WO2016156758A1 - Method for creating orifices in a thin-walled component manufactured from metal powder using additive manufacturing, and thin-walled component thus obtained - Google Patents

Method for creating orifices in a thin-walled component manufactured from metal powder using additive manufacturing, and thin-walled component thus obtained Download PDF

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Publication number
WO2016156758A1
WO2016156758A1 PCT/FR2016/050752 FR2016050752W WO2016156758A1 WO 2016156758 A1 WO2016156758 A1 WO 2016156758A1 FR 2016050752 W FR2016050752 W FR 2016050752W WO 2016156758 A1 WO2016156758 A1 WO 2016156758A1
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WO
WIPO (PCT)
Prior art keywords
thin
forming
orifice
angle
pattern
Prior art date
Application number
PCT/FR2016/050752
Other languages
French (fr)
Inventor
Ludovic André Joël NAUDOT
Frédéric Bonnet
Cyril AUDRA
Gérald André Charles SENGER
Guilhem VERRON
Original Assignee
Safran Helicopter Engines
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Publication date
Application filed by Safran Helicopter Engines filed Critical Safran Helicopter Engines
Publication of WO2016156758A1 publication Critical patent/WO2016156758A1/en

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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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of 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
    • 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
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
    • 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
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
    • 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
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • 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
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
    • 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
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • F01D5/186—Film cooling
    • 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
    • F05D2230/10—Manufacture by removing material
    • F05D2230/13—Manufacture by removing material using lasers
    • 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
    • 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
    • F05D2230/311—Layer deposition by torch or flame spraying
    • 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 invention relates to a method for forming orifices in a thin-walled part manufactured by an additive construction of metal powders by means of a high energy beam.
  • the invention relates more particularly to a method of forming orifices in a part intended to form a combustion chamber of a turbomachine, a blade of a distributor of a turbomachine, a turbine blade, an axial compressor blade or centrifugal, a housing bearing hollow arm, a nozzle, a jacket or a distributor insert and generally any thin-walled perforated piece intended to equip a turbine engine.
  • thin-walled part defines a part having at least one wall having a negligible thickness relative to the other dimensions of the wall.
  • a multi-pierced thin-walled part is required. This is for example the production of a combustion chamber of a turbomachine, a blade of a distributor of a turbomachine, a turbine blade, an axial compressor blade or centrifugal, a bearing housing hollow arm, a nozzle, a dispenser jacket or insert, etc.
  • the invention is particularly described in connection with a distributor blade. That being so, the invention also applies to all the parts described above and extends to any thin-walled perforated piece intended to equip a turbine engine.
  • a turbomachine distributor guides the gases at the turbine inlet. Because of the temperature of the gases, the vanes of the distributor, in particular those directly receiving the gases from the combustion chamber, are subjected to very severe operating conditions. So it is necessary to provide cooling means in the walls which are in contact with hot gases. The cooling is done by forced convection or by air impact on the inner faces of the blade walls.
  • a distributor vane is hollow and provided with an internal cooling circuit and has air passages.
  • a method of forming an orifice in a thin-walled part made of an additive metal powder construction is to provide circular orifices during the manufacturing process of the thin-walled part.
  • the thin walled part is obtained by the implementation of a high energy beam, such as a laser beam or an electron beam, to successively fuse layers of metal powders so as to form over a plateau of construction, the thin-walled part aimed at.
  • the orifices are formed leaving unfused circular areas. Once the part is formed, the non-fused areas form the circular orifices of the part.
  • the inventors have realized that the orifices thus formed tend to collapse on themselves. Also, it is difficult to reproduce identical orifices from one room to another, especially from one blade to another. In addition, the cooling air flows thus generated may, in certain cases, deviate from the nominal flow rates sought. The resulting cooling deviates from the desired cooling.
  • the inventors have therefore sought to improve the method of forming orifices in a blade of a distributor and generally in any thin-walled part, in particular intended to equip a turbomachine.
  • the aim of the invention is to overcome at least some of the disadvantages of the orifice forming process in a thin-walled part of the prior art.
  • the invention also aims to provide, in at least one embodiment of the invention, a method of forming orifices in a thin-walled part that is reproducible.
  • the invention also aims to provide, in at least one embodiment, a method of forming orifices in a thin-walled part that fits particularly at a dawn of a distributor or a combustion chamber.
  • the invention also aims to provide, in at least one embodiment of the invention, a method of forming orifices in a thin-walled part that can be implemented without difficulty.
  • the invention also aims to provide, in at least one embodiment, a thin-walled part obtained by such a method.
  • the invention relates to a method of forming at least one orifice in a thin-walled part manufactured by an additive construction of metal powders by means of a high energy beam.
  • the method according to the invention is characterized in that it comprises a step of delimiting at least one unfused zone by said high energy beam defined by a closed trajectory forming a pattern having at least two adjacent sides forming a salient angle between them, said unfused zone forming said orifice.
  • a method according to the invention thus makes it possible to form non-circular orifices delimited by at least two adjacent sides forming between them a projecting angle, that is to say an angle strictly between 0 ° and 180 °.
  • At least one salient angle is arranged at the top of the pattern delimiting said unfused zone.
  • Such a pattern makes it possible to form an orifice delimited at its apex by a projecting angle.
