferably comprises a powder conveying component capable of feeding a metal powder, metal alloy powder or ceramic material powder, preferably metal powder or metal alloy powder, into the manufacturing area of the additive manufacturing apparatus.
- devices for ad ⁇ ditive manufacturing have shown to be advantageous, which have a component for generating and controlling a laser beam and / or electron beam, wherein the laser beam and / or electron beam is suitable to melt a metal powder or metal alloy powder for additive manufacturing or a ceramic material powder sinter, preferably to melt a metal powder or metal alloy powder for additive manufacturing.
- the present OF INVENTION ⁇ dung relates to the aforementioned composite structure for use in a method of the invention.
- the composite structure further comprises fastening elements for the component. This is particularly advantageous to allow a stable connection with the auxiliary plate.
- FIG. 1 shows the detail of a schematic side view of an apparatus 8 for additive production during step f) of the method.
- selective laser melting is used here.
- ⁇ clearly is the composite structure 10 comprising an auxiliary ⁇ plate 3, a reference mark 4 and a component 5.
- two fastening elements 6 are used, in spite of the fir tree teeth at the lower end of the component 5 allow a secure fastening ⁇ tion in a defined position on the auxiliary plate 3. This allows the alignment of the component 5, so that the surface 1 to be processed is directed upward.
- the component 5 is a turbine blade in FIG. 1, which is a component of a gas turbine.
- the composite structure 10 has been introduced after the measurement in step d) during step e) in the device 8 for additive Ferti ⁇ supply and was releasably secured to the worktop 2 at a predetermined position and in a predetermined orientation. Worktop 2 is gradually lowered during processing in step f). After the respective lower ⁇ From the working plate 2 and of the composite structure 10 connected thereto, a new powder layer is applied the advertising before another layer of the structure is generated.
- the Pul ⁇ ver a nickel-base superalloy is used to provide a solid structure for crywarm-.
- work data obtained from measurement data of the step d) of the method is used.
- the Vorrich ⁇ device 8 is controlled for additive manufacturing such that connecting the structure to the produced additive to be machined upper surface ⁇ 1 and is fixedly connected thereto.
- the visible reference mark 4 has the shape of a cylinder with a circular base, which is attached to the auxiliary plate 3. As a reference mark 4 thus serves a 3-dimensional body. It is sunk in Figure 1 completely in the powder bed 7, from which in the device 8 for addi ⁇ tive production, the structure on the surface to be machined 1 of the component 5 is constructed.
- Figure 2 shows as Figure 1 shows the detail of a schematic side view of an apparatus 8 for additive manufacturing in the process already shown in Figure 1.
- Figure 2 represents a later date in which already the structure 9 on the surface to be processed. 1 has been built.
- FIG. 3 shows a schematic representation from step d) of the method already shown in FIG. 1 with the composite structure 10 shown therein. Due to the perspective view of the composite structure 10, three reference markings 4 are visible in FIG.
- the component 5 is fastened on the auxiliary plate 3 by means of two fastening elements 6. As already shown in Figure 1, the surface 1 to be processed is directed upward.
- the three visible reference marks 4 are cylinders with a circular base and thus 3-dimensional body, which are attached to the auxiliary plate 3.
- the stylized eye represents the optical measuring device, in this case a blue light scanner.
- the composite structure 10 is measured by means of an optical onsvons Detekti-, which in the present case, a blue light scanner which records the shape and Po ⁇ sition of the component 5 and the reference body by means of strip light.
- reference marks 4 and component 5 are measured by the same method.
- the measurement data obtained are used to determine the shape of the component 5 and to subsequently compare it with reference data. Based on this, if necessary, an adaptation of the data of the structure 9 to be constructed additively takes place, wherein the adapted data are forwarded to the device 8 as working data.
- the exact spatial arrangement of the surface 1 to be processed to at least one of the reference marks 4 is detected.
- These data allow subsequent precise control of the surface to be processed 1 of the component 5 in the device 8, without these ⁇ own measurement technique must have inside.
- the position and orientation of the surface 1 to be processed in the device 8 are indirectly determined from the known position of the reference mark 4 in the device 8 and the aforementioned spatial arrangement of the reference mark 4 and the surface 1 to be processed.
- Figure 4 shows the production of an auxiliary plate 3 in the device 8 for additive manufacturing, which is also shown in Figure 1.
- the auxiliary plate 3 is detachably mounted on the work plate 2 at a predetermined position with predetermined orientation. Since the Referenzmar ⁇ k ist is made 4 additive in the specific device at a specified location, the control data of the device 8 for the preparation of the auxiliary plate 3 with the reference mark 4 contain a reference possibility between subsequent measurements as in step d) and the reference system of the controller of the device 8. Thus, it can be indirectly determined which location within the device 8 must be driven, if the location is known relative to the Re ference ⁇ mark. 4
- the auxiliary plate 3 produced in Figure 4 is subsequently used directly in the process of Figures 1 and 2. Alternatively, for example, as described in the description this
- FIG. 8 shows a schematic sequence of the method also shown in Figures 1 and 2. Here, the steps a) to f) are passed through. Here, the procedural ⁇ ren either i) with step c), or ii) it can follow without ⁇ step c).
