US20140053956A1 - Method for manufacturing a three-dimensional article - Google Patents

Method for manufacturing a three-dimensional article Download PDF

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Publication number
US20140053956A1
US20140053956A1 US13/972,127 US201313972127A US2014053956A1 US 20140053956 A1 US20140053956 A1 US 20140053956A1 US 201313972127 A US201313972127 A US 201313972127A US 2014053956 A1 US2014053956 A1 US 2014053956A1
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Prior art keywords
heat treatment
powder
article
base material
conducted
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Thomas Etter
Julius SCHURB
Lukas Emanuel Rickenbacher
Andreas Künzler
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Ansaldo Energia IP UK Ltd
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Alstom Technology AG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • B22D23/06—Melting-down metal, e.g. metal particles, in the mould
    • 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
    • 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
    • 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
    • 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
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • 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
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/64—Treatment of workpieces or articles after build-up by thermal means
    • 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
    • B22F2003/248—Thermal after-treatment
    • 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
    • B22F3/10—Sintering only
    • B22F3/1035—Liquid phase sintering
    • 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
    • B22F3/12—Both compacting and sintering
    • B22F3/14—Both compacting and sintering simultaneously
    • B22F3/15—Hot isostatic pressing
    • 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 technology of high-temperature resistant components, especially for gas turbines. It refers to a method for manufacturing a three-dimensional article.
  • FIG. 5 shows a basic SLM arrangement 10 , wherein a 3-dimensional article 11 is manufactured by successive addition of powder layers 12 of a predetermined layer thickness d, area and contour, which are then melted by means of a scanned laser beam 14 from a laser device 13 and controlled by a control unit 15 .
  • a first specimen 16 a extending in z-direction shows properties different from a second specimen 16 b extending in the xy-plane.
  • FIG. 2 shows Young's modulus E at room temperature for three groups of specimen of identical nominal composition, namely A 1 - 3 , B 1 - 3 and C 1 - 3 .
  • the first group, A 1 - 3 is related to a reference plate made by a non-additive manufacturing process.
  • the second group, B 1 - 3 is related to an SLM-processed specimen extending in the z-axis (like specimen 16 a in FIG. 1 ).
  • the third group, C 1 - 3 is related to an SLM-processed specimen extending in the xy-plane (like specimen 16 b in FIG. 1 ).
  • Young's modulus E shows a substantial anisotropy with a difference of more than 20 GPa between the z-axis specimen B 1 and the xy-plane specimen C 1 , and is much lower (more than 50 GPa) for both specimen compared to the reference specimen A 1 .
  • the present invention assumes that an additional treatment may be necessary to reduce this anisotropy in the properties of an article made by an additive manufacturing process.
  • Document US 2012/000890 A1 discloses a method using laser metal forming (LMF) for repairing gas turbine blades which repairs a thickness-reduced portion of a blade tip of a gas turbine blade.
  • the method comprises a thickness-reduced portion removing step of working a surface of the blade tip into a flat surface by removing the thickness-reduced portion of the blade tip, a build-up welding step of forming a built-up portion with a predetermined thickness by melting powder of a build-up material higher in ductility than a base material forming the gas turbine blade by a laser beam and building up the melted powder in multiple layers on the blade tip whose surface is worked into the flat surface, a forming step of working the built-up portion into the same shape as a shape that the blade tip originally has before suffering a thickness loss; and a heat-treatment step of removing a residual strain caused by laser welding in the build-up welding step.
  • LMF laser metal forming
  • Document WO 2012/016836 A1 teaches a method for manufacturing a component by selective laser melting (SLM) comprising: building a heat treatment device adapted to provide a heat treatment to the component as part of the same selective laser melting for manufacturing the component; and providing a heat treatment to the component by the heat treatment device.
  • SLM selective laser melting
  • the heat treatment is used to make the component devoid of unwanted material property, for example, like ductility instead of embrittlement.
  • the method according to the invention for manufacturing a three-dimensional article comprises the steps of
  • said additive manufacturing process is one of laser metal forming (LMF), laser engineered net shape (LENS) or direct metal deposition (DMD), and that a metallic base material of wire form is used.
  • LMF laser metal forming
  • LENS laser engineered net shape
  • DMD direct metal deposition
  • said additive manufacturing process is one of selective laser melting (SLM), selective laser sintering (SLS) or electron beam melting (EBM), and that a metallic base material of powder form is used.