  • Such an orifice has the advantage of not being likely to collapse on itself. Indeed, the sides forming the projecting angle oppose each other so that each side opposes the collapse of the adjacent side.
  • the pattern is chosen from the group comprising a diamond, a triangle, a pentagon or a drop of water.
  • Each of these patterns makes it possible to form an orifice having at its apex a projecting angle formed by two adjacent sides.
  • each pattern allows an identical reproduction of the holes.
  • each pattern has a constant section which is not likely to decrease due to the collapse of the orifices formed according to these patterns.
  • at least one salient angle is a right angle.
  • a right angle provides good lift at the top while limiting the vertical size of the orifice.
  • the high energy beam is a laser beam.
  • the invention also relates to a thin-walled part obtained by implementing a method according to the invention comprising at least one orifice formed in said thin wall and having a shape comprising at least two adjacent sides forming a projecting angle between them. .
  • the projecting angle is arranged at the top of the orifice.
  • a part according to the invention comprises a plurality of orifices formed in said thin wall, each orifice having a shape comprising at least two adjacent sides forming a projecting angle between them.
  • the thin-walled part is chosen from the group comprising a blade of a distributor of a turbomachine, a combustion chamber of a turbomachine, a turbine blade, an axial compressor blade. or centrifugal, a bearing housing hollow arm, a nozzle, a jacket or a distributor insert.
  • the invention also relates to a method for manufacturing by selective melting of metal powders by means of a high energy beam of a thin-walled part comprising at least one orifice, said method comprising a step of depositing on a planar construction plate. a plurality of layers of metal powders; a step of melting said layers of metal powders according to the shape of the part to be manufactured, characterized in that it comprises during the melting step, a step of delimiting at least one unfused zone along a closed path forming a pattern having at least two adjacent sides forming an angle projecting therebetween, said unfused region forming said orifice
  • the invention also relates to a method of forming orifices in a thin-walled part, and a thin-walled part thus obtained, characterized in combination by all or some of the features mentioned above or hereinafter.
  • FIG. 1 is a schematic perspective view of the implementation of a method according to one embodiment of the invention
  • FIG. 2 is a schematic view of a part according to an embodiment of the invention; obtained by implementing the method according to one embodiment of the invention,
  • FIG. 3a, 3b and 3c are schematic views of different orifice cutting patterns for implementing the method according to one embodiment of the invention.
  • Figure 1 shows a distributor blade 5 which has been formed on a horizontal construction plate 6.
  • the blade has been formed on the plate 6 so that the wall 7 of the blade in which an orifice is formed extends perpendicularly to the plate 6.
  • the wall 7 of the blade 5 'extends vertically.
  • the manufacture of such a part comprises a step of depositing on the construction plate a plurality of layers of metal powders and a step of melting the powder particles so as to form above the construction plate, the thin-walled part targeted.
  • a high energy beam is for example a laser beam or an electron beam.
  • the invention is described with reference to a laser beam. However, this description is not limiting and any type of high energy beam can be used for the implementation of the invention.
  • the manufacture of a piece by additive construction of metal powders can for example be obtained by the use of a laser beam generator 12 and a device 13 for controlling the laser beam 12.
  • This device 13 is configured to be able to direct the laser beam 12 at any point of the part being built.
  • This control of the laser beam can for example be achieved by the control of a steerable mirror 18 on which the laser beam 12 is reflected before reaching the layers of metal powder successively deposited on the construction plate.
  • the shaping of the laser beam 12 and the variation of its diameter in the focal plane are respectively by means of a beam expander 14 and a focusing device 15.
  • the assembly forms an optical system.
  • FIG. 1 diagrammatically represents the step of delimiting an orifice during the manufacture of a part by melting of particles of metal powders.
  • the thin-walled part is shown in a finished version for purposes of illustration and clarity, it being understood that the orifices are formed as the thin-walled part is constructed.
  • the device 13 for controlling the laser beam 12 is parameterized so that it can delimit an unfused zone by a closed trajectory 9 forming a pattern having at least two adjacent sides forming a projecting angle between them.
  • the formation of an orifice consists in not fusing an area of the part under construction, this zone being delimited by a particular trajectory which defines a specific pattern comprising at least one projecting angle between two sides of the pattern.
  • a plurality of zones are provided during the fabrication of the part, each of these areas not being subjected to the high-energy beam so as not to be fused together.
  • FIGS. 3a, 3b and 3c represent various patterns making it possible to perform the step of delimiting an unfused zone of a method for forming an orifice in a thin-walled part according to the invention.
  • Figure 3a is a view of a diamond-shaped pattern. This pattern comprises two adjacent sides 31, 32 forming between them a salient angle.
  • Figure 3b is a view of a pentagon-shaped pattern of the house type. It also comprises two adjacent sides 31, 32 forming between them a salient angle.
  • Figure 3c is a schematic view of a water-like pattern. It also comprises two adjacent sides 31, 32 forming between them a salient angle.
  • the projecting angle is a right angle.
  • this angle can be an obtuse angle or an acute angle.
  • each of these patterns makes it possible to form a non-circular orifice that is no longer capable of collapsing. Indeed, once the orifice formed, the peripheral walls of this orifice, corresponding to the sides 31, 32 of the pattern, form a salient angle and are supported on one another. Also, each peripheral wall is maintained by the facing wall.
