EP4436734A1 - Procédé pour la production d'un composant, et composant corrélativement produit - Google Patents

Procédé pour la production d'un composant, et composant corrélativement produit

Info

Publication number
EP4436734A1
EP4436734A1 EP22821849.1A EP22821849A EP4436734A1 EP 4436734 A1 EP4436734 A1 EP 4436734A1 EP 22821849 A EP22821849 A EP 22821849A EP 4436734 A1 EP4436734 A1 EP 4436734A1
Authority
EP
European Patent Office
Prior art keywords
component
supplementary
additive manufacturing
basic structure
shape
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
EP22821849.1A
Other languages
German (de)
English (en)
Inventor
Karlmann Kanzler
Georg Wimmer
Christian Michael HERWERTH
Felix ARMBRÜSTER
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.)
Linde GmbH
Original Assignee
Linde 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 Linde GmbH filed Critical Linde GmbH
Publication of EP4436734A1 publication Critical patent/EP4436734A1/fr
Pending legal-status Critical Current

Links

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
    • B22F10/80—Data acquisition or data processing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • 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
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
    • 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
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
    • B23K1/0012—Brazing heat exchangers
    • 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
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/20—Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating
    • 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
    • B23K9/00—Arc welding or cutting
    • B23K9/04—Welding for other purposes than joining, e.g. built-up welding
    • B23K9/044—Built-up welding on three-dimensional surfaces
    • B23K9/046—Built-up welding on three-dimensional surfaces on surfaces of revolution
    • 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
    • B23K9/00—Arc welding or cutting
    • B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
    • 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
    • B33Y50/00—Data acquisition or data processing for 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
    • 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
    • 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
    • B33Y80/00—Products made by additive manufacturing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
    • F28F9/02—Header boxes; End plates
    • F28F9/04—Arrangements for sealing elements into header boxes or end plates
    • F28F9/16—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
    • F28F9/18—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding
    • F28F9/182—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding the heat-exchange conduits having ends with a particular shape, e.g. deformed; the heat-exchange conduits or end plates having supplementary joining means, e.g. abutments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/04—Tubular or hollow articles
    • B23K2101/14—Heat exchangers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/10—Aluminium or alloys thereof
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2275/00—Fastening; Joining
    • F28F2275/06—Fastening; Joining by welding
    • 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 a method for producing a component for a technical device and a component for a technical device.
  • a position of the highest load on the component can be assumed, for example.
  • the wall thickness of the component at this position can be selected in such a way that the wall can withstand the high loads there. In conventional manufacturing processes, this position with the highest loads defines the wall thickness of the entire component.
  • WO 2022/073640 A1 proposes providing a prefabricated component for a motor vehicle with additively manufactured reinforcement structures at certain points and in this way preventing or redirecting deformation in the event of an accident.
  • WO 2017/021440 A1 also proposes the additive application of reinforcement structures to a prefabricated component, with the component being held in a mold in order to prevent deformation during additive reinforcement.
  • the production of a component by means of purely additive manufacturing is known, for example, from US Pat. No. 11,022,967 B2.
  • a basic structure can be provided for the production of a component and supplemented by a supplementary structure by means of additive manufacturing.
  • the supplementary structure is applied to the basic structure by means of additive manufacturing and is connected to it with a material bond.
  • the present invention sets itself the task of improving the production of components, which is carried out in a corresponding manner, in part, by means of additive manufacturing.
  • the present invention proposes a method for producing a component for a technical device and a component for a technical device with the features of the independent patent claims. Configurations are the subject matter of the dependent patent claims and the following description.
  • the invention is now based on the finding that corresponding post-treatment can be avoided if the deformation caused by additive manufacturing is predicted and a form of the component present before additive manufacturing is carried out, hereinafter also referred to as the initial form, and the manner of the additive manufacturing in such a way that the component has the target shape after additive manufacturing.
  • the component provided with the supplementary structure and with the target shape, ie in particular without further deformation of the component, can then be installed in an arrangement of which the component becomes part.
  • An embodiment of the invention therefore also includes production of an arrangement using the component.
  • deformation of a component is therefore explicitly permitted in additive manufacturing and not minimized or prevented in a costly manner.
  • the deformation is thus an integral part of the manufacturing process to achieve the desired final shape.
  • the invention proposes a method for producing a component for a technical device, which has a basic structure and one or more supplementary structures.
  • the one or more supplementary structures is or are applied to the basic structure by means of additive manufacturing and the basic structure is subjected to deformation during additive manufacturing.
