EP4045212A1 - Procédé de fonctionnement d'un dispositif de fabrication additive d'un objet tridimensionnel et procédé de création d'une fenêtre de traitement pour mettre en oeuvre ledit procédé - Google Patents

Procédé de fonctionnement d'un dispositif de fabrication additive d'un objet tridimensionnel et procédé de création d'une fenêtre de traitement pour mettre en oeuvre ledit procédé

Info

Publication number
EP4045212A1
EP4045212A1 EP20792616.3A EP20792616A EP4045212A1 EP 4045212 A1 EP4045212 A1 EP 4045212A1 EP 20792616 A EP20792616 A EP 20792616A EP 4045212 A1 EP4045212 A1 EP 4045212A1
Authority
EP
European Patent Office
Prior art keywords
irradiation
area
process window
sensor
construction field
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
Application number
EP20792616.3A
Other languages
German (de)
English (en)
Inventor
Marc GRONLE
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Trumpf Laser und Systemtechnik GmbH
Original Assignee
Trumpf Laser und Systemtechnik GmbH
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Trumpf Laser und Systemtechnik GmbH filed Critical Trumpf Laser und Systemtechnik GmbH
Publication of EP4045212A1 publication Critical patent/EP4045212A1/fr
Pending legal-status Critical Current

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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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/368—Temperature or temperature gradient, e.g. temperature of the melt pool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
    • 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
    • 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
    • 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
    • B22F12/40—Radiation means
    • B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
    • 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
    • B22F12/40—Radiation means
    • B22F12/49—Scanners
    • 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
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • 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
    • 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
    • B22F2201/00—Treatment under specific atmosphere
    • B22F2201/10—Inert gases
    • 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
    • B22F2203/00—Controlling
    • B22F2203/11—Controlling temperature, temperature profile
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • 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 invention relates to a method for operating a device for the additive production of a three-dimensional object by applying layer by layer and selectively solidifying a, in particular powdery, building material.
  • the invention relates to a method for creating a process window for carrying out the aforementioned method.
  • Such devices for the additive manufacture of a three-dimensional object have an object formation chamber in which the object to be manufactured is created step by step.
  • a work surface is provided in the object formation chamber, which has a construction field for producing the three-dimensional object.
  • the method relates to manufacturing facilities that have at least one beam source and one scanning unit.
  • the method can be carried out on manufacturing devices which have at least two beam sources and two scanning units.
  • the scan unit or scan units are designed and arranged to direct a beam of the respective beam source controlled by the respective scan unit at different target points on the construction field.
  • the beam can be guided or directed to various points on the construction field via the scanning unit.
  • the individual partial beams of the split beam then represent the multiple beam sources within the meaning of the present invention.
  • the production device further comprises a sensor unit.
  • the sensor unit has a monitoring area, wherein the The sensor unit is designed to detect the radiation emitted from the construction field in the monitoring area.
  • the sensor unit can be designed, for example, as an on-axis sensor unit.
  • the monitoring area of the sensor unit can, however, also be steerable independently of the target point of the beam source or scanning unit.
  • the sensor unit can be an on-axis sensor unit of a second scanning unit with or without a second beam source.
  • the sensor unit can also have a fixed location
  • Such a sensor unit can, for example, cover the entire construction field with its monitoring area. Provision can also be made for several of the sensor units just described and / or further sensor units to be present in combination and used in the implementation of the method.
  • SLS Selective Laser Sintering
  • SLM Selective Laser Melting
  • a thin layer of powder is applied to the construction field of the chamber, which is sintered or melted with the laser light to produce the object.
  • the production of the object takes place step by step; Powder layers are applied one after the other and each sintered or melted.
  • the powdery build-up material is coated with a Application device, for example a wiper, a roller, a brush or a blade, applied or painted onto the construction platform.
  • DE 102018 200 721 A1 discloses a method by means of which process parameters that are locally adapted across the construction field are defined as a function of the component geometry to be created locally in each case.
  • the present invention is based on the object of enabling the above-mentioned production facility to be operated with the process parameters being set as precisely as possible and / or avoiding errors. This object is achieved by a method according to claim 1 and a method according to claim 8.
  • the method according to claim 1 accordingly has the following steps:
  • Irradiating a partial area of the building material within the building field by directing the beam from the beam source onto the building material by means of the scanning unit.
  • the amount of energy introduced is selected in such a way that the building material is solidified.
  • the solidification can take place by sintering the powdery building material or by a local melting (formation of a melt pool / melt pool) and then solidify. This forms a partial area of the three-dimensional object to be produced.
