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
  • 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
  • B22F12/30—Platforms or substrates
• • 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
  • B22F10/20—Direct sintering or melting
  • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/30—Process control
  • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
• • 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
  • 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
  • B29C64/10—Processes of additive manufacturing
  • B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
• • 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
  • B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
  • B29C64/194—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
• • 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
  • B29C64/245—Platforms or substrates
• • 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
  • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
• • 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
  • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
  • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2202/00—Treatment under specific physical conditions
  • B22F2202/01—Use of vibrations
• • 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 present invention relates to the field of additive manufacturing. More precisely the invention relates to method for additive manufacturing of metal products in layers on a build platform, which layers are fused during the layer formation to the previ- ously formed layers for forming the metal product.
• One known additive manufacturing method for forming products is powder bed fu sion process.
• the product is formed on a build platform in layers, wherein the powder is first spread in an even layer on the build platform, then the powder is melt and fused solid with energy beam, the build plat- form is lowered a step and new powder level is spread on the build platform and on the solidified layer of the product to be formed. This is repeated until the whole prod uct is finished.
• the typical methods for melting and fus ing the metal powder are electron beam melting (EBM), laser powder-bed fusion (L- PBF), selective laser melting (SLM) and direct metal laser sintering (DMLS), for ex- ample.
• EBM electron beam melting
• L- PBF laser powder-bed fusion
• SLM selective laser melting
• DMLS direct metal laser sintering
• directed energy deposition pro cess Another known additive manufacturing process is directed energy deposition pro cess.
• the layer formation of the product to be manufactured is implemented by melting material as it is being deposited on the build platform.
• metal powders can be used in this process.
• wire can also be used with direct energy deposition method.
• HIP hot isostatic pressing
• the present invention provides a novel solution for removing the pores and bubbles from the solidified metal during the additive manufacturing process so that the qual- ity of the manufactured metal product increases and need for further finishing ac tions and steps is minimized.
• the present invention also provides additional manu facturing parameter for the additive manufacturing process, which may be utilized for speeding up the manufacturing process and thus lowering the manufacturing costs.
• a metal product is formed on a build platform in layers and during the layer formation the metal ma terial is fused to the previously formed layers, wherein during the layer formation process the build platform onto which the product is formed, and via the build plat form the formed portion of the product on the build platform, are vibrated.
• the additive manufacturing method is powder bed fusion process or directed energy deposition process.
• the layer formation of the product takes place at two fusing steps and the vibrating is utilized in the second fusing step. This allows the first fusing step to sufficiently solidify the powder material, for exam ple, so that the vibrating does not move the material away from its place during the layer formation.
• the frequency of the vibrating is changed during formation of the product. This allows avoiding of the natural fre quencies of the product to be manufactured, which natural frequencies also change along the proceeding of the manufacturing process.
• the vibrating is applied in stages, wherein the frequency of the vibrations within a single stage preferably changes during the stage.
• the vibrating is started after the forming of the product on the build platform has started.
• the vibrating is implemented with a vibrating device integrated or connected to the build platform.
• the vibrating device may also be integrated or connected to a part directly connected to the build plat form.
• the vibrating device is preferably ultrasonic device, but can also be a mechan ical vibrator, for example.
• the method may be implemented with an apparatus for additive manufacturing of products, which apparatus comprises a build platform, devices for forming a metal layer on the build platform for forming of a product, and devices for fusing the metal layer to previously formed layers on the build platform during the layer formation, wherein the build platform comprises, or to the build platform is connected, a vibrat ing device for vibrating the build platform.
