JP2020507713A - 複合付加製造技術を用いた部品及び部品の製造方法 - Google Patents
複合付加製造技術を用いた部品及び部品の製造方法 Download PDFInfo
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- 239000002131 composite material Substances 0.000 title description 3
- 239000000463 material Substances 0.000 claims abstract description 44
- 238000000034 method Methods 0.000 claims description 90
- 239000000758 substrate Substances 0.000 claims description 40
- 239000000843 powder Substances 0.000 claims description 30
- 238000003754 machining Methods 0.000 claims description 16
- 229910052751 metal Inorganic materials 0.000 claims description 11
- 239000002184 metal Substances 0.000 claims description 11
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- 238000012805 post-processing Methods 0.000 description 17
- 238000002844 melting Methods 0.000 description 13
- 230000008018 melting Effects 0.000 description 13
- 238000000149 argon plasma sintering Methods 0.000 description 6
- 238000010894 electron beam technology Methods 0.000 description 5
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- 238000000137 annealing Methods 0.000 description 4
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- 238000011960 computer-aided design Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 239000012254 powdered material Substances 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 239000011324 bead Substances 0.000 description 3
- 230000005670 electromagnetic radiation Effects 0.000 description 3
- 239000000155 melt Substances 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 238000005507 spraying Methods 0.000 description 3
- 238000010146 3D printing Methods 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000008021 deposition Effects 0.000 description 2
- 238000005242 forging Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 229910001026 inconel Inorganic materials 0.000 description 2
- 229910001119 inconels 625 Inorganic materials 0.000 description 2
- 230000013011 mating Effects 0.000 description 2
- 238000001465 metallisation Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 229910000684 Cobalt-chrome Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- WAIPAZQMEIHHTJ-UHFFFAOYSA-N [Cr].[Co] Chemical compound [Cr].[Co] WAIPAZQMEIHHTJ-UHFFFAOYSA-N 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000001311 chemical methods and process Methods 0.000 description 1
- 239000010952 cobalt-chrome Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
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- 229910000816 inconels 718 Inorganic materials 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- NJPPVKZQTLUDBO-UHFFFAOYSA-N novaluron Chemical compound C1=C(Cl)C(OC(F)(F)C(OC(F)(F)F)F)=CC=C1NC(=O)NC(=O)C1=C(F)C=CC=C1F NJPPVKZQTLUDBO-UHFFFAOYSA-N 0.000 description 1
- 238000007781 pre-processing Methods 0.000 description 1
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- 239000002994 raw material Substances 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000000110 selective laser sintering Methods 0.000 description 1
- 238000005480 shot peening Methods 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 238000005482 strain hardening Methods 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
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- 229910052719 titanium Inorganic materials 0.000 description 1
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Classifications
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- 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
- 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]
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- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
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- 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
- B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
-
- 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
- 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
- B23K15/00—Electron-beam welding or cutting
- B23K15/0006—Electron-beam welding or cutting specially adapted for particular articles
-
- 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
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
-
- 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
- B23K15/00—Electron-beam welding or cutting
- B23K15/0046—Welding
- B23K15/0093—Welding characterised by the properties of the materials to be welded
-