  • the basic structure is provided with an initial shape which is selected in such a way that the deformation leads to a desired target shape of the basic structure.
  • the deformation can in particular be a stress deformation caused by thermal stresses during additive manufacturing.
  • a basic structure of the component (the singular is used below merely for the sake of simplicity, although the corresponding explanations also relate to components that are present in a plurality) can be manufactured with a predetermined wall thickness.
  • At least one area of the component expediently at least one area to be reinforced, can be determined or identified or localized with the aid of an optimization method.
  • a reinforcement structure can be applied to the base structure by means of an additive manufacturing process.
  • this reinforcement structure is a supplementary structure because it supplements the basic structure accordingly.
  • a (stress) deformation caused by the additive manufacturing process can be influenced in the desired way by a (further) supplementary structure.
  • the latter which does not have or need to have a reinforcing effect per se, is a structure that only serves to compensate for deformations. It is also referred to below as the compensation structure. As mentioned, all of the elements can be present in plural form, but are described below in a simplified manner in the singular.
  • the basic structure expediently represents a basic volume or a first volume of material.
  • the reinforcement structure represents in particular an additional volume or a second volume of material.
  • the compensation structure represents in particular a further additional volume or a third volume of material. The entire component or an overall volume of the component is thus formed by the basic structure or the basic volume and the reinforcing structure applied thereto and the compensating structure or their additional volumes.
  • the basic structure is or is produced non-additively, with the proposed method being able to include the production of the basic structure. It can be produced, for example, by means of a manufacturing process by archetypes or reshaping. According to the usual expert understanding, archetypes are understood here to mean a group of manufacturing processes in which a solid body is produced from an amorphous substance, which body has a geometrically defined shape. Primitive Forming is used to create the initial form of a solid body and to create the cohesion of matter.
  • the primary shaping can be carried out from the liquid or plastic state, in particular by a casting process such as gravity, pressure, low-pressure, centrifugal or continuous casting, or by compression or drawing molding. Forming can in particular be hot or cold forming or sheet metal or solid forming or compression, tension compression, bending or include thrust forms.
  • the present invention is not limited to a specific non-additive manufacturing process.
  • a corresponding manufacturing process is non-additive in particular if there is no step-by-step application of material, for example in more than 2, 3, 4, 5 or 10 steps, but the production is carried out in particular by providing a final shape that is essentially already desired (or a present form) having component or sub-component, but the sequencing of process steps such as primary and subsequent forming or the joining of different, corresponding workpieces, for example by welding or pressing, is not excluded.
  • a non-additive manufacturing process is carried out in several layers without melt or powder application.
  • an entire wall that defines the component can be produced in one piece.
  • individual partial walls can also be manufactured separately, e.g. by means of such manufacturing processes as primary shaping or forming, and combined to form the overall wall of the component, e.g. by means of a joining process, such as a welding process.
  • the wall thickness of the basic structure can be specified as the smallest possible, in particular minimal wall thickness, which is expediently designed for a low load acting on the component or which the basic structure requires at least in order to be able to withstand the loads acting on it.
  • the basic structure is then specifically reinforced at points with higher loads by the reinforcement structure, so that the component can also withstand the higher loads acting there at these points.
  • the reinforcement structure can thus be applied specifically to particularly stressed positions of the component and the component can be individually adapted to the load case at hand.
  • the compensating structure only serves to compensate for deformations, but does not necessarily provide a strengthening effect.
  • a plurality of supplementary structures can be added to the basic structure by means of additive manufacturing be applied, wherein the multiple supplementary structures comprise one or more reinforcement structures and one or more compensating structures, wherein, as mentioned, the reinforcing structures are in particular supplementary structures that increase the stability of the component at one or more points, and the compensating structures in particular are not necessarily supplementary structures that increase stability but cause desired deformation represent.
  • the reinforcement structures are therefore applied on the basis of a specified strength of the component and the compensating structures are applied on the basis of a deformation forecast.
  • first and “second” supplementary structures are used more generally.
  • additive manufacturing makes it possible to apply the reinforcement structure or a first supplementary structure and the compensation structure or a second supplementary structure with pinpoint accuracy and thus to produce precise local reinforcements of the basic structure and influences on the deformation.
  • Additive manufacturing is a manufacturing process in which a three-dimensional object or structure is created by consecutively adding a material layer by layer. A new layer of material is applied one after the other, solidified and firmly bonded to the layers below, e.g. with the help of a laser, electron beam or arc.
  • the areas or locations at which the reinforcement structure or first supplementary structure or the compensating structure or second supplementary structure is to be applied to the basic structure can be determined or identified or localized within the scope of the present method using the optimization method or a corresponding optimization algorithm.
