WO2017153313A1

WO2017153313A1 - Device for carrying out a selective laser melting and a laser metal deposition process, and component produced therewith

Info

Publication number: WO2017153313A1
Application number: PCT/EP2017/055140
Authority: WO
Inventors: Christian Brunhuber; Jonas Eriksson; Moritz Fischle; Andreas Graichen; Stefan Lampenscherf; Steffen Walter
Original assignee: Siemens Aktiengesellschaft
Priority date: 2016-03-07
Filing date: 2017-03-06
Publication date: 2017-09-14
Also published as: DE102016203680A1

Abstract

The invention relates to a device for carrying out a selective laser melting (SLM) and a laser metal deposition (LMD) production method, particularly for producing components with complex inner structures and/or a plurality of individual parts for turbines, particularly for gas turbines. The invention first discloses a component with complex fine inner thin-walled elements, which is provided with outer contours and mechanical stability by means of thick-walled elements, the two elements of the component being producible by generative methods such as SLM and LMD and still completed, for logical reasons, by prefabricated, for example, cast parts.

Description

description

DEVICE FOR CARRYING OUT A SELECTIVE LASER MELTING AND A LASER METAL DEPOSITION PROCESS AND COMPONENT MANUFACTURED THEREFOR

The invention relates to a device for carrying out a selective laser melting (SLM) production method, in particular for producing components having complex internal structures and / or many individual parts for turbines, in particular for gas turbines.

For example, the SLM process is known, in which three-dimensional metals are selectively melted by means of laser beams in a powder bed, and components are "erected" by lowering the powder bed, very fine structures, wall thicknesses in the range from 20 to 100 ym be represented include. However, the construction direction of the component disadvantage is defined in the SLM process from the beginning. of the process is therefore, that an anisotropic material behavior at about Herge ^¬ placed the SLM process components results and in particular also that the manufacture of overhanging structures in the SLM process is possible only by means of auxiliary structures. for example, was placed firmly ^¬ that the creep resistance of the components produced in the SLM process compared to driven components is greatly reduced.

It is therefore an object of the present invention to provide a device and a component produced thereby, which overcomes the disadvantages of the prior art in SLM-produced components.

This object is achieved by the subject matter of the present ^¬ invention as disclosed in the claims and the figures.

The invention accordingly provides an apparatus for carrying out a selective laser melting (SLM) process, wherein a powder bed, an inert gas chamber and a La ^¬ serstrahl comprehensive SLM device, which is based in a preferred direction, a component by at least a laser metal deposition apparatus comprising a laser beam and a powder spray, is added, such that at least one Laser metal deposition device is arranged transversely to the preferred direction of the SLM structure. In addition, subject matter of the invention, a component located in front ^¬, thin-walled and thick-walled elements comprising said thin-walled elements by means of se- lective laser melting and thick-walled elements by means of laser metal deposition are made, such that the thin-walled elements for SLM-produced components typical features such as Dimensions of the wall thicknesses between 20 and 200 ym and an anisotropic property profile of the material, as well as reduced creep show, whereas thick-walled Elemen ^¬ te wall thicknesses greater than 150ym, especially greater than 200ym and more preferably have greater than 300ym show no preference ^¬ direction and an isotropic property profile , The invention makes it possible to overcome the disadvantages of the SLM-made components because the weak, thin-walled structures of the SLM product are supplemented by strong structures that can be produced via LMD. For example, a prototype of a turbine blade is a ^¬ be ferred embodiment of the device according to the invention by the inner fine, complex, and responsible for the cooling of thin-walled structures typical SLM components and the thick-walled bearing outer contours are typical LMD components.

In particular, hybrid components of different material combinations ^¬ nations can be prepared via the combination of the SLM with the LMD procedures nevertheless have the inner fine SLM structures. For this purpose, for example, is a nere in ^¬ structure of a first material that is suitable for the development of fine herstel ^¬ cooling structures, and is an outer structure made of one or more materials and shows the thick-walled coarser structures with resolutions of over 200ym.