  • At least one irradiation parameter characterizing the irradiation is selected locally in such a way that it lies in a process window that changes as a function of the location over the area of the construction field.
  • a process window is meant a relationship that specifies permitted values for the respective irradiation parameter as a function of the detected sensor signal.
  • the process window specifies a relationship between a sensor signal detected by the sensor unit and permissible values for the irradiation parameter.
  • the sensor unit detects the temperature in the irradiated point (for example the local temperature of the melt pool, i.e. the pool of melted building material) and that the process window has a permissible value or a range of values for the irradiation parameter as a function of this temperature specifies which is adhered to in the process management.
  • a process window specifies a relationship between a sensor signal detected by the sensor unit and permissible values for the irradiation parameter.
  • the process window provides various selection options for permissible values for the irradiation parameter, and these values become closed selected using value of the irradiation parameter based on the sensor signal detected by the sensor unit.
  • the process window therefore optionally prescribes several different values for the irradiation parameter, the one to be used being selected on the basis of the sensor signal locally detected by the sensor unit.
  • the process window which changes over the area of the construction site as a function of location, also changes as a function of sub-area types in the area of the objects.
  • special sub-area types are thus defined and in these sub-area types, sub-area type-dependent relationships between the irradiation parameters detected by the sensor unit are specified by the process window.
  • the types of sub-areas in the surface of the objects can include: contour and / or upskin and / or downskin and / or inskin sub-areas with predetermined ones
  • a contour area is an area that forms the outer area of a solidified area; this is exposed or irradiated separately in a so-called contour travel in order to obtain a smooth outer contour in the plane.
  • Upskin areas are areas that form an upper limit of a solidified area, they form an upper "skin" or interface, so to speak. The material is solidified in the layers below, and unconsolidated material follows in the next layer above.
  • downskin areas are areas that form a lower limit of a solidified area; they quasi form a lower "skin” or interface.
  • the material is solidified in the layers above, while the next layer below contains non-solidified material.
  • Inskin areas in turn lie within solidified material, in other words, the material lying next to it is solidified (otherwise the area would be a contour subarea), the material below was solidified in the last exposure pass (otherwise the subarea would be a downskin subarea) and the material following above in the next layer is solidified in the next layer-by-layer exposure pass (otherwise the sub-area would be an upskin sub-area).
  • the sub-areas can also be a contour sub-area and another of the three further sub-area types. Another type of sub-area can be a support sub-area which relates to a material section to be solidified, which is then removed from the finished workpiece or object.
  • the requirements for the material quality are low and the irradiation can be adjusted accordingly.
  • bordering or not bordering on solidified material or powdery building material influences the heat dissipation properties and it is advantageous to adapt the irradiation parameters accordingly.
  • the process window which changes over the area of the construction site as a function of location, can take into account at least one Machine parameters are formed, in particular one of the following machine parameters:
  • the protective gas flows, preferably the speed, volume and homogeneity of the protective gas flow or type of protective gas,
  • the beam profile of the laser beam used preferably the projection of the laser beam onto the powder bed, and / or
  • the process window which changes over the area of the construction area as a function of location, is additionally formed taking into account at least one parameter of the powdery construction material, in particular one of the following parameters of the construction material:
  • the power of the beam source or the amount of energy introduced into the powdery building material by means of the beam is set as a function of the sensor signal, i.e. is in a value range specified by the process window.
  • the speed of movement of the laser or the irradiated point can also be specified as a function of the temperature of the melt pool or another sensor signal.
  • the pulse duration in the case of pulsed irradiation can also be a possible predetermined parameter.
  • a plurality of irradiation parameters characterizing the irradiation are each located in parameter-specific process windows.
  • several parameters that characterize the local irradiation can be selected as a function of location such that they are located in a respective process window that changes as a function of location over the area of the construction field.
  • Different process windows can therefore be provided for the different irradiation parameters.
  • the respective process windows specify a relationship between a sensor signal detected by the sensor unit and permissible values for the respective irradiation parameter.
  • the choice of the other irradiation parameters also influences the permitted process window for a specific irradiation parameter.
  • the process windows can therefore specify a permissible range of values for irradiation parameters as a function of sensor signals and other irradiation parameters.
  • the travel speed of the beam also limit the permitted values for the power of the radiation source.
  • the manufacturing device comprises several sensor units and the process window of the irradiation parameter specifies the range of permitted values of the irradiation parameter as a function of several sensor signals that are detected by the different sensor units. These relationships are also given by the process window, varying over the area of the construction site.
  • At least one irradiation parameter characterizing the irradiation in particular a plurality of characterizing the irradiation, can therefore be used