  • SLM selective laser melting
  • SLS selective laser sintering
  • EBM electron beam melting
  • said method comprises the steps of:
  • the grain size distribution of said powder is adjusted to the layer thickness of said powder layer in order to establish a good flowability, which is required for preparing powder layers with regular and uniform thickness.
  • the powder grains have a spherical shape.
  • an exact grain size distribution of the powder is obtained by sieving and/or winnowing (air separation).
  • said powder is provided by means of a powder metallurgical process, specifically one of gas or water atomization, plasma-rotating-electrode process or mechanical milling.
  • said additive manufacturing process uses a suspension instead of powder.
  • said metallic base material is a high-temperature Ni-based alloy.
  • said metallic base material is a high-temperature Co-based alloy.
  • said metallic base material is a high-temperature Fe-based alloy.
  • said alloy can contain finely dispersed oxides, specifically one of Y 2 O 3 , AlO 3 , ThO 2 , HfO 2 , ZrO 2 .
  • said heat treatment is used to reduce the anisotropy of Young's modulus.
  • said heat treatment is a combination of different individual heat treatments.
  • said heat treatment consists of multiple steps, each representing a specific combination of heating rate, hold temperature, hold time and cooling rate.
  • At least one of said heat treatment steps is conducted at a sufficient high temperature and for a hold time long enough to partially or completely dissolve constituents in the microstructure of said manufactured article, specifically intermetallic phases, carbides or nitrides.
  • At least one of said heat treatment steps is conducted at a sufficient high temperature and for a hold time long enough to precipitate metal-carbides, metal-nitrides or metal-carbonitrides, specifically one of M(C, N), M 6 C, M 7 C 3 or M 23 C 6 .
  • At least one of said heat treatment steps is conducted at a sufficient high temperature and for a hold time long enough to precipitate intermetallic phases, specifically one Ni 3 (Al, Ti) known as gamma-prime, or Ni 3 (Nb, Al, Ti), known as gamma-double-prime, or Ni 3 Nb known as delta-phase.
  • Ni 3 (Al, Ti) known as gamma-prime
  • Ni 3 (Nb, Al, Ti) known as gamma-double-prime
  • Ni 3 Nb known as delta-phase.
  • At least one of said heat treatment steps is conducted at a sufficient high temperature and for a hold time long enough to precipitate metal-borides, specifically M 3 B 2 , to improve grain boundary strength.
  • At least one of said heat treatment steps is conducted at a sufficient high temperature and for a hold time long enough to modify the volume fraction, size, shape and distribution of said precipitations.
  • At least one of said heat treatment steps can be conducted additionally under hot isostatic pressing (HIP) conditions, to further improve the microstructure.
  • HIP hot isostatic pressing
  • individual heat treatments or heat treatment steps, respectively, said manufactured articles are subjected to additional processing steps, specifically one of machining, welding or brazing.
  • FIG. 1 shows the different orientation of two specimen made by an additive manufacturing process like SLM
  • FIG. 2 shows values of Young's modulus at room temperature for three groups of specimen made of Hastelloy® X with and without heat treatment
  • FIG. 3 shows values of Young's modulus at 750° C. for three groups of specimen made of Hastelloy® X with and without heat treatment;
  • FIG. 4 shows photographs of the microstructure in two different magnifications (100 ⁇ m and 50 ⁇ m) for three different specimen made of Hastelloy® X without and with heat treatment;
  • FIG. 5 shows a basic arrangement for SLM manufacturing, which may be used in the present invention.
  • One drawback of powder-based additive manufacturing technology can be the strong anisotropy of material properties resulting from the layer-wise build-up process.
  • the Young's modulus (E in FIGS. 2 and 3 ) is significantly lower along the z-axis (z-specimen (B 1 -B 3 in FIG. 2 and B 1 ′-B 3 ′ in FIG. 3 ) compared to xy-specimens (C 1 -C 3 in FIG. 2 and C 1 ′-C 3 ′ in FIG. 3 ), for instance.
  • the z-axis is parallel to the build direction (see FIGS. 1 and 5 ).
  • specimen A 1 ′, B 1 ′ and C 1 ′ are without heat treatment, while specimen B 2 ′ and C 2 ′ were held for 0.5 h at 1125° C., and specimen B 3 ′ and C 3 ′ were held for 2 h at 1190° C.).
