EP4031310A1

EP4031310A1 - Method for the layer-by-layer additive manufacturing of a composite material

Info

Publication number: EP4031310A1
Application number: EP20789467.6A
Authority: EP
Inventors: Britta Stöhr; Jane Kuhn
Original assignee: Siemens Energy Global GmbH and Co KG
Current assignee: Siemens Energy Global GmbH and Co KG
Priority date: 2019-11-12
Filing date: 2020-09-25
Publication date: 2022-07-27
Also published as: US20220388064A1; WO2021094026A1; DE102019217434A1

Abstract

The invention relates to a method for the layer-by-layer additive manufacturing of a composite material (V), comprising the selective irradiation of a base material (P) to produce a first, dense material phase (1) and to produce a second, porous material phase (2), wherein the production of the first material phase (1) and the production of the second material phase (2) take place alternately. The invention also relates to a correspondingly produced composite material and to a component comprising the composite material.

Description

description

Process for the layer-by-layer additive manufacturing of a composite material

The present invention relates to a method for the layer-wise additive production of a composite material, for example a hierarchical material. The present invention further comprises a correspondingly produced material and a component comprising this material.

The component is preferably intended for use in a flow machine, preferably in the hot gas path of a gas turbine. The component is preferably made of a superalloy, in particular a nickel- or cobalt-based superalloy. The alloy can be precipitation hardened or precipitation hardenable. Alternatively, the component can relate to a thermally highly stressed component for use in aerospace and / or the automotive sector.

In gas turbines, thermal energy and / or flow energy of a hot gas generated by burning a fuel, e.g. a gas, is converted into kinetic energy (rotational energy) of a rotor. For this purpose, a flow channel is formed in the gas turbine, in the axial direction of which the rotor or a shaft is mounted. If a hot gas flows through the flow channel, a force is applied to the rotor blades, which is converted into a torque acting on the shaft, which drives the turbine rotor, whereby the rotational energy can be used, for example, to operate a generator.

Modern gas turbines are subject to constant improvement in order to increase their efficiency. However, this leads, among other things, to ever higher temperatures in the hot gas path. The metallic materials for rotor blades, especially in the first stages, are constantly being changed with regard to their (mechanical) properties at high temperatures, oxidation durability, crack resistance, creep load and thermomechanical fatigue improved.

Due to its potential to disrupt industry, generative or additive manufacturing is also becoming increasingly interesting for the series production of the above-mentioned turbine components, such as turbine blades, burner components, or other components.

Additive manufacturing processes include, for example, as powder bed processes, selective laser melting (SLM) or laser sintering (SLS), or electron beam melting (EBM). Further additive processes are, for example, "Directed Energy Deposition (DED)" processes, in particular laser application welding, electron beam or plasma powder welding, wire welding, metallic powder injection molding, so-called "sheet lamination" processes, or thermal spray processes (VPS LPPS, GDCS).

A method for selective laser melting is known for example from EP 2601 006 Bl.

Additive manufacturing processes have also proven to be particularly advantageous for complex or filigree components, for example labyrinth-like structures, cooling structures and / or lightweight structures Short chain of process steps, since a manufacturing or manufacturing step of a component can largely take place on the basis of a corresponding CAD file and the selection of appropriate manufacturing parameters. This prevents long product throughput and delivery times of the components in particular.

In the context of a so-called CAM process ("Computer-aided Manufacturing"), for example, irradiation parameters and other manufacturing parameters can be defined in a step that prepares production. accordingly by means of hardware or software technology, for example, with the aid of a computer program or computer program product.

A computer program product, such as a computer program means, can be used, for example, as a (volatile or non-volatile) storage medium, such as a memory card, a USB stick, a CD-ROM or DVD, or in the form of a file that can be downloaded from a server in provided or included in a network. The provision can also take place, for example, in a wireless communication network by transmitting a corresponding file with the computer program product or the computer program means. A computer program product can include program code, machine code, G-code and / or executable program instructions in general.

As a result of the additive manufacturing processes described, in particular the freedom of design of the components obtained can advantageously be significantly increased compared to conventional methods. However, high-strength materials can usually only be additively processed in very slow processes. This is due, among other things, to the high internal stresses that occur in the process, primarily caused by process-inherent temperature gradients, which can lead to crack formation during construction and, for example, to mechanical distortion in a subsequent heat treatment. Residual stresses are also relevant with less solid or heat-resistant materials and also with polymers and ceramic materials, for example, mean that the potential of additive manufacturing cannot be fully exploited.

