WO2008125354A2 - Production of large components by kinetic cold gas compacting material particles - Google Patents

Production of large components by kinetic cold gas compacting material particles Download PDF

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Publication number
WO2008125354A2
WO2008125354A2 PCT/EP2008/003052 EP2008003052W WO2008125354A2 WO 2008125354 A2 WO2008125354 A2 WO 2008125354A2 EP 2008003052 W EP2008003052 W EP 2008003052W WO 2008125354 A2 WO2008125354 A2 WO 2008125354A2
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WO
Grant status
Application
Patent type
Prior art keywords
characterized
method according
material particles
gas
component
Prior art date
Application number
PCT/EP2008/003052
Other languages
German (de)
French (fr)
Other versions
WO2008125354A3 (en )
Inventor
Markus Dirscherl
Original Assignee
Innovaris Gmbh & Co. Kg
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

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Classifications

    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18After-treatment
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00Coating starting from inorganic powder
    • C23C24/02Coating starting from inorganic powder by application of pressure only
    • C23C24/04Impact or kinetic deposition of particles
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06Metallic material
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18After-treatment
    • C23C4/185Separation of the coating from the substrate

Abstract

The present invention relates to a method for the production of a component having a height of at least 60, preferably 100 mm, by the kinetic cold gas compacting of material particles, wherein the component is produced by spraying material particles to form layers and each application layer is at least partially machined, particularly by milling, before the next application layer is sprayed on.

Description

Production of large components by kinetic cold gas compacting of material particles

description

The present application relates to a process for the preparation of tall components ren by kinetic Kompaktie-, in particular thermal spraying of material particles which are not melted essentially.

For coating surfaces by cold gas spraying or kinetic spraying with particles which are not melted, a number of applications are documented in scientific publications and in the patent literature. However, they essentially relate to layer thicknesses of the order of a few microns to millimeters. In exceptional cases, the production of thicker layers is described to a maximum of 40 mm, however, arise with increasing thickness of the problems with adhesion.

Classical methods for producing components having a thickness of several centimeters are pure molds or sintered forms a lost mold. pay to the newer generative manufacturing processes as the most important direct and indirect laser sintering in the powder bed, lektronenstrahlsintern the D and the cladding.

In traditional casting method or melt method, for example by welding, substantially no Mateπalkom- can bmationen such as aluminum steel to be processed.

Hardfacing builds complex porous, mostly steel geometries by-step process of a high-energy form-fitting layered welding process. Here, too, limits in the processability of certain combinations of materials, such as aluminum steel, are given.

Based on the laser build-up welding method, the so-called CMB was (controlled metal buildup) method developed, a combination of a laser metal deposition welding process and a high-speed Frasbearbeitung in a machine, wherein the order metallic material by laser deposition welding process and the generation of the required shape and dimensional tolerances and surface quality by the high-speed Frasprozess be ensured.

Indirect and direct laser sintering process are limited in the construction part great. Here, too, there is a technical limitation in that no material combinations such as steel or aluminum gradient materials can be manufactured with a smooth transition between two materials. The electron beam sintering process is the opposite, although very fast, but due to the very active enamel bath also inaccurate. In addition, the running in the vacuum process requires high technical complexity of the structural size accordingly limited. However, even here no material combinations such as aluminum copper or steel are possible due to physical limitations.

The object of the present invention is to provide a stable component by kinetic cold gas compacting of material-particles with a height of at least 60, preferably 100 mm to produce a combination verschiedenster materials.

This is achieved primarily in that the workpiece is produced by laminating spraying the particles, wherein each layer is at least partially machined, in particular by milling, edited before spraying the next layer. Besides pure leveling the component High, the object of processing to create the best possible liability by a specifically structured surface for the next injection layer. Em non-targeted roughening or removing the top layer of particles alleme has proven to be insufficient. By the inventive method components can be produced with a height of at least 60 mm, but also with a height of 100 mm and more.

Of crucial importance for the stability of the component generated here is the matching of job parameters and processing to achieve optimum adhesion of the layers. This is especially true on building with various materials with which eg gradient materials are built mensetzung of continuously varying Matenalzusam-.

The key parameters are the kinetic energy of the particles, the temperature and the distance and speed of the spray jet in order.

The initial pressure of Tragergases here is the relevant parameters for the Spruhduse, especially De Laval nozzle, achievable Mach number and thus for the maximum particle acceleration. In combination of steam and a suitable steam generator system prints could be realized up to 160 bar, where it was found that different materials have in the pressure range between 65 bar and 100 bar, particularly good coating qualities.