- 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
- B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
-
- 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
- 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
- B33Y80/00—Products made by additive manufacturing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
- F01D25/24—Casings; Casing parts, e.g. diaphragms, casing fastenings
-
- 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
- B22F10/22—Direct deposition of molten metal
-
- 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
- B22F10/60—Treatment of workpieces or articles after build-up
-
- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
-
- 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
- B23K2101/001—Turbines
-
- 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
- B23K2103/18—Dissimilar materials
- B23K2103/26—Alloys of Nickel and Cobalt and Chromium
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/22—Manufacture essentially without removing material by sintering
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/25—Manufacture essentially without removing material by forging
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/30—Manufacture with deposition of material
- F05D2230/31—Layer deposition
-
- 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
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- Physics & Mathematics (AREA)
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- Optics & Photonics (AREA)
- Composite Materials (AREA)
- General Engineering & Computer Science (AREA)
- Powder Metallurgy (AREA)
Abstract
Description
式1 C<=0.87X
さらに、一例として、変数Gで表される、鍛造ベース材料と同じ材料で形成された、変数Yで表わされる、環状部分72の600℃における極限引張強度は、以下の式を満たしてよい。
式2 Y<=0.85G
変数Fで表される、鍛造ベース材料と同じ材料で形成された、変数Tで表わされる、環状部分72の600℃における伸びは、以下の式を満たしてよい。
式3 T<=0.82F
Claims (19)
- 環状タービンエンジン部品であって、
降伏強度Xを有する鍛造材料でできた鍛造ベースと、
前記鍛造ベースに結合された金属円錐部分であって、前記金属円錐部分は、降伏強度Yであって、式Y<=0.87Xを満たす材料で形成された、金属円錐部分と、
を備える、環状タービンエンジン部品。 - 前記金属円錐部分はその表面に少なくとも1つのボスが形成されている、請求項1に記載の環状タービンエンジン部品。
- 前記鍛造ベースは環状リングである、請求項1に記載の環状タービンエンジン部品。
- 前記鍛造環状リングは第1のフランジ部分を有する、請求項3に記載の環状タービンエンジン部品。
- 前記金属円錐部分は第2のフランジ部分を有する、請求項4に記載の環状タービンエンジン部品。
- 前記鍛造環状ベースは、600℃においてXで表される極限引張強度を有し、前記金属円錐部分は600℃においてCで表される極限引張強度を有し、ここで、C<=0.85Xである、請求項1に記載の環状タービンエンジン部品。
- 前記鍛造環状ベースは、600℃においてFで表される伸びを有し、前記金属円錐部分は600℃においてTで表される伸びを有し、ここで、T<=0.82Fである、請求項1に記載の環状タービンエンジン部品。
- 環状タービンエンジン部品の作製方法であって、
ワイヤ供給式付加製造プロセスを用いて鍛造ベースの上に円錐部品を堆積することを含み、
前記鍛造ベースは円形フランジとなっている、部品作製方法。 - 前記鍛造ベースを機械加工して環状フランジを形成することを更に含み、前記鍛造ベースは前記鍛造ベース上に前記環状構造が形成された後に機械加工される、請求項8に記載の部品製造方法。
- 前記鍛造ベースを機械加工して環状フランジを形成することを更に含み、前記鍛造ベースは前記鍛造ベース上に前記環状構造が形成される前に機械加工される、請求項8に記載の部品製造方法。
- 前記円錐部品が堆積された後に前記円錐部品が機械加工される、請求項8に記載の前記部品の製造方法。
- 粉末供給式付加製造プロセスを用いて少なくとも1つのボス及びプロビジョン(provision)を前記円錐部品上に形成する、請求項11に記載の部品製造方法。
- 部品の製造方法であって、
第1の付加製造プロセスを用いて鍛造ベースプレート上に環状構造を形成するステップであって、前記第1の付加製造プロセスは、ソースワイヤを供給し、前記ソースワイヤをエネルギー源で照射して鍛造ベースプレートの第1の表面に溶融プールを形成することを含む、ステップと、
前記ソースワイヤをエネルギービームで照射中に、前記ソースワイヤとエネルギー源、並びに前記鍛造ベース基板のうちの少なくとも1つを移動させて、前記第1の表面上に第1の成長面を形成するステップと、
(a)前記ソースワイヤをエネルギービーム照射中に、前記ソースワイヤとエネルギー源、並びに前記鍛造ベース基板のうちの少なくとも1つを移動させて、既に固化した成長面上に溶融プールを形成するステップと、
(b)前記鍛造ベースプレート上に付加製造された環状構造が形成されるまで、ステップ(a)を繰り返すステップと、
を含み、
前記鍛造ベース基板と付加製造された環状構造の両方が前記最終部品の少なくとも一部となる、部品製造方法。 - 前記環状構造の少なくとも1つの面に第2の付加製造プロセスを行うことを更に含み、
前記第2のプロセスは、
(a)粉末層をエネルギービームの一連の走査線で照射して、溶融領域を形成するステップと、
(b)後続する粉末層を提供するステップと、
(c)前記環状構造の少なくとも1つの面に第3の部分が形成されるまでステップ(a)とステップ(b)を繰り返すステップと、
を含む、請求項13に記載の部品製造方法。 - 前記鍛造ベース基板を機械加工して環状フランジを形成することを更に含み、前記鍛造ベースプレートは前記鍛造ベースプレート上に前記環状構造が形成された後に機械加工される、請求項13に記載の部品製造方法。
- 前記鍛造ベースを機械加工して環状フランジを形成することを更に含み、前記鍛造ベースプレートは前記ベース基板上に前記環状構造が形成される前に機械加工される、請求項13に記載の部品製造方法。
- 前記環状構造は中心軸を有し、かつ少なくとも1つの内面及び外面を有し、前記内面は前記外面よりも前記中心軸に近く、
前記方法は、前記外面と前記鍛造ベースプレートを機械加工して第1の環状外面が形成されるようにすることを更に含み、
前記第1の環状外面は、前記付加製造された環状構造から前記鍛造ベース基板の少なくとも第1の部分を貫通して延在する連続する環状面として形成される、請求項13に記載の部品製造方法。 - 前記鍛造ベース基板の第2の部分は、機械加工されて環状フランジを形成し、前記環状フランジは、前記第1の環状外面よりも前記中心軸に関して半径方向外向きに更に延在する、請求項17に記載の部品製造方法。
- 前記第2の付加製造プロセスを用いて、前記環状構造の少なくとも表面上に、少なくとも1つの取り付けボスを形成する、請求項14に記載の部品の製造方法。
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US15/426,780 US20180221958A1 (en) | 2017-02-07 | 2017-02-07 | Parts and methods for producing parts using hybrid additive manufacturing techniques |
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PCT/US2018/014935 WO2018148010A1 (en) | 2017-02-07 | 2018-01-24 | Parts and methods for producing parts using hybrid additive manufacturing techniques |
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