  • Figure 2 is a schematic view of a blade 5 comprising a plurality of orifices formed by a method according to the invention.
  • the pattern used to form the orifices is a diamond-like pattern.
  • the other patterns shown in Figures 3b and 3c can also be implemented according to the invention and generally any pattern for defining a closed path comprising at least one salient angle, formed preferably at the top of the pattern .
  • the invention has been described in connection with a dawn of a dispenser, but the method according to the invention can of course be applied to any part comprising a thin wall, in particular a combustion chamber of a turbomachine a combustion chamber of a turbomachine, a turbine blade, an axial compressor blade or centrifugal, a bearing housing hollow arm, a nozzle, a jacket, a distributor insert, etc.

Abstract

The invention relates to a method for creating at least one orifice in a thin-walled component manufactured from metal powders by additive manufacturing using a high-energy beam, characterized in that it comprises a step of delimiting at least one zone that is not melted by the said high-energy beam defined by a closed path (9) forming a pattern (21, 22, 23) having at least two adjacent sides (31, 32) forming a salient angle (α) between them, the said non-melted zone forming the said orifice (8).

Description

PROCÉDÉ DE FORMATION D'ORIFICES DANS UNE PIÈCE À PAROI MINCE FABRIQUÉE PAR CONSTRUCTION ADDITIVE DE POUDRES METALLIQUES, ET PIÈCE À PAROI MINCE AINSI  METHOD FOR FORMING ORIFICES IN A THIN-WALL PART MADE BY ADDITIVE CONSTRUCTION OF METAL POWDERS, AND THIN PARTITION PIECE THUS
OBTENUE  OBTAINED
1. Domaine technique de l'invention 1. Technical field of the invention
L'invention concerne un procédé de formation d'orifices dans une pièce à paroi mince fabriquée par une construction additive de poudres métalliques au moyen d'un faisceau haute énergie. L'invention concerne plus particulièrement un procédé de formation d'orifices dans une pièce destinée à former une chambre de combustion d'une turbomachine, une aube d'un distributeur d'une turbomachine, une pale de turbine, une pale de compresseur axial ou centrifuge, un bras creux de boîtier palier, une tuyère, une chemise ou un insert de distributeur et de manière générale toute pièce à paroi mince percée destinée à équiper un turbomoteur.  The invention relates to a method for forming orifices in a thin-walled part manufactured by an additive construction of metal powders by means of a high energy beam. The invention relates more particularly to a method of forming orifices in a part intended to form a combustion chamber of a turbomachine, a blade of a distributor of a turbomachine, a turbine blade, an axial compressor blade or centrifugal, a housing bearing hollow arm, a nozzle, a jacket or a distributor insert and generally any thin-walled perforated piece intended to equip a turbine engine.
2. Arrière-plan technologique  2. Technological background
Dans tout le texte, on définit par les termes de « pièce à paroi mince », une pièce présentant au moins une paroi présentant une épaisseur négligeable par rapport aux autres dimensions de la paroi. Il existe de nombreuses applications où le recours à une pièce à paroi mince multi-percée est nécessaire. Il s'agit par exemple de la réalisation d'une chambre de combustion d'une turbomachine, d'une aube d'un distributeur d'une turbomachine, d'une pale de turbine, d'une pale de compresseur axial ou centrifuge, d'un bras creux de boîtier palier, d'une tuyère, d'une chemise ou d'un insert de distributeur, etc.  Throughout the text, the term "thin-walled part" defines a part having at least one wall having a negligible thickness relative to the other dimensions of the wall. There are many applications where the use of a multi-pierced thin-walled part is required. This is for example the production of a combustion chamber of a turbomachine, a blade of a distributor of a turbomachine, a turbine blade, an axial compressor blade or centrifugal, a bearing housing hollow arm, a nozzle, a dispenser jacket or insert, etc.
Dans tout le texte, l'invention est particulièrement décrite en lien avec une aube de distributeur. Cela étant, l'invention s'applique également à l'ensemble des pièces décrites ci-dessus et s'étend à toute pièce à paroi mince percée destinée à équiper un turbomoteur.  Throughout the text, the invention is particularly described in connection with a distributor blade. That being so, the invention also applies to all the parts described above and extends to any thin-walled perforated piece intended to equip a turbine engine.
Un distributeur de turbomachine assure le guidage des gaz en entrée de turbine. En raison de la température des gaz, les aubes du distributeur, notamment celles recevant directement les gaz issus de la chambre de combustion, sont soumises à des conditions de fonctionnement très sévères. Il est donc nécessaire de prévoir des moyens de refroidissement dans les parois qui sont au contact des gaz chauds. Le refroidissement est réalisé par convection forcée ou bien par impact d'air sur les faces internes des parois des aubes. En général, une aube de distributeur est creuse et munie d'un circuit de refroidissement interne et comporte des orifices de passage d'air. A turbomachine distributor guides the gases at the turbine inlet. Because of the temperature of the gases, the vanes of the distributor, in particular those directly receiving the gases from the combustion chamber, are subjected to very severe operating conditions. So it is necessary to provide cooling means in the walls which are in contact with hot gases. The cooling is done by forced convection or by air impact on the inner faces of the blade walls. In general, a distributor vane is hollow and provided with an internal cooling circuit and has air passages.