• the devices for forming a metal layer on the build platform may comprise devices for spreading a layer of metal powder onto the build platform and a printing head through which an energy beam is conveyed in the powder on the build platform for selectively fusing the powder substantially solid.
• the devices for forming a metal layer on the build platform may com prise devices for melting the metal powder as it is deposited on the build platform.
• the apparatus may comprise a plurality of vibrating devices capable of applying different vibrating frequencies during the manufacturing process.
• the apparatus may comprise a device for changing the vibration frequency of the vibrating device during the manufacturing process.
• the vibrating device may be installed below the build platform. This allows the vi brating device to be a fixed part of the apparatus and not removable with the build platform.
• the vibrating device may be an ultrasonic device. Mechanical vibrators may also be used.
• FIG 1 shows schematically an embodiment of an apparatus of the invention.
• Figure 1 shows schematically an embodiment of an apparatus 1 of the invention for additive manufacturing of products 2 with powder bed fusion process.
• the apparatus 1 comprises a printer head 3, which redirects and guides an energy beam 4 created by energy beam generator 5.
• the energy beam 4 can be for exam ple a laser beam.
• the energy beam 4 is directed into a powder bed 6 formed on build platform 7 for layer-by-layer fusion of the powder in the powder bed for forming the product 2.
• the apparatus 1 also comprises a powder stock 8, which is located next to and separated with a partition wall from the powder bed 6 on other side, and an overflow bin 9.
• the powder stock 8 is on a vertically movable powder platform 10, and the overflow bin 9 has vertically movable overflow platform 11 .
• a new layer of powder is spread on the powder bed 6 and on the already formed portion of the product 2. This is achieved by moving the build platform 7 lower for a distance equaling to the thick ness of a new powder layer and raising the powder platform 10 substantially equal distance (in this embodiment), which raises the upper surface of the powder stock 8 above the edge of the partition wall between the powder bed 6 and the powder stock 8.
• a powder recoater 12 is moved first over the powder stock 8 at the level of the upper edge of the partition wall between the powder bed 6 and the powder stock 8 surface towards the powder bed 6, which forces the powder from the powder stock to the area of the powder bed.
• the movement of the powder recoater 12 is then continued over the whole area of the powder bed 6, which creates and levels a new powder layer over the previous layer on the powder bed. After this is done the powder recoater 12 is re turned to its starting position, and new fusion step is started with the energy beam 4. This is then repeated until the whole product 2 to be manufactured is formed.
• the product 2 After the product 2 has been formed with the powder bed fusion process, it is re moved from the powder bed and finished with suitable finishing steps if necessary.
• the apparatus 1 also comprises a plurality of ultrasound devices 13 (three in this embodiment), which in this embodiment are located under the build platform 7 and connected to the lower surface of the build platform for vibrating the build platform within ultrasonic frequencies, and via the build platform the product to be formed on the build platform during the powder bed fusion process.
• a plurality of ultrasound devices 13 three in this embodiment, which in this embodiment are located under the build platform 7 and connected to the lower surface of the build platform for vibrating the build platform within ultrasonic frequencies, and via the build platform the product to be formed on the build platform during the powder bed fusion process.
• the ultrasonic device or devices 13 may also be connected or integrated in the support part 14 of the build platform 7, on which support part the build platform is fixed during the powder bed manufacturing process.
• the ultra sonic vibrations proceed via mechanical connections from the support part 14 to the build platform 7 and to a product 2 on the build platform.
• the vibrations from the ultrasonic devices 13 are conveyed to the product to be formed during the fusing of the powder to solid.
• This fusing can also be implements in two stages, where in the first fusing stage the powder is preliminary fused with suitable parameters and low heat supply quickly to somewhat solid without vibrating, and in the second stage the fusing is applied with high heat supply and more slowly with vibrating. With this two-stage fusing the undesired movement of the powder due to vibrations during fusing stage can be avoided.
• the present invention may also be utilized sim- ilarly with directed energy deposition process, for example.

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

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

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Family Cites Families (5)

• 2019
  • 2019-10-30 FI FI20195928A patent/FI20195928A1/en unknown
• 2020
  • 2020-10-30 EP EP20803895.0A patent/EP4051445A1/de active Pending
  • 2020-10-30 WO PCT/FI2020/050714 patent/WO2021084162A1/en unknown

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