In addition to this, the hot gas temperature was increased also an electrically conductive gas with an electric heater up to 1050 0 C, which leads in the refractory materials to particularly good results. Such temperatures could only be achieved by direct combustion and utilization of the flue gases before. However, this method can not be used with, for example zundfahigen particle mixtures.

In connection with these parameters, a line speed of the De Laval nozzle during the spraying zwischenlO m / s and 20 m / s drove preferably between 20 m / s and 60 m / s and a spraying distance between the application surface and the outlet of the De Laval nozzle between 80mm and 400 mm high adhesion, and thus high Werkstuckqualitat.

Another influencing factor is the choice of gas. It is preferred oxygen reduced using air with an oxygen content of less than 3% as the main gas contains water vapor and / or. Next ed air is used with an oxygen content of less than 3% as the carrier gas Sauerstoffredu-. After Pulverzumischung for carrier gas or water vapor can be mixed in addition to the carrier gas. A condensation of the water vapor has to but are largely prevented.

In addition, the components to be produced lying with complex internal geometries may be provided. Here, a component is built up with a base material A by thermal spraying. Are then created with a different material to the Material A B constituting areas having different properties. Thus, for example grouting the base material a very high thermal conductivity, while the grouted Erganzungsmaterial a very high wear resistance and hardness. While the structure already inner contours, such as cooling or Heizkanale be provided in the component. Prefabricated inserts from different materials to the base material during the construction of integrated.

The transition from material A to material B does not have to be sudden, but may also take the form of a gradient with an increasing proportion of the material B or the area with a fixed ratio of the materials A and B.

Such components are, for example tools for thermal molding, such as injection molding, die casting or blowing means and the cooling body or engine components. Particularly interesting this procedure if the parent compounds from inexpensive material, such as iron powder built up and built up only to the form-fitting areas with tool steel.

Finally, the mechanical properties can be altered by Vakuumgluhen. To compensate for a possible delay due to the heat treatment, the component may be provided in the accessible for repair them with an allowance in order to subsequently process to the final dimensions.

Finally, the component may be enhanced by additional, corresponding to the prior art methods, such as Hard, coating, heat treatment, preferably Vakuumgluhen, etc..

The foregoing description of the present invention is used for illustrative purposes only and not for purposes of limitation of the invention. In the invention, various changes and modifications are possible without departing from the scope of the invention and its equivalents.

Claims

claims
1. A method for manufacturing a component with a height of at least 60 mm, preferably 100 mm, by kinetic cold gas compacting, in particular thermal spraying of material particles, the component being produced by layer-wise spraying material particles, and any coating layer before spraying the next coat layer at least Processing partially machined, in particular by milling.
2. The method according to claim 1, characterized in that the carrier gas in the Spruhduse, in particular De Laval nozzle, is accelerated to supersonic speed.
3. The method according to claim 2, characterized in that the Spruhabstand between application surface and the outlet of the De Laval nozzle is between 80 mm and 400 mm can be set.
4. The method according to claim 2, characterized in that said De Laval nozzle at the spraying of the material particles at a speed of 10 m / s to 20 m / s, preferably higher speed, is moved.
5. The method according to any one of claims 1 to 4, characterized in that the material particles are applied with a Spruhdruck of Tragergases in the range of 65 bar to 100th
6. The method according to any one of claims 1 to 4, characterized indicated that the material particles are applied with a Spruhdruck of Tragergases in the range of 30 to 65 bar.
I. Method according to one of claims 1 to 6, characterized in that the material particles are coated with a gas-jet temperature of Tragergases 800 c C to 1050 ° C.
8. The method according to any one of claims 1 to 6, characterized in that the material particles are coated with a gas-jet temperature of Tragergases of 300 ° to 800 0 C.
9. The method according to any one of claims 1 to 8, characterized in that the host beam temperature of Tragergases is generated by an electrically heated gas heater.
10. The method according to claim 7, characterized in that the carrier gas and / or main gas for accelerating the material particles through the De Laval nozzle superheated steam and / or nitrogen and / or oxygen-reduced air having an oxygen content of less than 3%.
II. A method according to any one of claims 1 to 10, characterized in that the component to be located with complex internal geometries is formed.
12. The method according to any one of claims 1 to 11, characterized in that the component to be produced from at least two different metallic pulverulent materials is prepared.
13. The method according to claim 12, characterized in that the transition between the different materials in the form of a gradient of decreasing concentration of one and increasing concentration of the other material is carried out.
PCT/EP2008/003052 2007-04-16 2008-04-16 Production of large components by kinetic cold gas compacting material particles WO2008125354A3 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
DE102007017753.6 2007-04-16
DE200710017753 DE102007017753A1 (en) 2007-04-16 2007-04-16 Production of large components by kinetic cold gas compacting of material particles