  • Optimization methods or optimization are generally to be understood as meaning analytical or numerical calculation methods in order to find optimized, in particular minimized or maximized, parameters of a complex system.
  • the deformation can be forecast using a forecasting method while obtaining forecast data, and material can be applied in additive manufacturing on the basis of the forecast data.
  • the invention allows a particularly targeted, precise application of material.
  • the forecasting method can in particular include the use of a finite element method and/or an optimization algorithm. Corresponding methods can also be carried out to determine the material application required for the reinforcement structure.
  • a solution space Q ie a set of possible solutions or variables x and a target function f
  • a set of values for the variables or solutions x e Q is sought, so that f(x) satisfies a predetermined criterion, for example becoming a maximum or a minimum.
  • boundary or secondary conditions can also be specified, with admissible solutions x having to fulfill these specified boundary conditions.
  • a target function can be defined such that the overall wall thickness of the component is minimized as much as possible.
  • the optimization method can be carried out particularly expediently as a function of a numerical solution, in particular using the finite element method mentioned.
  • the finite element method is a numerical method based on the numerical solution of a complex system of partial differential equations.
  • the basic structure or another component is divided into a finite number of sub-areas of a simple form, i.e. into finite elements whose physical or thermo-hydraulic behavior can be calculated on the basis of their simple geometry.
  • the partial differential equations are replaced by simple differential equations or by algebraic equations.
  • the system of equations thus obtained is solved to obtain an approximate solution of the partial differential equations.
  • the physical behavior of the body as a whole is simulated by predetermined continuity conditions during the transition from one element to the neighboring element.
  • Such a finite element method is particularly advantageous for carrying out an optimization method.
  • the optimization method is carried out as a function of a simulation of the basic structure and additive manufacturing, in particular a numerical simulation.
  • a static or dynamic simulation can be carried out, for example a thermo-mechanical strength simulation.
  • the component or the entire technical device together with the component can be theoretically reproduced. The behavior of the part during additive manufacturing as well as the stresses, loads, etc. acting on the part can be simulated.
  • the quantities and positions of the material applied as a compensation structure can be changed in the course of the simulation in order to examine the behavior of the component under different conditions.
  • the component can thus be divided into a large number of individual areas as part of the optimization process, and it can be determined individually for these areas whether material should be applied in these areas by means of additive manufacturing.
  • the present method provides an advantageous possibility for producing a partially additively manufactured component.
  • the basic structure can be manufactured non-additively in a cost-effective and material-saving manner.
  • the use of the additive manufacturing process can be reduced, so that costs and material can also be saved here.
  • the component can be manufactured in a cost-effective, material-saving and weight-reduced manner and can be optimally adapted to the later application and its area of application.
  • the reinforcement structure or at least one of the plurality of reinforcement structures and the compensation structure or at least one of the plurality of compensation structures or, in other words, the first supplementary structure(s) and the second supplementary structure(s), by means of additive manufacturing can be applied at the same time or at different times.
  • the deformation can be determined and the application of the compensation structure or at least one of the several compensation structures, i.e. the second supplementary structure(s) dependent be carried out by this. This makes it possible to react precisely to the deformations that actually occur.
  • the supplementary structure(s) is/are applied to the basic structure by means of wire arc additive manufacturing (WAAM).
  • WAAM wire arc additive manufacturing
  • individual layers are created using a melting wire and an arc.
  • Welding torches for example for gas metal arc welding, can be used for this purpose, with an arc burning between the welding torch and the component to be produced.
  • a corresponding material e.g. in the form of a wire or strip, is continuously fed and melted by the arc.
  • molten drops are formed, which transfer to the workpiece to be manufactured and are firmly connected to it.
  • the respective material can be fed to the welding torch as a consumable wire electrode, for example, with the arc burning between this wire electrode and the component. It is also conceivable to supply the respective material in the form of an additional wire, which is melted by the arc of the welding torch.
  • additive manufacturing methods can be used, in the course of which the respective material of the support structure or the additional volume is applied, for example in powder form or in the form of wires or strips, and exposed to a laser and/or electron beam.
  • the respective material can be subjected to a sintering or melting process, for example, in order to be solidified.
  • the next layer can be created in an analogous manner.
  • additive manufacturing processes are, for example, selective laser sintering (SLS), selective laser melting (SLM), electron beam melting (EBM), stereolithography (SL) or fusion layering ( Fused Deposition Modeling (FDM) or Fused Filament Fabrication (FFF).
  • the support structure can preferably be produced by means of cold spraying or cold gas spraying.
  • Cold Spray, CS can be applied to the base structure.
  • the respective material is applied, for example in powder form, at high speed.
