JP2008069449A - 金属間化合物製の三次元製品の大量生産法 - Google Patents
金属間化合物製の三次元製品の大量生産法 Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 87
- 229910000765 intermetallic Inorganic materials 0.000 title claims abstract description 49
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 36
- 239000000843 powder Substances 0.000 claims abstract description 70
- 238000002844 melting Methods 0.000 claims abstract description 61
- 230000008018 melting Effects 0.000 claims abstract description 61
- 238000010894 electron beam technology Methods 0.000 claims abstract description 25
- 239000000203 mixture Substances 0.000 claims abstract description 15
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims abstract description 10
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 10
- 239000010936 titanium Substances 0.000 claims abstract description 10
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 10
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 9
- 239000000126 substance Substances 0.000 claims abstract description 6
- 239000002245 particle Substances 0.000 claims description 12
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- 238000001816 cooling Methods 0.000 claims description 6
- 239000001307 helium Substances 0.000 claims description 4
- 229910052734 helium Inorganic materials 0.000 claims description 4
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 claims description 4
- 238000013178 mathematical model Methods 0.000 claims description 4
- 238000009689 gas atomisation Methods 0.000 claims description 3
- 238000005245 sintering Methods 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 2
- 238000009751 slip forming Methods 0.000 claims description 2
- 239000000463 material Substances 0.000 abstract description 17
- 238000005516 engineering process Methods 0.000 abstract description 5
- 239000010410 layer Substances 0.000 description 18
- 150000001875 compounds Chemical class 0.000 description 9
- 230000015572 biosynthetic process Effects 0.000 description 8
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- 238000010309 melting process Methods 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- 230000008020 evaporation Effects 0.000 description 4
- 238000001704 evaporation Methods 0.000 description 4
- 239000013078 crystal Substances 0.000 description 3
- 229910001092 metal group alloy Inorganic materials 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229910010038 TiAl Inorganic materials 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 238000001465 metallisation Methods 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
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- 241000894007 species Species 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
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- OQPDWFJSZHWILH-UHFFFAOYSA-N [Al].[Al].[Al].[Ti] Chemical compound [Al].[Al].[Al].[Ti] OQPDWFJSZHWILH-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 229910021325 alpha 2-Ti3Al Inorganic materials 0.000 description 1
- UQZIWOQVLUASCR-UHFFFAOYSA-N alumane;titanium Chemical compound [AlH3].[Ti] UQZIWOQVLUASCR-UHFFFAOYSA-N 0.000 description 1
- 238000012512 characterization method Methods 0.000 description 1
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- 238000010030 laminating Methods 0.000 description 1
- 238000004372 laser cladding Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 150000002736 metal compounds Chemical class 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000012768 molten material Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