Actuellement, un procédé de formation d'un orifice dans une pièce à paroi mince fabriquée par une construction additive de poudres métalliques consiste à ménager des orifices circulaires au cours du procédé de fabrication de la pièce à paroi mince. La pièce à paroi mince est obtenue par la mise en œuvre d'un faisceau haute énergie, tel qu'un faisceau laser ou un faisceau d'électrons, pour fusionner successivement des couches de poudres métalliques de façon à former au dessus d'un plateau de construction, la pièce à paroi mince visée. Les orifices sont formés en laissant des zones circulaires non fusionnées. Une fois la pièce formée, les zones non fusionnées forment les orifices circulaires de la pièce.  At present, a method of forming an orifice in a thin-walled part made of an additive metal powder construction is to provide circular orifices during the manufacturing process of the thin-walled part. The thin walled part is obtained by the implementation of a high energy beam, such as a laser beam or an electron beam, to successively fuse layers of metal powders so as to form over a plateau of construction, the thin-walled part aimed at. The orifices are formed leaving unfused circular areas. Once the part is formed, the non-fused areas form the circular orifices of the part.
Les inventeurs ont réalisé que les orifices ainsi formés ont tendance à s'effondrer sur eux-mêmes. Aussi, il est difficile de reproduire des orifices identiques d'une pièce à l'autre, notamment d'une aube à l'autre. En outre, les débits d'air de refroidissement ainsi générés peuvent, dans certains cas, s'écarter des débits nominaux recherchés. Le refroidissement obtenu s'écarte alors du refroidissement recherché.  The inventors have realized that the orifices thus formed tend to collapse on themselves. Also, it is difficult to reproduce identical orifices from one room to another, especially from one blade to another. In addition, the cooling air flows thus generated may, in certain cases, deviate from the nominal flow rates sought. The resulting cooling deviates from the desired cooling.
Les inventeurs ont donc cherché à améliorer le procédé de formation d'orifices dans une aube d'un distributeur et de manière générale dans toute pièce à paroi mince, en particulier destinée à équiper une turbomachine.  The inventors have therefore sought to improve the method of forming orifices in a blade of a distributor and generally in any thin-walled part, in particular intended to equip a turbomachine.
3. Objectifs de l'invention  3. Objectives of the invention
L'invention vise à pallier au moins certains des inconvénients du procédé de formation d'orifices dans une pièce à paroi mince de l'art antérieur.  The aim of the invention is to overcome at least some of the disadvantages of the orifice forming process in a thin-walled part of the prior art.
En particulier, l'invention vise aussi à fournir, dans au moins un mode de réalisation de l'invention, un procédé de formation d'orifices dans une pièce à paroi mince qui soit reproductible.  In particular, the invention also aims to provide, in at least one embodiment of the invention, a method of forming orifices in a thin-walled part that is reproducible.
L'invention vise aussi à fournir, dans au moins un mode de réalisation, un procédé de formation d'orifices dans une pièce à paroi mince qui s'adapte particulièrement à une aube d'un distributeur ou à une chambre de combustion.The invention also aims to provide, in at least one embodiment, a method of forming orifices in a thin-walled part that fits particularly at a dawn of a distributor or a combustion chamber.
L'invention vise aussi à fournir, dans au moins un mode de réalisation de l'invention, un procédé de formation d'orifices dans une pièce à paroi mince qui puisse être mis en œuvre sans difficultés. The invention also aims to provide, in at least one embodiment of the invention, a method of forming orifices in a thin-walled part that can be implemented without difficulty.
L'invention vise aussi à fournir, dans au moins un mode de réalisation, une pièce à paroi mince obtenue par un tel procédé.  The invention also aims to provide, in at least one embodiment, a thin-walled part obtained by such a method.
4. Exposé de l'invention  4. Presentation of the invention
Pour ce faire, l'invention concerne un procédé de formation d'au moins un orifice dans une pièce à paroi mince fabriquée par une construction additive de poudres métalliques au moyen d'un faisceau haute énergie.  To do this, the invention relates to a method of forming at least one orifice in a thin-walled part manufactured by an additive construction of metal powders by means of a high energy beam.
Le procédé selon l'invention est caractérisé en ce qu'il comprend une étape de délimitation d'au moins une zone non fusionnée par ledit faisceau haute énergie définie par une trajectoire fermée formant un motif présentant au moins deux côtés adjacents formant un angle saillant entre eux, ladite zone non fusionnée formant ledit orifice.  The method according to the invention is characterized in that it comprises a step of delimiting at least one unfused zone by said high energy beam defined by a closed trajectory forming a pattern having at least two adjacent sides forming a salient angle between them, said unfused zone forming said orifice.
Un procédé selon l'invention permet donc de former des orifices non circulaires délimités par au moins deux côtés adjacents formant entre eux un angle saillant, c'est-à-dire un angle strictement compris entre 0° et 180°.  A method according to the invention thus makes it possible to form non-circular orifices delimited by at least two adjacent sides forming between them a projecting angle, that is to say an angle strictly between 0 ° and 180 °.