  • a process gas such as nitrogen or helium that has been heated to a few hundred degrees can be accelerated to supersonic speed, for example by expansion.
  • the powder particles of the respective material can be injected into the gas jet so that they are accelerated to high speed and form a firmly adhering layer when they hit the base structure.
  • the basic structure, the reinforcement structure and the compensating structure can be manufactured from the same material, for example from aluminum or an aluminum alloy. Furthermore, the basic structure, the reinforcement structure and the compensating structure (or part two of these components) can also be made from different materials.
  • the materials for the basic structure, the reinforcement structure and the compensating structure can each be selected based on their specific material properties and/or based on specific requirements for the component or based on the specific loads and deformations acting on the component.
  • the basic structure, the reinforcement structure and the compensating structure can be made from similar or dissimilar materials, in particular from aluminum materials or aluminum alloys.
  • similar or “identical” materials are to be understood in particular as materials that have the same or comparable structure and/or the same or comparable thermal expansion, which is not the case with “dissimilar” or “dissimilar” materials.
  • Similar types are, for example, different carbon steels. Carbon steel and stainless steel, for example, are dissimilar due to the different material structure (microstructure and thermal expansion). Similar materials can also be understood to mean different aluminum alloys, which lead to large differences in mechanical and thermal parameters due to the variety of possible alloys.
  • connection of an aluminum material with a (stainless) steel material can be dissimilar, which is "not compatible" in the common understanding.
  • a material of the supplementary structure, in particular of the compensating structure can be a material with known or particularly advantageous deformation properties.
  • the component is a component of a process engineering apparatus, a pressure vessel or a lightweight component of a land vehicle or aircraft.
  • the present invention is suitable for a large number of different areas of application and for the production of components for various technical devices in process, regulation and/or control technology.
  • a technical device is to be understood in particular as a unit or a system of different units for executing a technical process, in particular a procedural, regulation and/or control engineering process.
  • the technical device can advantageously be designed as a machine, ie in particular as a device for converting energy or force, and/or as an apparatus, ie in particular a device for converting substance or matter.
  • the technical device can also be designed in particular as a plant, ie in particular as a system made up of a large number of components, which can each be machines and/or apparatuses, for example.
  • the component is a component through which fluid flows or through which fluid can flow for a process engineering device.
  • the component is a component for a pressure vessel or a pressure vessel itself.
  • a pressure vessel can be provided in particular for storing a substance under positive or negative internal or external pressure.
  • Pressure vessels can be exposed to high alternating pressure loads.
  • configurations of the present invention are not limited to use in corresponding technical areas, but are generally used in the manufacture of other components, in particular structural components, for example in apparatus and container construction, but also in other areas in which additive manufacturing is used, e.g. for lightweight construction in aircraft or vehicle construction.
  • the component is a header with nozzle of a plate fin heat exchanger (PFHE), for example a brazed aluminum plate fin heat exchanger (Brazed Aluminum Plate-Fin Heat Exchangers, PFHE; designations according to the German and English edition of ISO 15547-2:3005).
  • PFHE plate fin heat exchanger
  • Plate heat exchangers of this type have a large number of separating plates and fins arranged in a stack, as well as cover plates, edge strips or sidebars, distributors or headers.
  • pieces of pipe or pipelines are provided for supplying and removing individual media. Such elements can be exposed to high loads during operation of the heat exchanger, e.g. high temperatures or temperature differences as well as high pressures and mechanical stresses, and are therefore particularly suitable for being produced using the present method.
  • the basic shape can in particular be a non-complex shape that is easy to produce, which is selected in particular from a cylindrical shape, a spherical shape, a hemispherical shape, a spherical shape, a plate shape and partial shapes thereof.
  • the production is particularly simple due to the combined production.
  • the basic shape can in particular also be selected from a round or polygonal tube or a full profile, which can be deformed in a targeted manner by applying a corresponding material.
  • a component for a technical device that has a basic structure and one or more supplementary structures, the basic structure being manufactured non-additively and the one or more supplementary structures being applied to the basic structure by means of additive manufacturing and the basic structure being subjected to deformation during additive manufacturing also subject of the present invention.
  • the basic structure was provided with an initial shape that was chosen in such a way that the deformation led to a desired target shape of the basic structure.
  • the supplemental structures include one or more reinforcement structures and one or more balancing structures.
  • the present invention also relates to a component for a technical device, which in particular is made according to the present method. Configurations of this component according to the invention result from the above description of the method according to the invention in an analogous manner.
  • FIG. 1 shows a heat exchanger in a simplified isometric representation.
  • FIGS 2A through 2C illustrate aspects of the present invention.
  • a heat exchanger is shown schematically in FIG.
  • the heat exchanger represents a technical or procedural device, wherein individual elements or components of the heat exchanger 100, in particular through which fluid flows, in particular its header 7 and socket 6, are particularly advantageously manufactured according to an embodiment of the invention.