In this case, it is possible, for example, for the thick-walled structures to serve as auxiliary structures during the construction of the thin-walled, finer and preferably internal structures, so that overhanging thin-walled structures without auxiliary structures can also be produced in the SLM process. According to one embodiment of the component, the thick-walled coarse elements are transverse to the fine thin-walled elements, as far as the construction direction of the production of the elements can be seen. In particular, also voluminous elements of fine

Structures that can be produced via SLM, such as the cooling structures of turbine blades or turbine blades as a base or base plate for the application and production of coarser and thicker wall elements such as housing of turbine blade are used, so that at the connection of inner ^¬ cooling structure and outer shell or housing is detectable, as each item, via rapid prototyping ^¬ up was introduced. Finally a component may according to the invention, thin-walled and thick-walled, about generative manufacturing methods erzeug ^¬ te elements comprising, hammered with the cast, transmission ^¬ NEN, or otherwise be as conventionally produced elements combined to form one component.

In a component obtainable in this way, two preferred directions are formed, which can be detected by the grains and / or dendrites forming. The construction direction is detectable for example in the structure of the component, because the forming grains and / or dendrites along a

Temperature gradient grow. In particular, they grow out from the hot ^¬ SEN laser spot in the cooler substrate material. This is the case with both SLM and LMD. There are many very long grains and / or dendrites in their

Longitudinal structure show how the component was built. In the following, the invention will be described by way of example

Embodiments, which are shown schematically in the figures, explained in more detail:

1 shows on the top left part according to an exemplary of the invention, the thin-walled and thick-walled struc ^¬ Ren and bottom right the construction of such a component, wherein the one hand the construction direction of the thin-walled elements, which are preferably produced via a SLM process and second, the construction direction of the thick-walled elements, which are preferably produced in the LMD process, are shown.

Figure 1 shows a wing 1 of a rotor having cells 2 inside with highly complex and therefore finely structured cooling elements. These inner cells 2 comprise beispiels- example and preferably complex cooling designs as Kühlkanä ^¬ le, spirals, grinding, -gitterstrukturen, periodic and non-periodic -raster which can be realized in thin-walled dreidimensio ^¬ dimensional structures. It is particularly advantageous if these thin-walled structures have wall thicknesses of less than / equal to 200 ym, and in particular of less than 150ym and particularly preferably of less than 100 mm ^¬.

These inner cells 2 are located in a housing 3, which shows the NÖ-term mechanical stability for the operation of a Rotorblat ^¬ tes. The housing has an outer wall, which is realized in thicker wall thicknesses, for example, with a wall ^¬ strength in the millimeter range, in particular wall thicknesses of ... to.

2 shows a component according to an embodiment of the invention in detail, wherein an exemplary position of the at least two mounting directions 4, 5 of the two components th of a component according to the invention to each other, the thin-walled element 2 on the one hand and the thick-walled element 3 on the other hand, is shown. The two mounting directions 4 of the thin-walled element 2 and the mounting direction 5 of the thick-walled element 3 are perpendicular to each other here.

In addition to the embodiment shown in Figure 2, the two mounting directions 4 and 5 in any other embodiments of the invention include any angle to Shen, as by a LMD device, for example, by 5 axes and / or rotatable by robots by applying material to a base plate a complete Three-dimensional element is forth ^¬ adjustable. In Figure 2, two essential elements of the ge in Figure 1 ^¬ showed rotor blade are illustrated. In this case, the views are reproduced from the outside on the housing wall 3. The thin-walled elements 2 are located behind the housing wall 3. The mounting direction 4, for example the thin-walled structures, such as the cooling cells produced in the SLM process and the construction direction 5 of a thick-walled structure, can be seen

Structure, for example, the housing outer wall 3 of the rotor ^¬ sheet 1 of Figure 1, which can be produced by LMD method. This thick-walled member 3 is, for example, in building direction up 5 is produced, wherein as a base plate or base surface ^¬ a part, for example a side wall of a thin-walled ^¬, produced in the SLM-method, three-dimensional cooling element 2 is used.