Avantageusement et selon l'invention, au moins un angle saillant est agencé au sommet du motif délimitant ladite zone non fusionnée.  Advantageously and according to the invention, at least one salient angle is arranged at the top of the pattern delimiting said unfused zone.
Un tel motif permet de former un orifice délimité en son sommet par un angle saillant. Un tel orifice présente l'avantage de ne pas être susceptible de s'effondrer sur lui-même. En effet, les côtés formant l'angle saillant s'opposent l'un à l'autre de sorte que chaque côté s'oppose à l'effondrement du côté adjacent.  Such a pattern makes it possible to form an orifice delimited at its apex by a projecting angle. Such an orifice has the advantage of not being likely to collapse on itself. Indeed, the sides forming the projecting angle oppose each other so that each side opposes the collapse of the adjacent side.
Avantageusement et selon l'invention, le motif est choisi dans le groupe comprenant un losange, un triangle, un pentagone ou une goutte d'eau.  Advantageously and according to the invention, the pattern is chosen from the group comprising a diamond, a triangle, a pentagon or a drop of water.
Chacun de ces motifs permet de former un orifice présentant en son sommet un angle saillant formé par deux côtés adjacents.  Each of these patterns makes it possible to form an orifice having at its apex a projecting angle formed by two adjacent sides.
Chaque motif permet une reproduction à l'identique des orifices. En outre, chaque motif présente une section constante qui n'est pas susceptible de diminuer du fait de l'effondrement des orifices formés suivant ces motifs. Avantageusement et selon l'invention, au moins un angle saillant est un angle droit. Each pattern allows an identical reproduction of the holes. In addition, each pattern has a constant section which is not likely to decrease due to the collapse of the orifices formed according to these patterns. Advantageously and according to the invention, at least one salient angle is a right angle.
Un angle droit permet de bénéficier d'une bonne portance en sommet tout en limitant l'encombrement vertical de l'orifice.  A right angle provides good lift at the top while limiting the vertical size of the orifice.
Avantageusement et selon l'invention, le faisceau haute énergie est un faisceau laser.  Advantageously and according to the invention, the high energy beam is a laser beam.
L'invention concerne également une pièce à paroi mince obtenue par la mise en œuvre d'un procédé selon l'invention comprenant au moins un orifice ménagé dans ladite paroi mince et présentant une forme comprenant au moins deux côtés adjacents formant un angle saillant entre eux.  The invention also relates to a thin-walled part obtained by implementing a method according to the invention comprising at least one orifice formed in said thin wall and having a shape comprising at least two adjacent sides forming a projecting angle between them. .
Avantageusement et selon l'invention, l'angle saillant est agencé au sommet de l'orifice.  Advantageously and according to the invention, the projecting angle is arranged at the top of the orifice.
Avantageusement, une pièce selon l'invention comprend une pluralité d'orifices ménagés dans ladite paroi mince, chaque orifice présentant une forme comprenant au moins deux côtés adjacents formant un angle saillant entre eux.  Advantageously, a part according to the invention comprises a plurality of orifices formed in said thin wall, each orifice having a shape comprising at least two adjacent sides forming a projecting angle between them.
Selon une variante avantageuse de l'invention, la pièce à paroi mince est choisie dans le groupe comprenant une aube d'un distributeur d'une turbomachine, une chambre de combustion d'une turbomachine, une pale de turbine, une pale de compresseur axial ou centrifuge, un bras creux de boîtier palier, une tuyère, une chemise ou un insert de distributeur.  According to an advantageous variant of the invention, the thin-walled part is chosen from the group comprising a blade of a distributor of a turbomachine, a combustion chamber of a turbomachine, a turbine blade, an axial compressor blade. or centrifugal, a bearing housing hollow arm, a nozzle, a jacket or a distributor insert.
L'invention concerne également un procédé de fabrication par fusion sélective de poudres métalliques au moyen d'un faisceau haute énergie d'une pièce à paroi mince comprenant au moins un orifice, ledit procédé comprenant une étape de dépose sur un plateau de construction plan d'une pluralité de couches de poudres métalliques ; une étape de fusion desdites couches de poudres métalliques suivant la forme de la pièce à fabriquer, caractérisé en ce qu'il comprend au cours de l'étape de fusion, une étape de délimitation d'au moins une zone non fusionnée suivant une trajectoire fermée formant un motif présentant au moins deux côtés adjacents formant un angle saillant entre eux, ladite zone non fusionnée formant ledit orifice  The invention also relates to a method for manufacturing by selective melting of metal powders by means of a high energy beam of a thin-walled part comprising at least one orifice, said method comprising a step of depositing on a planar construction plate. a plurality of layers of metal powders; a step of melting said layers of metal powders according to the shape of the part to be manufactured, characterized in that it comprises during the melting step, a step of delimiting at least one unfused zone along a closed path forming a pattern having at least two adjacent sides forming an angle projecting therebetween, said unfused region forming said orifice
L'invention concerne également un procédé de formation d'orifices dans une pièce à paroi mince, et une pièce à paroi mince ainsi obtenue, caractérisés en combinaison par tout ou partie des caractéristiques mentionnées ci-dessus ou ci- après. The invention also relates to a method of forming orifices in a thin-walled part, and a thin-walled part thus obtained, characterized in combination by all or some of the features mentioned above or hereinafter.