  • the present invention relates to the heat treatment of articles/components made of Ni/Co/Fe-based superalloys produced by a powder-based additive manufacturing technology, such as selective laser melting SLM or laser metal forming LMF.
  • a powder-based additive manufacturing technology such as selective laser melting SLM or laser metal forming LMF.
  • These articles have different microstructures compared to conventionally cast material or wrought products of the same alloy (specimen A 1 -A 3 in FIG. 2 and A 1 ′ in FIG. 3 ), for instance.
  • the material is very homogeneous with respect to chemical composition and principally free of segregations.
  • the material in the “as built” condition has a very fine microstructure (e.g. precipitates and grain size), much finer compared to conventionally cast or wrought superalloys.
  • Ni/Co/Fe-based superalloys produced by powder-based additive manufacturing technologies are generally free of residual eutectic contents and heat treatments can be realized at higher temperatures compared to conventionally cast components of same composition. This allows an adjustment of the microstructure over a wide range, including grain size and precipitation optimization, leading to improved material properties.
  • the present invention disclosure relates to specially adjusted heat treatments for Ni/Co/Fe based superalloys processed by powder-based additive manufacturing technology to reduce inherent anisotropy of this technology.
  • This invention disclosure is based on the discovery that anisotropic material behaviour can be reduced by appropriate heat treatments.
  • this invention disclosure includes the manufacturing of three-dimensional articles specifically made of a Ni/Co/Fe based superalloy by powder-based additive manufacturing technologies followed by a specially adapted heat treatment resulting in reduced anisotropic material behaviour.
  • Said powder-based additive manufacturing technology is especially selective laser melting (SLM), selective laser sintering (SLS), electron beam melting (EBM), laser metal forming (LMF), laser engineered net shape (LENS), direct metal deposition (DMD) or like processes.
  • SLM selective laser melting
  • SLS selective laser sintering
  • EBM electron beam melting
  • LMF laser metal forming
  • LENS laser engineered net shape
  • DMD direct metal deposition
  • Said powder-based additive manufacturing technology may be used to build up an article, such as a blade or vane of a gas turbine, entirely or partly, e.g. blade crown build up.
  • manufacturing of the three-dimensional articles comprises the following steps:
  • the grain size distribution of the powder used in this process is adjusted to the layer thickness d to have to a good flowability, which is required for preparing powder layers with regular and uniform thickness d.
  • the powder grains of the powder used in this process have a spherical shape.
  • the exact grain size distribution of the powder may be obtained by sieving and/or winnowing (air separation).
  • the powder may be obtained by gas or water atomization, plasma-rotating-electrode process, mechanical milling and like powder metallurgical processes.
  • a suspension may be used instead of powder.
  • said high temperature material is a Ni-based alloy
  • a plurality of commercially available alloys may be used like Waspaloy®, Hastelloy® X, IN617®, IN718®, IN625®, Mar-M247®, IN100®, IN738®, 1N792®, Mar-M200®, B1900®, RENE 80®, Alloy 713®, Haynes 230®, Haynes 282®, or other derivatives.
  • said high temperature material is a Co-based alloy
  • a plurality of commercially available alloys may be used like FSX 414®, X-40®, X-45®, MAR-M 509® or MAR-M 302®.
  • said high temperature material is a Fe-based alloy
  • a plurality of commercially available alloys may be used like A 286®, Alloy 800 H®, N 155®, S 590®, Alloy 802®, Incoloy MA 956®, Incoloy MA 957® or PM 2000®.
  • these alloys may contain fine dispersed oxides such as Y 2 O 3 , AlO 3 , ThO 2 , HfO 2 , ZrO 2 .
  • the heat treatment according to the invention advantageously reduces anisotropic material behaviour, especially the Young's modulus E (see FIGS. 2 and 3 ).
  • the Young's modulus Eat room temperature FIG. 2
  • B 1 no heat treatment HT
  • B 2 0.5 h at 1125° C.
  • B 3 2 h at 1190° C.
  • FIG. 4 shows photographs of the microstructure in two different magnifications (100 ⁇ m and 50 ⁇ m) for three different z-direction specimen B 4 , B 5 and B 6 made of Hastelloy® X after having been tensile-tested, with and without heat treatment, whereby specimen B 4 had no heat treatment with a tensile test conducted at 750° C., specimen B 5 had a heat treatment for 0.5 h at 1125° C. with a tensile test conducted at room temperature, and specimen B 6 had a heat treatment for 2 h at 1190° C. with a tensile test conducted at room temperature.
