Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C14/00—Alloys based on titanium
• • 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
  • B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
  • B22F10/47—Structures for supporting workpieces or articles during manufacture and removed afterwards characterised by structural features
• • 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
  • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
  • B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
  • B23K26/0626—Energy control of the laser beam
• • 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
  • 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
  • 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
  • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• • 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
• • 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
  • B22F12/50—Means for feeding of material, e.g. heads
  • B22F12/53—Nozzles
• • 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
  • B22F2301/00—Metallic composition of the powder or its coating
  • B22F2301/20—Refractory metals
  • B22F2301/205—Titanium, zirconium or hafnium
• • 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
  • B23K2103/00—Materials to be soldered, welded or cut
  • B23K2103/08—Non-ferrous metals or alloys
  • B23K2103/14—Titanium or alloys thereof
• • 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 field of additive manufacturing and in particular that of additive manufacturing by direct metal deposition (DMD, from the English “Direct Metal Deposition”).
• DMD direct metal deposition
• additive manufacturing process by direct metal deposition is meant an additive manufacturing process in which a metallic material, for example in the form of powder or wire, is supplied to a substrate and melted by an energy beam, for example a laser or electron beam, to form a bead of molten metal on the substrate. After solidification of this bead, other cords can be successively superimposed on it in the same way, to form a three-dimensional metal part.
• a metallic material for example in the form of powder or wire
• an energy beam for example a laser or electron beam
• the present disclosure aims to remedy these drawbacks, by proposing an additive manufacturing process of a part which makes it possible to insert a frangible zone between a first and a second part of the part to stop the part. propagation of cracks between said first and second parts of the part.
• this object can be achieved thanks to the fact that in this method, which comprises steps of supplying metallic material on a substrate, fusion of one or more initial beads of the metallic material brought to the first part of the part, solidification of the initial beads, addition of metallic material to the initial beads, fusion of one or more subsequent beads of the metallic material brought to the initial cords, and solidification of the subsequent cords, the fusion of the subsequent cords is carried out by an energy input of a second intensity per unit of cord length, which is appreciably greater than a first intensity per unit of cord length which is that of the energy contribution by which the fusion of the initial cords takes place.
• the wetting surface of the initial cords on the first part of the part, and therefore their strength of adhesion to this first part, can be less than that between the superimposed cords, thus creating a frangible zone to stop the propagation of cracks between the first part of the part and a second part formed at least partially by the subsequent beads.
• the metallic material can be supplied in powder form, and in particular be supplied by spraying from a spray nozzle.
• alternatives such as for example the provision of a wire of the metallic material, may possibly be considered.
• the initial cords can comprise at
• the second, higher intensity of the energy input per unit length of bead can only be used from a third layer of material, thus avoiding the boundary layer between the substrate and the initial beads. can be remelted by the energy input for the fusion of the subsequent beads, which could consolidate the substrate to the initial beads.
• the energy input during the melting steps can be carried out by scanning an energy beam, in particular a laser beam, and more precisely a laser beam emitted in continuous mode.
• a transmission power of the energy beam during the fusion of the initial cords can be appreciably less than a transmission power. of the energy beam during the fusion of the subsequent cords, and in particular to be between one half and three quarters, and more specifically about two thirds, of the emission power of the energy beam during the fusion of the subsequent cords.
• a scanning speed and / or a laser point diameter may be substantially equal during the fusion of the initial beads and during the fusion of the subsequent beads, so as to ensure the continuity of the beads.
• Alternative means to the laser beam can nevertheless be envisaged for ensuring the energy supply during the fusion steps, for example an electron beam.
• the material may be an alloy based on
• titanium and in particular TÎ6AI4V.
• nickel-based alloys are also possible.
• the method can include a preliminary step of additive manufacturing of the first part of the part, before the step of adding metallic material to the first part of the part
• FIG. 2A-2B Figures 2A and 2B illustrate cross sections of
• beads of metallic material deposited on a substrate and melted with different energy inputs per unit length of the bead
• FIG. 3 illustrates the operation of separating the substrate from a part produced by additive manufacturing according to the process illustrated in Figures 1 A to 1 D
• LMD laser metal deposition
• Figures 1A to 1 D beads 1a to 1d of metallic material can be successively formed on a substrate, which can be formed by a first part 2 of a three-dimensional part to be manufactured, superimposed to create a wall forming a second part 3 of the three-dimensional part.
• the metallic material can be projected in the form of powder, comprising particles of diameters for example between 45 and 75 ⁇ m, from a projection nozzle 4, and melted by a beam
• the particles can be impelled by an inert gas such as argon, and form a beam of particles 6 converging, which can be, as illustrated, coaxial with the energy beam 5, for example by using an annular projection nozzle 4.