For example, in the area of high-strength hot gas components, the problem of crack formation, especially with regard to hot or solidification cracks, during additive manufacturing or during normal operation of the component produced, has not yet been completely resolved. Precipitation-hardened nickel- or cobalt-based superalloys or alloys with a high proportion of so-called gamma or gamma-ray phases (cf.g-, g'-

Phase separations) cannot currently be produced or welded using additive methods in a sufficiently reproducible and process-reliable manner.

The production of less solid metallic materials is manageable. However, the problem of high internal stresses, which require mechanical and / or thermal aftertreatment, is also generally evident here.

It is therefore an object of the present invention to provide means which solve the problems described. In particular, the present invention provides a composite material which can be manufactured by additive methods and which in particular has improved properties with regard to its crack behavior or growth. Inventive advantages, such as a resulting longer service life under load, therefore result for each component which at least partially comprises the composite material described.

This problem is solved by the subject matter of the independent patent claims. Advantageous refinements are the subject matter of the dependent claims.

One aspect of the present invention relates to a method for the layer-by-layer additive production of a composite material, for example a hierarchical material, comprising the selective irradiation of a base material to produce a first, dense material phase or material structure, and to produce a second, a certain Po rosity exhibiting material phase or material structure. The second material phase is in particular different from the first material phase. However, the material phases mentioned can be chemically the same material. The porosity of the second material phase is preferably greater than a possibly remaining, unavoidable porosity of the first material phase.

The selective irradiation is preferably part of a selective laser sintering process, a selective laser melting process or an electron beam melting process.

The production of the first material phase and the production of the second material phase take place alternately by way of the method described. In other words, during the production of the composite material, first the first material phase can be produced, and then the second material phase, or vice versa. The method is preferably carried out in such a way that the corresponding material phases are produced alternately several times.

The alternating provision of a dense and a slightly porous material phase for the production of the composite material described advantageously enables the reduction of internal stresses and hot cracks arising in the process. The (hierarchical) material or composite material produced accordingly by the method described may have a reduced strength compared to a largely dense, for example completely melted, material. However, due to the alternating additive structure of the different (first and second) material phases described in cooperation with the special embodiments described here, anisotropic crack propagation behavior can be achieved during manufacture and during the intended operation of the component. This is particularly advantageous in the production of high-strength, precipitation-hardened materials that can only be mechanically (re) processed with great difficulty. Alternatively or additionally, an anisotropic and / or targeted mechanical Behavior of the correspondingly produced materials can be achieved particularly easily and thus inexpensively.

The advantages of the described invention also include the avoidance of residual stresses in the additive build-up process, the avoidance of multiple heat input, as is the case, for example, with checkerboard irradiation strategies, and the acceleration of the additive process overall due to fewer surface radiation vectors required (so-called hatching "), which have to be scanned with the corresponding welding beam, and a possibly reduced need for the base material, in particular special powder.

The composite material obtained has improved or superior mechanical and thermomechanical material properties such as anisotropic or favored crack propagation behavior, improved damping properties through areas of the second material phase with reduced density or increased porosity and weight savings.

In one embodiment, the first material phase is produced by completely melting the base material.

In one embodiment, the second material phase is produced by sintering or sintering or partially melting the base material. In the context of sintering or internally, which can be achieved, for example, by a - compared to complete melting - reduced local energy input during the additive process, the base material is advantageously also structurally connected or strengthened with the first material phase.

In one embodiment, the first material phase and the second material phase are produced alternately within a layer, for example laterally or lamellar, for the composite material. In one embodiment, the first material phase and the second material phase are at least partially produced alternately along a direction of construction of the composite material. According to this embodiment, a “sandwich” -like composite structure with alternating layers of first material phase and second material phase can advantageously be achieved.

In one embodiment, both the first material phase and the second material phase are metallic. According to this embodiment, the base material is also expediently metallic.

In one embodiment, both the first material phase and the second material phase are ceramic. According to this configuration, the base material is also expediently ceramic.

In one embodiment, the first material phase is metallic and the second material phase is ceramic, or vice versa.

In one embodiment, the composite material is produced by selective laser melting or laser sintering, or electron beam melting.

In one embodiment, an energy input, in particular an energy beam, for example a laser power or laser power density, is changed during the production of the composite material when changing from the production of the first material phase to the production of the second material phase. This can be done by way of process preparation, for example via CAM "means".

In one embodiment, an energy input during the manufacture of the composite material is reduced when changing from the manufacture of the first material phase to the manufacture of the second material phase. Both by reducing tion and by increasing the energy input, for example, porosity can be brought about in the structure achieved. Too high a power density of the welding beam (energy beam) can, for example, lead to partial evaporation, scaling or sublimation of the material, whereas an energy input that is selected too low in the base material also leaves a porosity behind.