5. Liste des figures  5. List of figures
D'autres buts, caractéristiques et avantages de l'invention apparaîtront à la lecture de la description suivante donnée à titre uniquement non limitatif et qui se réfère aux figures annexées dans lesquelles :  Other objects, features and advantages of the invention will become apparent on reading the following description given solely by way of non-limiting example and which refers to the appended figures in which:
- la figure 1 est une vue schématique en perspective de la mise en œuvre d'un procédé selon un mode de réalisation de l'invention, - la figure 2 est une vue schématique d'une pièce selon un mode de réalisation de l'invention obtenue par la mise en œuvre du procédé selon un mode de réalisation de l'invention,  FIG. 1 is a schematic perspective view of the implementation of a method according to one embodiment of the invention; FIG. 2 is a schematic view of a part according to an embodiment of the invention; obtained by implementing the method according to one embodiment of the invention,
- les figures 3a, 3b et 3c sont des vues schématiques de différents motifs de découpe d'orifices pour la mise en œuvre du procédé selon un mode de réalisation de l'invention.  - Figures 3a, 3b and 3c are schematic views of different orifice cutting patterns for implementing the method according to one embodiment of the invention.
6. Description détaillée d'un mode de réalisation de l'invention Sur la figure, les échelles et les proportions ne sont pas strictement respectées et ce, à des fins d'illustration et de clarté. Dans toute la description détaillée qui suit en référence aux figures, sauf indication contraire, chaque portion de la pièce à paroi mince, en l'occurrence une aube de distributeur, est décrite telle qu'elle est agencée lorsque la pièce est construite sur un plateau de construction plan horizontal. Cet agencement est notamment représenté sur la figure 1. En outre, les éléments identiques, similaires ou analogues sont désignés par les mêmes références. Enfin, les termes vertical et horizontal sont utilisés à titre non limitatif en référence au plan H et à la direction V représentés sur le trièdre de la figure 1.  6. DETAILED DESCRIPTION OF AN EMBODIMENT OF THE INVENTION In the figure, the scales and the proportions are not strictly adhered to for purposes of illustration and clarity. Throughout the following detailed description with reference to the figures, unless indicated otherwise, each portion of the thin-walled part, in this case a distributor blade, is described as it is arranged when the part is built on a tray Horizontal plane construction. This arrangement is in particular represented in FIG. 1. In addition, identical, similar or similar elements are designated by the same references. Finally, the terms vertical and horizontal are used in a nonlimiting manner with reference to the plane H and the direction V represented on the trihedron of FIG.
La figure 1 représente une aube 5 de distributeur qui a été formée sur un plateau 6 de construction horizontal. L'aube a été formée sur le plateau 6 de telle sorte que la paroi 7 de l'aube dans laquelle un orifice est ménagé s'étende perpendiculairement au plateau 6. En d'autres termes, la paroi 7 de l'aube 5 s'étend verticalement. Le principe de fabrication d'une aube par fusion sélective ou frittage sélectif de poudres métalliques au moyen d'un faisceau de haute énergie n'est pas décrit ici en détail. De manière connue, la fabrication d'une telle pièce comprend une étape de dépose sur le plateau de construction d'une pluralité de couches de poudres métalliques et une étape de fusion des particules de poudre de façon à former au dessus du plateau de construction, la pièce à paroi mince visée. Un tel faisceau haute énergie est par exemple un faisceau laser ou un faisceau d'électrons. Dans toute la suite, on décrit l'invention en référence à un faisceau laser. Cela étant, cette description n'est pas limitative et tout type de faisceau haute énergie peut être utilisé pour la mise en œuvre de l'invention. Figure 1 shows a distributor blade 5 which has been formed on a horizontal construction plate 6. The blade has been formed on the plate 6 so that the wall 7 of the blade in which an orifice is formed extends perpendicularly to the plate 6. In other words, the wall 7 of the blade 5 'extends vertically. The principle of making a dawn by selective fusion or selective sintering of metal powders by means of a high energy beam is not described here in detail. In known manner, the manufacture of such a part comprises a step of depositing on the construction plate a plurality of layers of metal powders and a step of melting the powder particles so as to form above the construction plate, the thin-walled part targeted. Such a high energy beam is for example a laser beam or an electron beam. In the following, the invention is described with reference to a laser beam. However, this description is not limiting and any type of high energy beam can be used for the implementation of the invention.
La fabrication d'une pièce par construction additive de poudres métalliques peut par exemple être obtenue par l'utilisation d'un générateur 11 de faisceau laser 12 et un dispositif 13 de commande du faisceau laser 12. Ce dispositif 13 est configuré pour pouvoir diriger le faisceau laser 12 en tout point de la pièce en cours de construction. Ce pilotage du faisceau laser peut par exemple être réalisé par la commande d'un miroir 18 orientable sur lequel le faisceau laser 12 se réfléchit avant d'atteindre les couches de poudre métallique déposées successivement sur le plateau de construction. La mise en forme du faisceau laser 12 et la variation de son diamètre sur le plan focal se font respectivement au moyen d'un dilatateur de faisceau 14 et d'un dispositif de focalisation 15. L'ensemble forme un système optique.  The manufacture of a piece by additive construction of metal powders can for example be obtained by the use of a laser beam generator 12 and a device 13 for controlling the laser beam 12. This device 13 is configured to be able to direct the laser beam 12 at any point of the part being built. This control of the laser beam can for example be achieved by the control of a steerable mirror 18 on which the laser beam 12 is reflected before reaching the layers of metal powder successively deposited on the construction plate. The shaping of the laser beam 12 and the variation of its diameter in the focal plane are respectively by means of a beam expander 14 and a focusing device 15. The assembly forms an optical system.