  • Irradiation parameters each locally selected such that it lies in a process window that changes over the area of the construction site as a function of location, the process window (or in the case of several irradiation parameters) each having a relationship between several sensor signals detected by the sensor units and permissible values for specifies the irradiation parameter (s).
  • the process window or in the case of several irradiation parameters each having a relationship between several sensor signals detected by the sensor units and permissible values for specifies the irradiation parameter (s). It can be provided that at least one sensor unit has the monitoring area with the irradiated point (aimed directly at the irradiated point or offset from it) moved with it, furthermore it can be provided that a further sensor unit has a stationary monitoring area.
  • the process window is defined by locally specified fixed points. These locally specified fixed points are distributed over the construction site, but they do not correspond to the entire area of the construction site. A relationship between one or more detected sensor signals (possibly also further irradiation parameters) and permissible values for the irradiation parameter or parameters is defined in the respective fixed points. As explained above, the permissible values of the irradiation parameter in these fixed points can also depend on the values of one or more of the other irradiation parameters.
  • the method can further include that at points on the construction field which deviate from these locally specified fixed points, the corresponding relationship is determined by linear interpolation of the relationships between the fixed points.
  • the distance from a point located between several fixed points to these fixed points can be used to weight the process windows of the surrounding fixed points and thus to arrive at a local process window in the point located between the fixed points.
  • the three fixed points closest to this point are typically taken into account and a linear interpolation is carried out between their process windows.
  • the weighting of the fixed points surrounding a point lying between several fixed points can also take place within the framework of the interpolation using triangles spanned between the point and the fixed point, the spanned triangle opposite it with respect to the point is assigned to a respective fixed point.
  • a locally variable process window specifies at least the travel speed of the laser beam as an irradiation parameter as a function of a detected sensor signal.
  • a locally variable process window specifies at least the power of the laser beam as an irradiation parameter as a function of a detected sensor signal.
  • a locally variable process window specifies at least the pulse duration of the laser beam as an irradiation parameter as a function of a detected sensor signal.
  • Another example of a corresponding irradiation parameter are values of the scanning unit.
  • Another example of a corresponding irradiation parameter is a beam diameter.
  • the process window determines the corresponding irradiation parameter as a function of at least one characterizing the melt pool Sensor signal.
  • "Sensor signals characterizing the melt pool” in this sense include at least the local temperature at the momentarily irradiated point (before melting or temperature of the melt pool), the local temperature at a measuring point preceding the irradiated point, the local temperature at a measuring point following the irradiated point, the cooling process of an already irradiated point and / or the heating behavior of a point towards which the irradiated point is moving.
  • the sensor signal which is used to determine the permissible values of the irradiation parameter can be determined, for example, in that the monitoring area of the sensor unit is advanced to the movement of the beam or the movement of the target point of the beam during the irradiation process. With the preceding it is meant that the monitoring area moves along the area that will be irradiated later on the construction field in front of the beam. The monitored area can be guided at a constant distance from the target point of the beam. It is also conceivable, however, that the monitored area is moved to the target point of the beam with a certain lead time. This means that the monitoring area always passes a point on the construction site at exactly the same time offset as the target point of the beam.
  • conclusions can be drawn about the conditions, in particular temperature conditions, of the still powdery and not yet solidified
  • Build-up material is drawn, these can then be used in the context of the process window when "setting" the appropriate irradiation parameters. It is also possible to determine the sensor signal, which is used to determine the permissible values of the irradiation parameter, by means of a monitoring area of the sensor unit that tracks the movement of the beam during the irradiation process. “Followed” means that the monitoring area follows the movement pattern of the beam. The monitoring area can follow the beam at a defined distance. The distance can be defined in terms of time or geometry. The monitored area can therefore be guided over the construction field with a specific time offset following the beam or be moved following the beam at a specific spatial distance. On the basis of the detected signals of the sensor unit, for example, conclusions can be drawn about the conditions, in particular temperature conditions, of the solidifying or cooling building material. These can then be used in the context of the process window when "setting" the suitable irradiation parameters.
  • the local adaptation of the process window makes it possible to take into account non-uniform conditions over the area of the construction field. Even if the sensor signals are identical at different points on the construction site, different conditions may still prevail at different points on the construction site or different irradiation parameters may be necessary to achieve the same results. This can be due, for example, to different angles at which the beam hits the construction field or to different protective gas flows.