In one embodiment, the second material phase is only produced by a subsequent heat treatment. According to this configuration, the regions of the second material phase can possibly be spared from irradiation.

Another aspect of the present invention relates to a composite material which can be produced or produced by the method described. The composite material accordingly comprises the first material phase and the second material phase, with areas of the second material phase connecting areas of the first material phase along at least one direction of expansion, for example the main direction of symmetry, of the material material, in particular structurally.

In one embodiment, the areas of the first material phase are largely or quasi as hexagonal or polygonal plates or areas.

In one embodiment, the areas of the second material phase are, in particular only, in the spaces between the areas of the first material phase. Preferably, an area or volume content of the interspaces is significantly smaller, for example ten times smaller, than a corresponding content of the first material phase.

In one embodiment, the base material comprises a nickel- or cobalt-based superalloy, such as "CM 247", "Mar- M247 "or" IN939 ". The base material can also consist of "IN738" or "Rene 80".

In one embodiment, the second material phase is arranged in or in the form of a matrix in which the first material phase is embedded.

Another aspect of the present invention relates to a component comprising the composite material, the component being a turbine rotor blade or another component of the hot gas path of a gas turbine.

Another aspect of the present invention relates to a turbine comprising the component described.

Refinements, features and / or advantages that relate to the method here can also relate to the composite material itself or the component, or vice versa.

As used herein, "and / or" when used in a series of two or more items means that any of the listed items can be used alone, or any combination of two or more of the listed items can be used .

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

FIG. 1 shows a schematic sectional view of an additive manufacturing plant, indicating an additive, powder bed-based build-up process.

Figure 2 shows in a simplified schematic

Sectional view of a composite material according to the invention.

FIG. 3 shows a composite material according to the invention in a simplified schematic plan view. FIG. 4 uses a schematic diagram to indicate method steps according to the invention.

FIG. 5 shows a simplified view of a turbine component, comprising the composite material according to the invention.

In the exemplary embodiments and figures, elements that are the same or have the same effect can each be provided with the same reference characters. The elements shown and their size relationships to one another are generally not to be regarded as true to scale; rather, individual elements can be shown exaggeratedly thick or with large dimensions for better illustration and / or for better understanding.

FIG. 1 shows a system or device (not explicitly identified) for the layer-by-layer or additive production of a component or workpiece 10.

The component 10 can be manufactured or manufacturable three-dimensional bodies according to any predetermined geometry, which for example go by means of a beam melting process, such as selective laser melting (SLM), selective laser sintering (SLS) or electron beam melting (EBM) through a large number of individual layers (compare reference L in Figure 2) is built.

The component 10 can be a turbine component, for example a part that is used in the hot gas path of a gas turbine, in particular made of a nickel- or cobalt-based superalloy.

In Figure 1, the component 10 is preferably only partially and not completely built up or manufactured, ie shown during its additive manufacturing. The system also includes a coating device 4 for providing a powder or base material P in layers for the component 10. The system also includes containers (compare left and right in the illustration) in which the base material P is preferably used for a layer-by-layer production of the component 10 and for the corresponding supply and discharge, is held.

The system comprises a building platform 5. The building platform 5 is preferably designed to be lowerable.

The system also has an irradiation device 3, for example a laser or an electron beam device.

According to the additive manufacturing method further described with reference to FIG. 4, base material P is applied in layers and the (applied) starting material 8 is solidified, preferably one after the other, so that component 10 is built up step by step along a build direction Z / will be produced.

The base material P is preferably a metallic base material. Alternatively, it can be a ceramic material. Furthermore, the material can be a material with both metallic and ceramic material properties and / or a so-called MCrAlY alloy or a “cermet” material.

After the production or construction of a single layer for the workpiece 1, the construction platform 5 is further lowered abge preferably by an amount corresponding to the layer thickness L and then individually melted and solidified, for example with a laser beam. In such powder-bed-based processes, a layer thickness of between 20 and 40 μm can usually be achieved. Depending on the predetermined dimensions, a selective irradiation of several a thousand or tens of thousands of individual layers may be required.

In the SLM process, in the context of solidification, a powder bed in particular is rasterized in punctiform, linear or two-dimensional form and / or preferably irradiated according to a predetermined radiation geometry, comprising a large number of irradiation vectors. Corresponding data for the exposure geometry are preferably taken from a CAD file or a corresponding data record.