La figure 1 représente schématiquement l'étape de délimitation d'un orifice au cours de la fabrication d'une pièce par fusion de particules de poudres métalliques. Sur la figure 1, la pièce à paroi mince est représenté dans une version finie à des fins d'illustration et de clarté, étant entendu que les orifices sont formés au fur et à mesure de la construction de la pièce à paroi mince.  FIG. 1 diagrammatically represents the step of delimiting an orifice during the manufacture of a part by melting of particles of metal powders. In Fig. 1, the thin-walled part is shown in a finished version for purposes of illustration and clarity, it being understood that the orifices are formed as the thin-walled part is constructed.
Selon l'invention, le dispositif 13 de commande du faisceau laser 12 est paramétré de sorte qu'il puisse délimiter une zone non fusionnée par une trajectoire 9 fermée formant un motif présentant au moins deux côtés adjacents formant un angle saillant entre eux. En d'autres termes, la formation d'un orifice consiste à ne pas fusionner une zone de la pièce en cours de construction, cette zone étant délimitée par une trajectoire particulière qui définie un motif spécifique comprenant au moins un angle saillant entre deux côtés du motif. Pour former une pluralité d'orifices dans la pièce à paroi mince, une pluralité de zones sont prévues au cours de la fabrication de la pièce, chacune de ces zones n'étant pas soumise au faisceau haute énergie pour ne pas être fusionnée. According to the invention, the device 13 for controlling the laser beam 12 is parameterized so that it can delimit an unfused zone by a closed trajectory 9 forming a pattern having at least two adjacent sides forming a projecting angle between them. In other words, the formation of an orifice consists in not fusing an area of the part under construction, this zone being delimited by a particular trajectory which defines a specific pattern comprising at least one projecting angle between two sides of the pattern. To form a plurality of orifices in the thin-walled part, a plurality of zones are provided during the fabrication of the part, each of these areas not being subjected to the high-energy beam so as not to be fused together.
Les figures 3a, 3b et 3c représentent différents motifs permettant de réaliser l'étape de délimitation d'une zone non fusionnée d'un procédé de formation d'un orifice dans une pièce à paroi mince selon l'invention.  FIGS. 3a, 3b and 3c represent various patterns making it possible to perform the step of delimiting an unfused zone of a method for forming an orifice in a thin-walled part according to the invention.
Par exemple, la figure 3a est une vue d'un motif en forme de losange. Ce motif comprend deux côtés 31, 32 adjacents formant entre eux un angle a saillant.  For example, Figure 3a is a view of a diamond-shaped pattern. This pattern comprises two adjacent sides 31, 32 forming between them a salient angle.
La figure 3b est une vue d'un motif en forme de pentagone, du type maison. Il comprend également deux côtés 31, 32 adjacents formant entre eux un angle a saillant.  Figure 3b is a view of a pentagon-shaped pattern of the house type. It also comprises two adjacent sides 31, 32 forming between them a salient angle.
La figure 3c est une vue schématique d'un motif en forme de goûte d'eau. Il comprend également deux côtés 31, 32 adjacents formant entre eux un angle a saillant.  Figure 3c is a schematic view of a water-like pattern. It also comprises two adjacent sides 31, 32 forming between them a salient angle.
Selon le mode de réalisation des figures 3a, à 3c, l'angle saillant est un angle droit. Cela étant, selon d'autres modes de réalisation, cet angle peut être un angle obtus ou un angle aigu.  According to the embodiment of Figures 3a, 3c, the projecting angle is a right angle. However, according to other embodiments, this angle can be an obtuse angle or an acute angle.
Chacun de ces motifs permet de former un orifice non circulaire qui n'est plus susceptible de s'affaisser. En effet, une fois l'orifice formé, les parois périphériques de cet orifice, correspondant aux côtés 31, 32 du motif, forment un angle a saillant et sont en appui l'une sur l'autre. Aussi, chaque paroi périphérique est maintenue par la paroi en regard.  Each of these patterns makes it possible to form a non-circular orifice that is no longer capable of collapsing. Indeed, once the orifice formed, the peripheral walls of this orifice, corresponding to the sides 31, 32 of the pattern, form a salient angle and are supported on one another. Also, each peripheral wall is maintained by the facing wall.
La figure 2 est une vue schématique d'une aube 5 comprenant une pluralité d'orifices formées par un procédé selon l'invention. Selon le mode de réalisation représenté sur les figures 1 et 2, le motif mis en œuvre pour former les orifices est un motif du type losange. Cela étant, les autres motifs représentés sur les figures 3b et 3c peuvent également être mis en œuvre selon l'invention et de manière générale tout motif permettant de définir une trajectoire fermée comprenant au moins un angle saillant, formé, de préférence en sommet du motif.  Figure 2 is a schematic view of a blade 5 comprising a plurality of orifices formed by a method according to the invention. According to the embodiment shown in Figures 1 and 2, the pattern used to form the orifices is a diamond-like pattern. However, the other patterns shown in Figures 3b and 3c can also be implemented according to the invention and generally any pattern for defining a closed path comprising at least one salient angle, formed preferably at the top of the pattern .