  • the beam profile of the laser beam used can also vary depending on the location. In particular the flow of the used Protective gas can vary depending on the location and thus lead to different convective heat dissipation conditions at different points on the construction site.
  • the process window or the process window assigned to the individual inventory parameters is created in accordance with one of the following types.
  • a process window for carrying out a method for operating a production facility or for carrying out the irradiation in accordance with one of the embodiments described here can include:
  • Construction of several three-dimensional reference objects by applying layer by layer and selective consolidation of construction material within the construction area.
  • the different building processes of the reference objects each changed at least one irradiation parameter.
  • one or more irradiation parameters are acquired and recorded.
  • the local position on the construction site is also recorded and recorded.
  • a map of the construction field is created, which shows the respective value of the irradiation parameters used at the various points of the construction field.
  • the method for creating the process window comprises the acquisition and recording of one or more irradiation parameters as a function of the irradiated position on the construction field.
  • the creation of the process window also includes monitoring the construction process by detecting sensor signals by means of one or more sensor units as a function of the irradiated position on the construction field and recording the sensor signals.
  • the sensor signals are also recorded and stored as a function of the respective position on the construction field. Subsequently, the irradiation parameters used and the detected sensor signals are then available for the various positions on the construction site as a function of the position.
  • the reference objects are also checked. It can therefore be checked whether the construction process on the reference objects has led to a satisfactory result in each case, in particular at which positions on the construction site satisfactory results were achieved. Because different reference objects were set up and the irradiation parameters were changed in the process, a value corridor for permissible irradiation parameters for the respective locations on the construction field can be determined. For example, it can be identified if at a certain point with a certain power of the laser source the energy input into the building material was no longer sufficient to completely melt the material and thus lead to a defect-free reference object. Provision can also be made for the “checking” of the reference objects to take place by means of a simulation based on the recorded irradiation parameters and sensor signals.
  • the parameters used and received sensor signals lead to a sufficiently satisfactory quality of the reference object obtained.
  • the physical analysis of the reference objects is provided, for example by means of sectional images, visual inspection, load tests and, for example, other metallurgical examination methods.
  • a location-dependent process window can then be created.
  • This creation of the process window is based on the recorded and recorded irradiation parameters and sensor signals as well as the result of the inspection of the reference objects.
  • the corresponding process window specifies a relationship between at least one sensor signal or several sensor signals and permissible values for the irradiation parameter or several irradiation parameters. It can be provided that the construction field is divided into fictitious sub-areas when the process window is created.
  • the recorded irradiation parameters and sensor signals can then be averaged over the respective sub-areas and, using the averaged values for each sub-area, a fixed point with a predetermined relationship between one or more detected sensor signals and permissible values for the irradiation parameter or parameters can be determined.
  • the spatial arrangement of the fixed points on the construction site can correspond in particular to the respective centroids of the sub-areas. This means that local "outliers" in the measured sensor signals can be "averaged out” and the determination of the process window is less prone to failure.
  • the partial areas used can in particular have a hexagonal shape.
  • Each entry of the vector can correspond to a sensor signal averaged with respect to the sub-area.
  • a covariance matrix can also be created. The covariance matrix describes the respective variance of the individual sensor signals of the mean value vector as well as the respective covariances of the sensor signals to one another.
  • the sensor units used in the method or one of the sensor units used can be designed as an on-axis sensor unit. It is also possible to use a sensor unit with a locally fixed monitoring area or sensor units Monitoring area that can be moved independently of a beam source.
  • the sensor units can be formed, for example, by photosensitive sensors, for example a photodiode, a camera, a spectrometer and / or a pyrometer.
  • photosensitive sensors for example a photodiode, a camera, a spectrometer and / or a pyrometer.
  • the creation of the process window can also be summarized in that reference construction jobs are created with certain, for example, partially already tested irradiation parameters and the sensor values and irradiation parameters are recorded. The values can then be segmented based on their position (formation of the sub-areas). Statistical process windows can then be determined on the basis of the segmented values. Due to the local segmentation, these process windows vary depending on the position. Compared to an averaging over the entire construction site, a more precise process window is achieved and local conditions of the construction site can be taken into account.
  • the acquisition and recording of the sensor signals and irradiation parameters is typically done with a frequency in the range of 25-600kHz.
  • FIG. 1 shows a schematic view of a production device for the additive production of a three-dimensional object on which the method according to the invention is carried out;
  • FIG. 2 shows a schematic representation of the sequence of the method for irradiation
  • FIG. 3 shows a schematic representation of the sequence of the method for creating the process window