- step d) measured data to the component and at least egg ⁇ ner reference marker can be obtained. These are used to create work data for the control of the device. Further, for controlling the device, the information of the known position of the at least one reference mark in the apparatus for additive manufacturing is used at a known position and orientation of the auxiliary plate in the device. Preferably, the information of the known Posi ⁇ tion is used at least one reference mark in the apparatus for manufacturing the additive directly to generate together with the measurement data from step d) a data set for controlling the device. This allows the typically lower computing capacity of a control device to avoid a device for additive manufacturing as a limiting factor.
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Abstract
Description
Claims
Applications Claiming Priority (2)
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DE102017219333.6A DE102017219333A1 (en) | 2017-10-27 | 2017-10-27 | Method of modifying components using additive manufacturing |
PCT/EP2018/077447 WO2019081197A1 (en) | 2017-10-27 | 2018-10-09 | Method for modifying components using additive manufacturing |
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EP (1) | EP3658316A1 (en) |
CN (1) | CN111278588A (en) |
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RU (1) | RU2746913C1 (en) |
WO (1) | WO2019081197A1 (en) |
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EP3892402A1 (en) | 2020-04-06 | 2021-10-13 | Siemens Aktiengesellschaft | Positioning means for additive manufacturing |
CN112045186B (en) * | 2020-09-02 | 2023-05-23 | 中国航发北京航空材料研究院 | Method and tool for repairing blade tip of cast equiaxial-crystal superalloy turbine rotor blade |
CN112077310B (en) * | 2020-09-02 | 2023-05-23 | 中国航发北京航空材料研究院 | Method and tool for repairing tip of turbine rotor blade made of monocrystalline and directional solidification materials |
DE102021105918A1 (en) | 2021-03-11 | 2022-09-15 | Lufthansa Technik Aktiengesellschaft | Additive repair system |
SE2100059A1 (en) * | 2021-04-22 | 2022-10-23 | Sandvik Machining Solutions Ab | Method and device for determining the position of a base device |
DE102021204729B4 (en) | 2021-05-10 | 2022-12-01 | Trumpf Laser- Und Systemtechnik Gmbh | Measuring device, manufacturing device with such a measuring device and method for operating a manufacturing device for the generative manufacturing of a component from a powder material |
DE102022118664A1 (en) | 2022-07-26 | 2024-02-01 | Lufthansa Technik Aktiengesellschaft | Construction platform for additive repair of components and their use |
US20240082962A1 (en) * | 2022-09-09 | 2024-03-14 | Pratt & Whitney Canada Corp. | Adaptive component overhaul using structured light scan data |
WO2024094256A1 (en) | 2022-11-03 | 2024-05-10 | additiveStream4D GmbH | Calibration system and calibration method for calibrating a construction platform system in an additive manufacturing device |
DE102022129035A1 (en) | 2022-11-03 | 2024-05-08 | additiveStream4D GmbH | Build platform system for additive manufacturing |
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DE19918613A1 (en) | 1999-04-23 | 2000-11-30 | Eos Electro Optical Syst | Method for calibrating a device for producing a three-dimensional object, calibration device and method and device for producing a three-dimensional object |
DE10150129C1 (en) * | 2001-10-11 | 2003-04-17 | Siemens Ag | Calibration method for laser machining device compares actual pattern described by laser beam with required pattern for correction of beam deflection unit |
DE102008031925B4 (en) * | 2008-07-08 | 2018-01-18 | Bego Medical Gmbh | Dual manufacturing process for small series products |
DE102009033753A1 (en) | 2009-07-17 | 2011-01-27 | Rolls-Royce Deutschland Ltd & Co Kg | Hollow turbine blade i.e. hollow guide vane, film cooling method, involves passive-controlling flow separation at blade, and bending nozzles under angle in transverse direction to mainstream direction of gas and under another angle |
DE102009048665A1 (en) | 2009-09-28 | 2011-03-31 | Siemens Aktiengesellschaft | Turbine blade and method for its production |
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DE102016204462A1 (en) * | 2015-03-31 | 2016-10-06 | Krause DiMaTec GmbH | A method of manufacturing a component and a carrier plate for supporting additively to be manufactured components, designed for carrying out such a method |
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CN107097036B (en) | 2017-05-24 | 2019-09-24 | 西北工业大学 | Metal parts restorative procedure based on increase and decrease material manufacture |
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DE102017219333A1 (en) | 2019-05-02 |
RU2746913C1 (en) | 2021-04-22 |
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