L'invention a été décrite en lien avec une aube d'un distributeur, mais le procédé selon l'invention peut bien sur s'appliquer à toute pièce comprenant une paroi mince, notamment une chambre de combustion d'une turbomachine une chambre de combustion d'une turbomachine, une pale de turbine, une pale de compresseur axial ou centrifuge, un bras creux de boîtier palier, une tuyère, une chemise, un insert de distributeur, etc. The invention has been described in connection with a dawn of a dispenser, but the method according to the invention can of course be applied to any part comprising a thin wall, in particular a combustion chamber of a turbomachine a combustion chamber of a turbomachine, a turbine blade, an axial compressor blade or centrifugal, a bearing housing hollow arm, a nozzle, a jacket, a distributor insert, etc.

Claims

REVENDICATIONS
1. Procédé de formation d'au moins un orifice dans une pièce à paroi mince fabriquée par une construction additive de poudres métalliques au moyen d'un faisceau haute énergie, caractérisé en ce qu'il comprend une étape de délimitation d'au moins une zone non fusionnée par ledit faisceau haute énergie définie par une trajectoire (9) fermée formant un motif (21, 22, 23) présentant au moins deux côtés (31, 32) adjacents formant un angle (a) saillant entre eux, ladite zone non fusionnée formant ledit orifice (8). 1. A method of forming at least one orifice in a thin-walled part manufactured by an additive construction of metal powders by means of a high-energy beam, characterized in that it comprises a step of delimiting at least one zone not fused by said high energy beam defined by a closed trajectory (9) forming a pattern (21, 22, 23) having at least two adjacent sides (31, 32) forming an angle (a) projecting between them, said non fused forming said orifice (8).
2. Procédé selon la revendication 1, caractérisé en ce qu'au moins un angle (a) saillant est agencé au sommet dudit motif (21, 22, 23).  2. Method according to claim 1, characterized in that at least one angle (a) salient is arranged at the top of said pattern (21, 22, 23).
3. Procédé selon l'une des revendications 1 ou 2, caractérisé en ce que ledit motif (21, 22, 23) est choisi dans le groupe comprenant un losange (21), un triangle, un pentagone (22) ou une goutte d'eau (23).  3. Method according to one of claims 1 or 2, characterized in that said pattern (21, 22, 23) is selected from the group consisting of a rhombus (21), a triangle, a pentagon (22) or a drop of water (23).
4. Procédé selon l'une des revendications 1 à 3, caractérisé en ce qu'au moins un angle (a) saillant est un angle droit.  4. Method according to one of claims 1 to 3, characterized in that at least one angle (a) projecting is a right angle.
5. Procédé selon l'une des revendications 1 à 4, caractérisé en ce que ledit faisceau haute énergie est un faisceau laser.  5. Method according to one of claims 1 to 4, characterized in that said high energy beam is a laser beam.
6. Pièce à paroi mince obtenue par la mise en œuvre d'un procédé selon l'une des revendications 1 à 5 comprenant au moins un orifice (8) ménagé dans ladite paroi (7) mince présentant une forme comprenant au moins deux côtés adjacents formant un angle saillant entre eux. 6. thin-walled part obtained by the implementation of a method according to one of claims 1 to 5 comprising at least one orifice (8) formed in said thin wall (7) having a shape comprising at least two adjacent sides forming a salient angle between them.
7. Pièce selon la revendication 6, caractérisée en ce que ledit angle saillant est agencé au sommet de l'orifice.  7. Part according to claim 6, characterized in that said projecting angle is arranged at the top of the orifice.
8. Pièce à paroi mince selon l'une des revendications 6 ou 7, caractérisée en ce qu'elle comprend une pluralité d'orifices ménagés dans ladite paroi mince, chaque orifice présentant une forme comprenant au moins deux côtés adjacents formant un angle saillant entre eux.  8. thin-walled part according to one of claims 6 or 7, characterized in that it comprises a plurality of orifices in said thin wall, each orifice having a shape comprising at least two adjacent sides forming a salient angle between them.
9. Pièce à paroi mince selon l'une des revendications 6 à 8, caractérisée en ce que ladite pièce est choisie dans le groupe comprenant une aube (5) d'un distributeur d'une turbomachine, une chambre de combustion d'une turbomachine, une pale de turbine, une pale de compresseur axial ou centrifuge, un bras creux de boîtier palier, une tuyère, une chemise ou un insert de distributeur. 9. thin-walled part according to one of claims 6 to 8, characterized in that said piece is selected from the group comprising a blade (5) of a distributor of a turbomachine, a combustion chamber of a turbomachine, a turbine blade, an axial or centrifugal compressor blade, a housing bearing hollow arm, a nozzle, a jacket or a distributor insert.
PCT/FR2016/050752 2015-04-03 2016-04-01 Method for creating orifices in a thin-walled component manufactured from metal powder using additive manufacturing, and thin-walled component thus obtained WO2016156758A1 (en)

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