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- 229910021324 titanium aluminide Inorganic materials 0.000 description 1
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Abstract
【解決手段】a)製造された製品を構成する最終の金属間化合物と同じ化学組成を持つチタン及びアルミニウムを基材とする金属間化合物の粉末を準備する。b)溶融チャンバー内において粉末1を敷設して、一定かつ実質的に均一な厚さを持つ粉末層を形成する。c)該粉末層を予熱工程によって予熱する。d)コントロールユニットに保存した三次元モデルに従って、前記製品の断面部分に相当する区域において集束電子ビームにて走査することによって溶融を行う。上記b)〜d)の操作を繰り返すことにより、金属間化合物製の三次元製品を生産する。
【選択図】図2A
Description
G. Sauthoff, "Intermetallics(金属間化合物)", Weinheim, New Yark (1995);及び
H. Clemens, F. Appel, A. Baur, R. Gerling, V. Guther, H. Kestler, "エンジニアリングg-TiAl系合金の加工及び適用", Ti-2003 Science and Technology, Vo. IV, Wiley-VCH
"レーザーを使用する直接金属付着に関する実用的な検討及び可能性", G.K. Lewisら;
"レーザー成形チタン部材", D.H. Abbotら;
"レーザー成形を使用する粉末からのチタン航空宇宙産業用部材の製造", F.G. Arcellaら;及び
"直接レーザー製造TiAl合金部材のミクロ構造の加工パラメーターの最適化及び特徴付け", D. Srivastavaら
a)製品の三次元数学的モデルを作製し、これをコントロールユニットに保存する工程;
b)使用する金属間化合物の粉末を調製する工程;
c)溶融チャンバー内において粉末を敷設して、一定かつ実質的に均一な厚さを持つ粉末層を形成する工程;
d)溶融チャンバー内において敷設した粉末層を、粉末の融点より低い温度に予熱する工程;
e)コントロールユニットに保存した三次元モデルに従って、製品の断面部分に相当する区域において集束電子ビームにて走査することによって溶融を行う工程;
f)このようにして形成された製品の最後の断面部分の上面が、溶融チャンバー内に配置され、製品の既に形成された部分の周囲に敷設される粉末のレベルに位置するようにする工程;及び
g)工程c)〜f)を、コントロールユニットに保存した三次元モデルに従って、製品の最終の断面部分に達成するまで繰り返す工程
を包含することを特徴とする金属間化合物製の三次元製品の大量生産法に関する。
低圧ガスタービンブレードを製造するために、General Electric Aviation(米国)によって供給された仕様に従って、金属間化合物γTiAl 48Al-2Cr-2Nbの粉末を調製した。使用する金属間化合物は、融点約1550℃を有する。
この粉末を、EBM装置A2(ARCAM AB(スウェーデン)製)の溶融チャンバー内に配置したディストリビューターに入れた。
集束電子ビームのみを使用し、粉末が温度約900℃となるまで、予熱工程を行った。
使用した数学的モデルは、タービンブレード30個(すべてが、幾何学的形状及び寸法について同じ特性を持つ)の同時生産用に構成されている。
高真空下で行われる製造法は、製造完了に計約30時間及びヘリウム雰囲気中での冷却を必要とする。
ついで、ブレード30個を分離し、約0.2mmの表面層(取り代)を除去するためにブレードを表面仕上げ加工操作に供する前に、支持部分(図3における羽根車についての例によって示されるもの)を除去する。本発明による方法を使用する場合、γTiAl金属間化合物製のガスタービン用ブレードの大量生産のコストが、従来技術の方法を使用する場合の大量生産のコストと比べて、約4倍低減されることが予測される。
2 層
10 タービンブレード
11 固定脚
12 ベースフランジ
13 翼
20 可動性支持表面
30 ディストリビューター
40 集束電子ビーム発生装置
50 羽根車
55 支持部分
56 スロット
Claims (18)
- 電子ビーム溶融によって、金属間化合物製の三次元製品を大量生産する方法であって、
a)前記製品の三次元数学的モデルを作製し、これをコントロールユニットに保存する工程;
b)使用する金属間化合物の粉末を調製する工程;
c)溶融チャンバー内において、粉末を敷設して、一定かつ実質的に均一な厚さを持つ粉末層を形成する工程;
d)溶融チャンバー内において、敷設した粉末層を、粉末の融点より低い温度に予熱する工程;
e)コントロールユニットに保存した三次元モデルに従って、前記製品の断面部分に相当する区域において集束電子ビームにて走査することによって溶融を行う工程;
f)このようにして形成された前記製品の最後の断面部分の上面が、溶融チャンバー内に配置され、製品の既に形成された部分の周囲に敷設される粉末のレベルに位置するようにする工程;及び
g)工程c)〜f)を、コントロールユニットに保存した三次元モデルに従って、前記製品の最終の断面部分に達成するまで繰り返す工程
を包含し、前記粉末が、製造された製品を構成する最終の金属間化合物と同じ化学組成を持つチタン及びアルミニウムを基材とする金属間化合物の粉末であることを特徴とする金属間化合物製の三次元製品の大量生産法。 - 粉末及び製品がγTiAl金属間化合物製である請求項1記載の方法。
- さらに、不活性ガス雰囲気中での製品の最終冷却工程を含む請求項1記載の方法。
- 不活性ガスがヘリウム又はその混合物である請求項3記載の方法。
- 予熱工程d)を、完全に又は部分的に、集束電子ビームにて走査することによって行う請求項1記載の方法。
- 予熱工程d)を、完全に又は部分的に、電気抵抗を使用して溶融チャンバーを加熱することによって行う請求項1記載の方法。
- 予熱工程d)を、充分に高い温度で行って、少なくとも製品の各断面部分の区域において、粉末の弱い焼結を生じさせる請求項1記載の方法。
- 予熱工程d)を温度少なくとも700℃で行う請求項1記載の方法。
- 工程e)を、下方の断面部分の溶融工程を行った際の走査経路に対して60〜90°の角度で交差する走査経路に沿って集束エネルギービームを移動させることによって行う請求項1記載の方法。
- 溶融工程が、初めに、製品の断面部分に相当する区域の周囲に沿って集束電子ビームにて溶融することを含むものである請求項1記載の方法。
- 工程e)における集束電子ビームでの溶融を、少なくとも、溶融チャンバーを高真空条件に維持して行う請求項1記載の方法。
- 工程c)〜f)の各繰返しの間に、連続して形成される電面部分を支持するために、1以上の部分を形成する請求項1記載の方法。
- 製品が形成された後、1以上の支持部分を除去する請求項12記載の方法。
- 粉末の粒径が20〜150μmの範囲である請求項1記載の方法。
- 粉末の粒径が約70μmである請求項1記載の方法。
- 粉末がガスアトマイゼーション法によって得られたものである請求項1記載の方法。
- 工程c)〜f)の各繰返しサイクル時、厚さ20〜150μmを持つ製品の断面部分を形成する請求項1記載の方法。
- 請求項1〜17のいずれかに記載の方法によって製造された製品。
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US7815847B2 (en) | 2010-10-19 |
ATE544548T1 (de) | 2012-02-15 |
US20080014457A1 (en) | 2008-01-17 |
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