The housing 3 can be produced either partially or entirely by the LMD method, but it is also possible to construct an LMD housing on a base, which is cast, for example, which also includes components which, in turn, rest on the thin-walled structures 2 are constructed.

The component according to the invention comprises elements that are each available via different manufacturing methods, wherein the thin-walled elements are available at least in part via SLM processes and the thick-walled elements can be produced at least in part via LMD processes. Further components of the component, which can be completed by conventional and other production methods, can thereby complete the component.

Figure 3 shows a further embodiment of the invention wherein a component is shown in a core-shell structure as a longitudinal cross-section.

An internal lattice structure with cooling elements already in wing or blade shape for example a gas turbine blade, comprising thin-walled elements 6, which are sur- rounded by a scraping ^¬ le of mechanically stable, thick-walled elements. 7 In the embodiment shown in Figure 3 embodiment, the blade shown is characterized in that a ge ^¬ cast vane core with an inner blade or turbine blade mold 8 in SLM process walled complex and fine cooling structures 6 are applied, on the one part, by means of LMD method with mechanically stable shell 7 are surrounded.

Finally, FIG. 4 shows the construction from FIG. 3 in cross-section in the front view. One recognizes again the poured core 8, for example as a prefabricated element for ra ^¬ pid prototyping, therefore there are thin-walled fine cooling structures 6, which in turn are surrounded by a shell 7 produced by LMD. The invention for the first time discloses a device having complex fine inner thin-walled elements, which receives outer contours and mechanical stability by thick-walled elements where ^¬ at the two elements of the component can be produced by generative procedural ^¬ acids, such as SLM and LMD and usefully also molded by prefabricated example parts he be ^¬ supplemented.

Claims

claims

An apparatus for performing a selective laser melting (SLM) process, comprising a SLM device comprising a powder bed, an inert gas chamber and a laser beam, which builds a component in a preferred direction by means of at least one laser metal deposition apparatus comprising a laser beam and a powder spray is added, such that at least one laser metal deposition device is arranged transversely to the preferred direction of the SLM structure.

2. Device according to claim 1, wherein an inert gas chamber is provided, in which alternately a laser beam for performing the SLM process and a laser beam for performing the LMD process can be activated.

3. The component obtainable by carrying out a selective La ^¬ ser Melting process and a laser metal deposition Pro ^¬ zesses means of a device according to any one of claims 1 or 2, characterized in that two preferred directions are detectable in the construction of the component, the respective both Laser beams are assigned.

4. component comprising thin-walled and thick-walled elements, wherein thin-walled elements by means of selective laser melting and thick-walled elements by means of laser metal deposition ge ^{¬ made} , such that the thin-walled elements for SLM-manufactured components typical features such as dimensions of the wall thicknesses between 20 and 200 ym and an anisotropic property profile of the material and reduced Kriechfestig ^¬ ness show, whereas thick-walled elements wall thicknesses greater than 150ym, in particular greater than 200ym and particularly preferably greater than 300ym have show no preferred direction, and an isotropic property profile.

5. The component of claim 4, which is fitted in the core-shell principle ^¬ builds, wherein the thick-walled elements inside the thin-walled elements and are provided as saddle ^¬ le.

6. Component according to claim 4 or 5, wherein a layer structure is provided from the inside to the outside, such that on an inner core of a cast material thin-walled ele ^¬ ments, which can be produced by SLM method lie, and then a layer with thick-walled elements that can be produced by LMD method.

7. Component according to one of claims 4 to 6, which represents a Turbi ^¬ nenschaufel or a turbine blade or a rotor blade ^¬ .

8. Component according to one of claims 4 to 7, wherein the thin ^¬ walled, produced in the SLM process elements complex internal cooling structures of a turbine blade or a tur ^¬ binenblatts represent.