• the metallic material of the particles can in particular be a titanium-based alloy, such as for example TÎ6AI4V, and the particle beam 6 have a mass flow rate dm / dt of, for example, 2 to 3 g / min.
• the first part 2 can be in the same metallic material or in a material with a sufficiently similar composition.
• the energy beam 5 can be a laser beam, and in particular a continuous laser beam, emitted for example by a YAG disk laser or by a fiber laser.
• the wavelength l of this laser beam can be, for example,
• the process can be carried out under an inert atmosphere, in particular under argon.
• a first bead 1a can thus be formed directly on the first part 2.
• the focal points of convergence f p and fi of the particle beam 6 and of the energy beam 5, respectively, can be located above the surface of the first part 2 so that these beams have respective diameters d p and di of, for example, 1, 5 to 2 mm and 2 to 3 mm, at the level of the surface of the first part 2.
• the metallic material is simultaneously deposited on the first part 2 and melted by the energy input of the energy beam 5, so as to create a liquid bath 10 solidifying downstream with respect to the direction of scanning of the beams of particles 6 and energy 5 on the first part 2, to form this first bead 1 a .
• the energy input of the energy beam 5 can be regulated so as to minimize the wetting surface of the liquid bath 10 on a first part 2, and therefore the contact surface A c of the bead 1 a with the first part 2, as illustrated on FIG. 2A, illustrating a cross section of the bead 1 A on the first part 2.
• This regulation can in particular take place through the transmission power P-, of the energy bundle 5 for this first bead 1 a.
• This first emission power P- can thus be, for example, between 350 and 430 W. It is thus possible to obtain a liquid bath 10 with a first depth r 1; which may be for example 1.1 mm, and a first length h, which may be for example 2.6 mm.
• the distance in the Z axis between the first part 2 and the projection nozzle 4 can be increased by an increment Ad z , before starting to form, on the first bead 1 a, a second bead 1 b analogously, as illustrated in FIG. 1 B.
• This increment Ad z can be, for example, between 0.7 and 0.9 mm.
• the various parameters of the particle 6 and energy 5 beams such as their angles of convergence, the mass flow rate dm / dt as well as the emission power R 1; used to form the first bead 1 a, can be maintained for this second bead 1 b, just like the scanning speed v, so as to maintain an energy supply per unit length of the bead which is substantially identical and therefore substantially the same length h and depth p-, of the liquid bath 10, and avoid remelting the first bead 1 a in the first part 2.
• the energy input per unit of length of bead can be increased substantially to form subsequent cords 1 c, 1 d superimposed on the first and second cords 1 a, 1 b, in order to increase the cohesion between the superimposed cords.
• a second transmission power P 2 substantially greater than the first transmission power P 1 can be used, while maintaining the angles of convergence of the beams 5 and 6, the mass flow dm / dt and the scanning speed v.
• the second transmission power P 2 can in particular be greater by a third up to twice the first transmission power Pi.
• the second transmission power P 2 can be approximately 600 W. It is thus possible to obtain a liquid bath 10 ′ with a second depth p 2 and a second length l 2 substantially greater, respectively, than the first depth p-, and the first length li, which were those of the liquid bath 10 obtained with the first transmission power Pi.
• the second depth p 2 can increase to 1, 7 mm, and the second length l 2 to 3.5 mm.
• first part 2 and the projection nozzle 4 can be further increased by an additional Ad z increment, as illustrated in FIGS. 1 C and 1 D.
• the superimposed beads 1 a to 1 d can thus form a second part 3, for example in the form of a wall, with a frangible zone 1 1 of reduced thickness compared to the second part 3, directly interposed between the first and second parts 2, 3 of the part, thus facilitating their subsequent separation, as illustrated in FIG. 3 , in particular to prevent the propagation of cracks between the first and second parts 2, 3 of the part.
• the present invention has been described with reference to a specific embodiment, with projection of the metallic material in powder form and energy supply by laser beam, it is obvious that various modifications and changes can be made on these examples without departing from the general scope of the invention as defined by the claims.
• the number of initial stacked cords for which the energy input per unit cord length is significantly less than that of Subsequent cords can be one, rather than two, or greater than two.
• the energy input per unit length of cord can be regulated not only through the transmission power of the energy beam, but also, alternatively or in addition to this power regulation, through the scanning speed v and / or the mass flow dm / dt of the metallic material supplied.
• the metallic material may be supplied in the form of a wire and / or the energy supply may be effected by an electron beam.
• the first part of the part may itself have been manufactured at least partially by additive manufacturing in a step prior to the addition of metallic material intended to form the frangible zone. Therefore, the description and the drawings should be taken in an illustrative rather than a restrictive sense.

Landscapes

• Engineering & Computer Science (AREA)
• Physics & Mathematics (AREA)
• Chemical & Material Sciences (AREA)
• Optics & Photonics (AREA)
• Materials Engineering (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Plasma & Fusion (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Powder Metallurgy (AREA)

Applications Claiming Priority (2)

Publications (1)

Family

ID=67441264

Family Applications (1)

Country Status (4)

Families Citing this family (1)

Family Cites Families (10)

• 2020
  • 2020-02-07 WO PCT/FR2020/050216 patent/WO2020165530A1/fr unknown
  • 2020-02-07 EP EP20706800.8A patent/EP3924122A1/de active Pending
  • 2020-02-07 CN CN202080014625.7A patent/CN113438997A/zh active Pending
  • 2020-02-07 US US17/425,968 patent/US20220111441A1/en active Pending

Also Published As

Similar Documents

Legal Events