  • the heat exchanger 100 shown in FIG. 1 is a brazed aluminum plate-fin heat exchanger (PFHE; designations according to the German and English editions of ISO 15547-2:3005). how it can be used in a variety of systems at different pressures and temperatures.
  • Corresponding heat exchangers are used, for example, in the low-temperature separation of air, in the liquefaction of natural gas or in plants for the production of ethylene.
  • aluminum can also refer to an aluminum alloy.
  • Brazed fin-plate heat exchangers made of aluminum are shown in Figure 2 of the mentioned ISO 15547-2:3005 and on page 5 of the publication "The Standards of the Brazed Aluminum Plate-Fin Heat Exchanger Manufacturers' Association” by ALPEMA, 3rd edition 2010. shown and described.
  • the present figure 1 essentially corresponds to the illustrations of said ISO standard and is to be explained below in order to explain the background of the invention.
  • the plate heat exchanger 100 shown partially open in Figure 1 is used for the heat exchange of five different process media A to E in the example shown.
  • the plate heat exchanger 100 comprises a large number of separating plates 4 arranged parallel to one another (in the publications mentioned above , to which the following information in brackets also refers, referred to in English as parting sheets), between which heat exchange passages 1 are defined by structured sheets with lamellae 3 (fins) for one of the process media A to E, which can thus exchange heat with one another, are trained.
  • the structural sheets with the lamellae 3 are typically folded or corrugated, flow channels being formed by the folds or corrugations, as also shown in FIG. 1 of ISO 15547-2:3005.
  • the provision of the structured plates with lamellae 3 offers the advantage of improved heat transfer, more targeted fluid guidance and an increase in the mechanical (tensile) strength.
  • the process media A to E flow separately from one another, in particular through the separating plates 4, but can optionally pass through the latter in the case of perforated structured plates with lamellae 3.
  • the individual passages 1 or the structured metal sheets with the lamellae 3 are each surrounded laterally by so-called sidebars 8, which, however, leave feed and removal openings 9 free.
  • the sidebars 8 keep the separating plates 4 at a distance and ensure mechanical reinforcement of the pressure chamber.
  • Reinforced cover plates 5 (cap sheets), which are arranged parallel to the separating plates 4, serve to close off at least two sides.
  • headers 7 which are provided with nozzles 6 (nozzles)
  • the process media A to E are supplied and discharged via feed and removal openings 9.
  • distributor fins 2 distributed fins
  • distributer lamellae 2 which guide the process media A to E from the passages 1 into the header 7 where they are collected and drawn off via the corresponding nozzles 6 .
  • the structured metal sheets with the lamellae 3, the further structured metal sheets with the distributor lamellas 2, the sidebars 8, the separating sheets 4 and the cover sheets 5 form a cuboid heat exchanger block 20 overall, with the term "heat exchanger block” being used here to describe the elements mentioned without the headers 7 and nozzle 6 are to be understood in a connected state.
  • the plate heat exchanger 100 can be formed from a plurality of corresponding cuboid heat exchanger blocks 20 connected to one another, in particular for manufacturing reasons.
  • Corresponding plate heat exchangers 100 are brazed from aluminum.
  • the individual passages 1, comprising the structural sheets with the lamellae 3, the other structural sheets with the distributor slats 2, the cover sheets 5 and the sidebars 8 are each provided with solder, stacked on top of one another or arranged accordingly and heated in an oven.
  • the header 7 and the socket 6 are welded onto the heat exchanger block 20 produced in this way.
  • the headers 7 are manufactured using, for example, semi-cylindrical extrusions cut to the required length brought and then welded onto the heat exchanger block 20.
  • the headers 7 are often manufactured with a constant wall thickness, with this wall thickness being based on the position of the highest utilization.
  • the present method makes it possible, for example, to produce headers 7 with sockets 6 in a cost-effective and material-saving manner, in particular with a varying wall thickness which is specifically adapted to the individually present load case. This is done by partially additive manufacturing, with deformations being compensated for in a particularly advantageous manner, as explained below.
  • FIGS. 2A to 2C illustrate aspects of the present invention, a header with socket 6, as designated by 7 above, being illustrated in each case.
  • At least one section of the header is in the form of a semi-circular tube.
  • this section can be produced with a constant wall thickness and from the same material throughout.
  • a piece of pipe that forms the socket 6 is, in the language used here, a basic structure which, as mentioned, according to embodiments of the invention must also be another component.
  • Supplementary structures in the form of reinforcement structures 6.1 are applied to the basic structure, that is to say the header 6 in the present example, by means of an additive manufacturing process.
  • the header 7 itself is also provided with appropriate reinforcement structures 7.1 in order to stabilize it.
  • FIGS. 2A and 2B illustrate, in particular, different stages of a multi-stage manufacturing process.
  • additional supplementary structures are applied in the form of compensation structures 6.2 described above, which also cause deformation.
  • the type, location and material of the compensating structures 6.2 are selected in such a way that their application compensates for the deformation caused by the application of the reinforcing structures 6.1 and a target shape is achieved.
  • compensating structures 6.2 can be provided by means of additive manufacturing on the outer circumference of the basic structure, ie the socket 6, and in its interior, designated 6.3 here.
  • FIG. 2C shows a view from above onto or into the socket 6.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Powder Metallurgy (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)