  • FIG. 4 shows a schematic plan view of the construction field of the production facility, this being subdivided into individual partial areas;
  • FIG. 5 shows a schematic plan view of a section of the construction field of the production facility, with the individual subregions being assigned respective process windows;
  • FIG. 6 shows an illustration of a weighting of different fixed points
  • FIG. 7 shows a schematic view of a further production device for the additive production of a three-dimensional object on which the method according to the invention is carried out.
  • FIG. 1 shows a manufacturing device 10 on which the method according to the invention is carried out.
  • the device 10 has an object formation chamber 12.
  • a work surface 14 which has a construction field 16.
  • An application device 18 is also arranged in the object formation chamber 12, which in the present example is in the form of a roller but can also be in the form of a doctor blade, for example.
  • Powdery building material 20 which in the present case is arranged in layers on the building field 16, is shown only schematically and in certain areas, the illustration being greatly enlarged.
  • Powdery building material 20 is distributed in layers over the building field 16 by means of the application device 18.
  • the production device 10 comprises two scanning units 22.
  • a primary beam source 24a is assigned to the primary scanning unit 22a and a further or secondary beam source 24b is assigned to the further or secondary scanning unit 22b.
  • the method is carried out by means of a manufacturing device 10 with only a single scanning unit 22 and beam source 24.
  • a respective sensor unit 26 and a beam splitter 28 are assigned to the respective scan units 22.
  • a monitoring area 30 of the sensor units 26 is guided onto the scanning units 22 and, on the other hand, a respective beam 32 of the beam sources 24 are coupled into the same optical path.
  • Both sensor units 26 are designed as on-axis sensor units 26 in the present example.
  • the secondary beam source 24b is shown in the deactivated state in FIG. 1, so that no beam 32b emanates from it.
  • the primary beam source 24a is shown in the activated state in FIG. 1, so that a beam 32a emanates from it.
  • the beam 32a is directed via the scanning unit 22a onto an object 34 to be built on the construction field 16, so that it irradiates a target point 36a.
  • the monitoring areas 30 of the sensor units 26 are also directed at the construction field 16 via the respective scanning units 22.
  • the method is carried out by means of a manufacturing device 10 which does not have a secondary beam source 24b.
  • a secondary scanning unit 22b which is independent of the primary beam source 24a or the primary scanning unit 22a can also be provided, which makes it possible to move the monitoring area 30b of the secondary sensor unit 26b over the construction field 16.
  • the target point 36a of the primary scanning units 22a is moved along a movement direction 38 over the construction field 16.
  • the target point 36a is that area on the construction field 16 to which the scanning unit 22 guides the corresponding beam 32.
  • the monitoring area 30b is moved in advance of the beam 32a or the target point 36a.
  • the monitoring area 30a is directed at the target point 36a and is moved along with it.
  • a correspondingly constructed manufacturing device 10 with only one beam source 24, scanning unit 22 and on-axis sensor unit 26 is illustrated in FIG. 6 and can also carry out the method.
  • Block 101 illustrates irradiating a point on the construction field.
  • Block 103 illustrates moving the irradiated point.
  • Block 105 illustrates an adaptation of the irradiation parameters carried out during the movement.
  • Block 201 illustrates irradiating a point on the construction field in order to build up a reference object.
  • Block 203 illustrates the acquisition and recording of the local irradiation parameters.
  • Block 205 illustrates a simultaneous monitoring of the construction process by detecting and recording the local sensor signals.
  • Block 207 illustrates checking the reference objects.
  • Block 209 illustrates the creation of a location-dependent process window based on the acquired and recorded irradiation parameters and sensor signals as well as the result the examination of the reference objects.
  • the process window specifies a relationship between sensor signals and permissible values for the irradiation parameters.
  • the local process windows generated can then be used to carry out the irradiation with the corresponding irradiation parameters.
  • FIG. 4 shows a view of the construction field 16, this being divided into sub-areas 40.
  • the subregions 40 are designed in a hexagonal shape.
  • Each of the subregions 40 has a centroid 42.
  • the centroids 42 each form fixed points 44.
  • the irradiation parameters and sensor signals detected in steps 203 and 205 have been averaged over the respective subregions 40. On the basis of the averaged values, a relationship between one or more detected sensor signals and irradiation parameters B and permissible values for the other irradiation parameters was determined for each sub-area 40 for the respective fixed point 44.
  • FIG. 5 illustrates how different process windows 46 are assigned to the different subregions 40 or fixed points 44.
  • Each sub-area 40 assigns a set 48 of permissible irradiation parameters B and a set 50 of irradiation parameters B to be preferably used to a sensor signal S. If a point 52 that does not lie on any of the fixed points 44 is to be irradiated in order to build up an object 34, the process windows 46 of the adjacent fixed points 44a, 44b and 44c are linearly interpolated to create a process window 46 with permissible values for the point 52 determined.
  • the respective fixed points 44a-44c surrounding the point 52 can be used as weightings of the fixed points 44a-44c, each spanned between the fixed points and the point 52.
  • the triangle 54a -54c opposite it with respect to point 52 is assigned to each of the fixed points 44a-44c.
  • the fixed point 44a is weighted with the area of the triangle 54a and the fixed point 44b is weighted with the area of the triangle 54b and the fixed point 44c is weighted accordingly with the area of the triangle 54c.