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WO2008125354A2 true true WO2008125354A2 (en) 2008-10-23
WO2008125354A3 true WO2008125354A3 (en) 2009-04-30

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Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102009048706A1 (en) * 2009-10-08 2011-04-28 Hermle Maschinenbau Gmbh Method and apparatus for producing a molded part by means of applying generative
DE102010024226A1 (en) 2010-06-18 2011-12-22 Mtu Aero Engines Gmbh Producing or repairing component, preferably components of turbomachine, comprises applying first material layer on base and solidifying, producing first component portion, and applying second material layer on produced component portion
DE102015203234B4 (en) * 2015-02-24 2018-04-26 MTU Aero Engines AG A method for producing a component, namely einens housing of a gas turbine and the corresponding component

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3806178A1 (en) * 1988-02-26 1989-09-07 Siemens Ag Method for applying layers of high-temperature superconducting material to substrates
EP0554033A1 (en) * 1992-01-31 1993-08-04 Fritz B. Prinz Method for fabrication of three-dimensional articles
US5301415A (en) * 1990-12-03 1994-04-12 Prinz Fritz B Method for fabrication of three-dimensional articles
EP0911426A1 (en) * 1997-10-27 1999-04-28 Linde Aktiengesellschaft Production of mouldings
EP0911424A1 (en) * 1997-10-27 1999-04-28 Linde Aktiengesellschaft Making of composite materials
DE10131657A1 (en) * 2000-07-25 2002-02-14 Ford Global Tech Inc Directly producing an abrasion resistant open die forming tool comprises preparing a tool to contour an open die surface, and dynamically cold gas spraying the contoured surface to form butt welding metal particle layers
DE10039481A1 (en) * 2000-08-08 2002-02-21 Thermico Gmbh & Co Kg Process for applying surface coatings in the path of high speed flame spraying comprises atomizing kerosene in a burner containing the kerosene, oxygen and hydrogen using a combustion gas such as hydrogen, ethylene or methane, and igniting
US20020033135A1 (en) * 2001-05-02 2002-03-21 Asb Industries, Inc. Cold spray system nozzle
WO2002042056A1 (en) * 2000-11-27 2002-05-30 Innovaris Gmbh Generative method for producing a part and device for carrying out this method

Family Cites Families (3)

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Publication number Priority date Publication date Assignee Title
DE19747386A1 (en) * 1997-10-27 1999-04-29 Linde Ag Process for the thermal coating of substrate materials
DE10222301B4 (en) * 2002-05-18 2006-08-10 Leoni Ag A method for manufacturing an electrical stretching element
DE10314249B3 (en) * 2003-03-29 2004-10-21 Daimlerchrysler Ag Process for preparing a surface, e.g. cylinder face, to be coated with a thermally sprayed layer comprises removing material from the surface by machining and providing the surface with a rough structure

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3806178A1 (en) * 1988-02-26 1989-09-07 Siemens Ag Method for applying layers of high-temperature superconducting material to substrates
US5301415A (en) * 1990-12-03 1994-04-12 Prinz Fritz B Method for fabrication of three-dimensional articles
EP0554033A1 (en) * 1992-01-31 1993-08-04 Fritz B. Prinz Method for fabrication of three-dimensional articles
EP0911426A1 (en) * 1997-10-27 1999-04-28 Linde Aktiengesellschaft Production of mouldings
EP0911424A1 (en) * 1997-10-27 1999-04-28 Linde Aktiengesellschaft Making of composite materials
DE10131657A1 (en) * 2000-07-25 2002-02-14 Ford Global Tech Inc Directly producing an abrasion resistant open die forming tool comprises preparing a tool to contour an open die surface, and dynamically cold gas spraying the contoured surface to form butt welding metal particle layers
DE10039481A1 (en) * 2000-08-08 2002-02-21 Thermico Gmbh & Co Kg Process for applying surface coatings in the path of high speed flame spraying comprises atomizing kerosene in a burner containing the kerosene, oxygen and hydrogen using a combustion gas such as hydrogen, ethylene or methane, and igniting
WO2002042056A1 (en) * 2000-11-27 2002-05-30 Innovaris Gmbh Generative method for producing a part and device for carrying out this method
US20020033135A1 (en) * 2001-05-02 2002-03-21 Asb Industries, Inc. Cold spray system nozzle

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Publication number Publication date Type
DE102007017753A1 (en) 2008-10-23 application
WO2008125354A3 (en) 2009-04-30 application

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