Abstract

L'invention concerne un procédé de production d'un composant pour un dispositif technique (100) qui possède une structure de base (6) et une ou plusieurs structures supplémentaires (6.1 à 6.3). La structure de base (6) n'est pas fabriquée de manière additive, les une ou plusieurs structures supplémentaires (6.1 à 6.3) est/sont appliquée(s) sur la structure de base (6) au moyen d'un processus de fabrication additive, et la structure de base (6) est soumise à une déformation pendant le processus de fabrication additive. La structure de base (6) est munie d'une forme de départ qui est sélectionnée de telle sorte que la déformation conduise à une forme cible souhaitée de la structure de base (6). L'invention concerne par ailleurs un composant correspondant.
EP22821849.1A 2021-11-25 2022-11-24 Procédé pour la production d'un composant, et composant corrélativement produit Pending EP4436734A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP21020593 2021-11-25
PCT/EP2022/025536 WO2023094029A1 (fr) 2021-11-25 2022-11-24 Procédé pour la production d'un composant, et composant corrélativement produit

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EP4436734A1 true EP4436734A1 (fr) 2024-10-02

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US (1) US20240424565A1 (fr)
EP (1) EP4436734A1 (fr)
JP (1) JP2024546059A (fr)
CN (1) CN118234581A (fr)
WO (1) WO2023094029A1 (fr)

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DE102024110875B3 (de) 2024-04-18 2025-06-18 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Verfahren zum Herstellen von Kraftfahrzeugen

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Publication number Priority date Publication date Assignee Title
EP3164239A1 (fr) 2014-07-03 2017-05-10 Autotech Engineering, A.I.E. Composants structuraux renforcés
DE102014014202A1 (de) * 2014-09-22 2016-03-24 Technische Universität Dortmund Verfahren und Vorrichtung zur kombinierten Herstellung von Bauteilen mittels inkrementeller Blechumformung und additiver Verfahren in einer Aufspannung
WO2017021440A1 (fr) 2015-08-04 2017-02-09 Autotech Engineering A.I.E. Éléments structuraux renforcés
CN110168546B (zh) * 2017-01-26 2024-01-09 西门子工业软件有限公司 用于增材制造过程的热-结构模拟的自适应域约简的系统与方法
EP3451202B1 (fr) 2017-09-01 2021-02-24 dSPACE digital signal processing and control engineering GmbH Procédé de génération d'un modèle d'un système technique exécutable sur un appareil d'essai et appareil d'essai
CN116057487A (zh) 2020-10-06 2023-05-02 林德有限责任公司 一种用于生产技术设备的部分增材制造型部件的方法

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CN118234581A (zh) 2024-06-21
JP2024546059A (ja) 2024-12-17
WO2023094029A1 (fr) 2023-06-01

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