As an alternative to the SLM process, the layered production process can involve selective laser sintering (SLS) or electron beam melting (EBM).

FIG. 2 shows a schematic side or sectional view of a component 10. The component 10 has a composite material V on its upper side or tip. The composite material V is preferably produced additively by the method described with reference to FIG.

This configuration of the component 10 or of the composite material V can represent, for example, a turbine rotor blade or a part thereof.

The composite material V has a first material phase 1 and the second material phase 2, areas of the second material phase 2 connecting areas of the first material phase 1 along at least one direction of extension, in the present embodiment the vertical z-direction.

Without limiting the generality, the sequence of layers or material phases 1 and 2 can be arranged or formed along any other spatial or main direction of extent (compare reference symbols X, Y) of the corresponding component. In particular, the component 10 can accordingly comprise a layer stack of layers 1 and 2. A layer thickness is identified with the reference symbol L for example. Although this is not explicitly shown, the layer thickness of the layers 1 can differ from that of the layers 2. This allows the layer thicknesses of the layers of the stack to vary overall.

The layers 1 preferably represent the first material phase 1. The layers 2 preferably represent the second material phase 2. Accordingly, the layers and the material phases can be referred to synonymously. A layer preferably at least partially or completely comprises the correspondingly designated material phase.

The layer stack shown can, for example, represent a sandwich structure at the tip of a turbine blade.

The second material phase or its arrangement can correspond to that of a matrix in which the first material phase is embedded.

As shown in FIG. 2, the matrix of the second material phase can be an interlamellar matrix.

The first material phase 1 preferably has a dense material structure without significant porosity.

The second material phase preferably has a certain porosity.

In other words, the described blade tip preferably has alternately completely or largely dense and porous layers, the dense layers 1 being produced by complete melting with an energy beam (see the same reference number 3 in FIG. 1), and the porous layers 2 by a only partial melting, sintering or sintering. As a result, a certain porosity expediently remains in the layers 2.

Although the turbine blade tip described, for example in comparison to a bulk material with a fully melted structure, may have a reduced strength, in particular the crack propagation behavior is improved in the radial (vertical) direction. Furthermore, in the case of an appropriately selected alloy, such as so-called “Alloy247”, Mar-M247, In939 (“Inconel 939”), In738 or Rene 80, improved oxidation resistance or improved high temperature resistance can be achieved.

As shown, an advantageous application can be a turbine rotor blade tip in the high temperature range, for example in the first or second turbine stage.

FIG. 3 uses a schematic plan view to indicate an alternative embodiment of the composite material V according to the invention. Areas of the first material phase 1 and the second material phase 2 are again shown.

In contrast to the illustration in FIG. 2, the areas of the first material phase 1 are largely or quasi hexagonal platelets, and the areas of the second material phase 2 are arranged in the spaces between the areas of the first material phase 1 and connect them.

The technical advantages of the composite materials presented in the embodiments described so far or the correspondingly structured hierarchical structures of material phases are that the residual stresses that occur in the additive build-up process and also those that only occur later during the intended operation or use of the component, can advantageously be reduced. In particular, an anisotropic, customized or improved crack propagation behavior can be generated by suitable mutual arrangement of the first and second material phases. The typical effects of shear reinforcement, which are used in composite materials, for example including a crack deflection, crack blunting, or crack bridging function, so-called "pullout" of the (completely) dense areas and sliding of the corresponding layers, can just be with the material produced here if used to advantage.

The embodiment indicated by way of example with reference to FIG. 3 can in particular be designed similar to a natural mother-of-pearl material or be emulated accordingly.

For example, a volume or mass fraction of the first material phase 1 can be between 80% and 95% of the composite material V. Accordingly, the corresponding proportion of the second material phase 2 can be between 5 and 20% in the composite V material. The first material phase 1 can - as illustrated - be in the form of areas of hexagonal platelets with dimensions or diameters of 5 to 15 μm and heights corresponding to one or more layer thicknesses L.

As shown in FIG. 3, the matrix of the second material phase can be an intertabular matrix.

FIG. 4 uses a schematic diagram to indicate a method according to the invention for the additive manufacture of a composite material V in layers. The method comprises, a), the selective irradiation of the base material P for the manufacture of the first, dense material phase 1, and for the manufacture of a second, porous material phase 2, the manufacture of the first material phase 1 and the manufacture of the second material phase 2 alternately or one after the other. Method step aa) is intended to indicate that an energy input, which can be set using the additive method described, for example by regulating or controlling the irradiation power or the energy density introduced in the process in terms of time or space, when changing from the production of the first material phase 1 changed to the production of the second material phase 2 who can.