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Abstract

L'invention concerne un procédé de fonctionnement d'un dispositif de fabrication additive d'un objet tridimensionnel, les paramètres d'irradiation se trouvant à l'intérieur d'une fenêtre de traitement localement variable, et l'invention concerne également un procédé de création d'une fenêtre de traitement pour mettre en œuvre ledit procédé.
EP20792616.3A 2019-10-16 2020-10-14 Procédé de fonctionnement d'un dispositif de fabrication additive d'un objet tridimensionnel et procédé de création d'une fenêtre de traitement pour mettre en oeuvre ledit procédé Pending EP4045212A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102019127952.6A DE102019127952A1 (de) 2019-10-16 2019-10-16 Verfahren zum Betreiben einer Einrichtung zur additiven Herstellung eines dreidimensionalen Objekts sowie Verfahren zum Erstellen eines Prozessfensters zur Durchführung des vorgenannten Verfahrens
PCT/EP2020/078840 WO2021074188A1 (fr) 2019-10-16 2020-10-14 Procédé de fonctionnement d'un dispositif de fabrication additive d'un objet tridimensionnel et procédé de création d'une fenêtre de traitement pour mettre en œuvre ledit procédé

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EP4045212A1 true EP4045212A1 (fr) 2022-08-24

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US (1) US20220241861A1 (fr)
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WO (1) WO2021074188A1 (fr)

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DE102022126951A1 (de) 2022-10-14 2024-04-25 Siemens Energy Global GmbH & Co. KG Verfahren und Vorrichtung zur Regelung eines Wärmeeintrags in ein Bauteil

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CN108883575A (zh) * 2016-02-18 2018-11-23 维洛3D公司 准确的三维打印
EP3258219A1 (fr) * 2016-06-15 2017-12-20 Eidgenössische Materialprüfungs- und Forschungsanstalt EMPA Contrôle qualité in situ et en temps réel dans des processus de fabrication additive
US20180178285A1 (en) * 2016-12-23 2018-06-28 General Electric Company Method for controlling plume trajectories in additive manufacturing
DE102017202725B3 (de) * 2017-02-21 2018-07-19 SLM Solutions Group AG Vorrichtung und Verfahren zum Kalibrieren eines Bestrahlungssystems, das zum Herstellen eines dreidimensionalen Werkstücks verwendet wird
JP7121109B2 (ja) * 2017-07-12 2022-08-17 スリーディー システムズ インコーポレーテッド 直接金属レーザ溶融で用いられる高出力密度レーザを直接校正するためのセンサシステム
DE102018200721A1 (de) * 2018-01-17 2019-07-18 Realizer Gmbh Verfahren zur Ermittlung von Daten zur verbesserten Steuerung einer Vorrichtung zur Herstellung von Gegenständen nach der Methode des selektiven Pulverschmelzens sowie Vorrichtung dazu
DE102018203444A1 (de) * 2018-03-07 2019-09-12 MTU Aero Engines AG Verfahren und Vorrichtung zum selbstoptimierenden, additiven Herstellen von Bauteilkomponenten
EP3542928A1 (fr) * 2018-03-23 2019-09-25 United Grinding Group Management AG Dispositif de fabrication additive

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US20220241861A1 (en) 2022-08-04
WO2021074188A1 (fr) 2021-04-22
CN114585498A (zh) 2022-06-03
DE102019127952A1 (de) 2021-04-22
WO2021074188A8 (fr) 2022-05-12

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