  • the whole article may be subjected to said heat treatment. In other cases, only part of it may be subjected to said heat treatment.
  • Said heat treatment can be one-time treatment. However, it can be a combination of different individual heat treatments.
  • said heat treatment may consist of multiple steps, each representing a specific combination of heating rate, hold temperature, hold time and cooling rate.
  • the three-dimensional articles may be subject to different processing steps such as, but not limited to, machining, welding or brazing, especially in order to use the specific advantages of the specific microstructure, e.g. small grains, which are beneficial for welding.
  • At least one of said heat treatment steps should be conducted at a sufficient high temperature and for a hold time long enough to partially or completely dissolve constituents in said microstructure such as intermetallic phases, carbides or nitrides. Furthermore, it is clear that at least one of said heat treatment steps is conducted at a sufficient high temperature and for a hold time long enough to recrystallize and/or coarsen the grains.
  • At least one of said heat treatment steps may be conducted at a sufficient high temperature and for a hold time long enough to precipitate metal-carbides, metal-nitrides or metal-carbonitrides such as but not limited to, M(C, N), M 6 C, M 7 C 3 or M 23 C 6 .
  • At least one of said heat treatment steps may be conducted at a sufficient high temperature and for a hold time long enough to precipitate intermetallic phases such as, but not limited to, Ni 3 (Al, Ti) known as gamma-prime, or Ni 3 (Nb, Al, Ti), known as gamma-double-prime, or Ni 3 Nb known as delta-phase.
  • intermetallic phases such as, but not limited to, Ni 3 (Al, Ti) known as gamma-prime, or Ni 3 (Nb, Al, Ti), known as gamma-double-prime, or Ni 3 Nb known as delta-phase.
  • At least one of said heat treatment steps is conducted at a sufficient high temperature and for a hold time long enough to precipitate metal-borides such as, but not limited to, M 3 B 2 , to improve grain boundary strength.
  • At least one of said heat treatment steps is conducted at a sufficient high temperature and for a hold time long enough to modify the volume fraction, size, shape and distribution of said precipitations mentioned before.
  • At least one of said heat treatment steps can be conducted additionally under isostatic pressure, known as hot isostatic pressing HIP, to further improve the microstructure.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Optics & Photonics (AREA)
  • Thermal Sciences (AREA)
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US13/972,127 2012-08-21 2013-08-21 Method for manufacturing a three-dimensional article Abandoned US20140053956A1 (en)

Applications Claiming Priority (2)

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EP12181126.9A EP2700459B1 (en) 2012-08-21 2012-08-21 Method for manufacturing a three-dimensional article
EP12181126.9 2012-08-21

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US (1) US20140053956A1 (enExample)
EP (1) EP2700459B1 (enExample)
JP (1) JP5901585B2 (enExample)
KR (1) KR101627520B1 (enExample)
CN (1) CN103624257B (enExample)
CA (1) CA2824042C (enExample)
RU (1) RU2566117C2 (enExample)

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WO2017117041A1 (en) * 2015-12-28 2017-07-06 Matheson Tri-Gas, Inc. Use of reactive fluids in additive manufacturing and the products made therefrom
WO2017184771A1 (en) * 2016-04-20 2017-10-26 Arconic Inc. Fcc materials of aluminum, cobalt, iron and nickel, and products made therefrom
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WO2017184778A1 (en) * 2016-04-20 2017-10-26 Arconic Inc. Fcc materials of aluminum, cobalt and nickel, and products made therefrom
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US9959613B2 (en) 2015-03-20 2018-05-01 Technology Research Association For Future Additive Manufacturing Optical Processing head, optical processing apparatus, and control method and control program of optical processing apparatus
US10094240B2 (en) 2015-02-12 2018-10-09 United Technologies Corporation Anti-deflection feature for additively manufactured thin metal parts and method of additively manufacturing thin metal parts
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US20190168302A1 (en) * 2015-12-25 2019-06-06 Daihen Corporation Metal powder, method of producing additively-manufactured article, and additively-manufactured article
US10724122B2 (en) 2016-03-10 2020-07-28 Nuovo Pignone Tecnologie Srl High oxidation-resistant alloy and gas turbine applications using the same
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US10889872B2 (en) 2017-08-02 2021-01-12 Kennametal Inc. Tool steel articles from additive manufacturing
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