According to method step ab), an energy input during the production of the composite material V when changing from the production of the first material phase 1 to the production of the second material phase 2 can in particular be reduced (see above).

In particular, by means of the described production of the second material phase 2, it can only be solidified in a step downstream of the actual additive structure, in particular by a subsequent heat treatment (see same reference symbol ac)).

The definition of irradiation parameters, including the described energy input into a powder bed made from the base material P mentioned, can already be carried out in the course of a preparatory step for the actual additive manufacturing. In particular, the definition or assignment of specific structural parameters, such as the layer thickness L or the energy input mentioned (not explicitly identified) relative to the geometry data (CAD) of the component 10, can be carried out by means of a CAM method.

The advantages according to the invention thus manifest themselves as possible in preparation for production and can be disseminated and used in the form of functional CAM data. Accordingly, the specified method, indicated with the reference symbol CPP, can be at least partially computer-implemented. FIG. 5 uses a schematic view to indicate a component 10 according to a further embodiment. In particular, it is shown that the component described can meet a housing part of a turbomachine, such as a gas turbine. The described advantageous anisotropic crack propagation behavior or a material behavior improved with regard to the crack propagation in at least one fixed direction of the component can be used, for example, in the radial direction or in the circumferential direction.

It can be seen that a curved part of the housing consists of the composite material V or includes it. The structures marked with dashed lines in this part are intended to denote the first material phase 1, which, according to the embodiments described in FIGS. 2 and 3, is arranged in layers on top of one another and in one and the same layer alternating with a second material phase, which is not further identified.

This configuration advantageously makes it possible to improve the propagation of cracks, which may already be initiated during the additive manufacturing, both in the circumferential direction of the arc identified in FIG. 5 and also radially to it.

Alternatively, the component 10 can be another component of a turbomachine, for example a construction part, which is used in the hot gas path of a turbomachine, for example a gas turbine. In particular, the component can be a rotor or guide vane, a ring segment, a burner part or a burner tip, a frame, a shield, a heat shield, a nozzle, a seal, a filter, an orifice or lance, a resonator, a punch or denote a vortex, or a corresponding transition, insert, or a corresponding retrofit part. The invention is not restricted to these by the description based on the exemplary embodiments, but rather encompasses any new feature and any combination of features. This includes in particular any combination of features in the claims, even if this feature or this combination is not itself explicitly specified in the claims or exemplary embodiments.

Claims

1. A method for the layer-by-layer additive production of a composite material (V) comprising the selective irradiation of a base material (P) for producing a first, dense material phase (1), and for producing a second, a porosity material phase (2), wherein the The first material phase (1) and the second material phase (2) are produced alternately, and the first material phase (1) and the second material phase (2) are produced alternately within a layer (L) for the composite material (V) become.

2. The method according to claim 1, wherein the first material phase (1) is produced by completely melting the base material (P), and the second material phase (2) is produced by sintering the base material (P).

3. The method according to any one of the preceding claims, where in the first material phase (1) and the second material phase (2) along a direction of construction (z) of the composite material (V) are produced alternately.

4. The method according to any one of the preceding claims, where both the first material phase (1) and the second material phase (2) are metallic.

5. The method according to any one of the preceding claims, where in the composite material (V) is produced by selective laser melting.

6. The method according to claim 5, wherein an energy input during the production of the composite material (V) when changing from the production of the first material phase (1) to the production of the second material phase (2) is changed (aa)).

7. The method according to claim 5 or 6, wherein an energy entry during the production of the composite material (V) when changing from the production of the first material phase (1) to the production of the second material phase (2) is reduced

(ab)) will.

8. The method according to any one of the preceding claims, where the production of the second material phase (2) only takes place by a subsequent heat treatment (ac)).

9. Composite material (V), produced by a method according to one of the preceding claims, comprising the first material phase (1) and the second material phase (2), Be rich of the second material phase (2) along areas of the first material phase (1) connect at least one direction of expansion (x, y, z) of the material.

10. The composite material (V) according to claim 9, wherein the regions of the first material phase (1) are largely or quasi-hexagonal platelets, and the regions of the second material phase (2) are present in the spaces between the regions of the first material phase (1).

11. The composite material (V) according to claim 9 or 10, wherein the base material comprises a nickel- or cobalt-based superalloy such as "Mar M 247" or "In939".

12. Component (10) comprising the composite material (V) according to one of claims 9 to 11, wherein the component (10) is a turbine blade or another component of the hot gas path of a gas turbine.

13. Turbine (100), comprising the component according to claim 12.