WO2017180116A1 - Système et procédé de fabrication d'additifs - Google Patents

Système et procédé de fabrication d'additifs Download PDF

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Publication number
WO2017180116A1
WO2017180116A1 PCT/US2016/027244 US2016027244W WO2017180116A1 WO 2017180116 A1 WO2017180116 A1 WO 2017180116A1 US 2016027244 W US2016027244 W US 2016027244W WO 2017180116 A1 WO2017180116 A1 WO 2017180116A1
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WO
WIPO (PCT)
Prior art keywords
path
wire
laser
layer
nozzle
Prior art date
Application number
PCT/US2016/027244
Other languages
English (en)
Inventor
Mark V. EVERS
Original Assignee
Gkn Aerospace North America Inc.
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
Application filed by Gkn Aerospace North America Inc. filed Critical Gkn Aerospace North America Inc.
Priority to PCT/US2016/027244 priority Critical patent/WO2017180116A1/fr
Publication of WO2017180116A1 publication Critical patent/WO2017180116A1/fr

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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
    • 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
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/53—Nozzles
    • 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
    • B22F10/30—Process control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/03—Observing, e.g. monitoring, the workpiece
    • 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
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/0869—Devices involving movement of the laser head in at least one axial direction
    • B23K26/0876—Devices involving movement of the laser head in at least one axial direction in at least two axial directions
    • B23K26/0884—Devices involving movement of the laser head in at least one axial direction in at least two axial directions in at least in three axial directions, e.g. manipulators, robots
    • 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
    • B23K26/14—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
    • B23K26/1462—Nozzles; Features related to nozzles
    • B23K26/1464—Supply to, or discharge from, nozzles of media, e.g. gas, powder, wire
    • B23K26/147—Features outside the nozzle for feeding the fluid stream towards the workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/02—Carriages for supporting the welding or cutting element
    • 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
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
    • B23K37/0408—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work for planar work
    • 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
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • 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
    • B22F12/22—Driving 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
    • 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
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/14—Titanium or alloys thereof
    • 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

  • Additive manufacturing is a process of manufacturing parts by successively depositing material in layers.
  • a manufacturing device may deposit material in an already molten state, or the device may melt material as it is being deposited.
  • An example of depositing molten material is fused deposition modeling, which involves extruding, from a nozzle, a bead of material that immediately hardens.
  • Two examples of melting a solid material include laser metal deposition-wire (LMD-w), which uses a laser to melt a continuously fed wire; and powder-fed directed energy deposition, which uses a laser to melt a metal powder that is being continuously fed.
  • LMD-w laser metal deposition-wire
  • powder-fed directed energy deposition which uses a laser to melt a metal powder that is being continuously fed.
  • Other types of additive manufacturing use powder beds rather than continuously feeding powder.
  • each layer of an additively manufactured part has at least one start point and at least one stop point. If the start point abuts the stop point, then localized defects and metallurgical discontinuities may form on a boundary between the start point and the stop point. Localized defects may include voids and lack of fusion along the boundary.
  • a method of manufacturing a part includes the step of melting a substance along a path in a layer. At least one of a start point and a stop point of the path lie outside an intended boundary of the layer of the part. Furthermore, the path passes more than once through points on a path segment that defines a one-dimensional curve that tracks the intended boundary.
  • the method may include adjusting a deposition rate of melting the substance for the path segment.
  • all the start points and stop points of the path may lie outside the intended boundary of the layer.
  • the substance may be a wire; moreover, the wire may be formed of metal.
  • the step of melting the wire may include aiming a laser at a target point, where the target point is an end of the wire. Melting the wire may further include moving the end of the wire and the target point of the laser along the path. Additionally, the method may include feeding the wire through a nozzle toward the target point of the laser.
  • the method may include removing material outside the intended boundary of each layer from the part.
  • Removing material may be further defined as machining away material.
  • the method may include determining the path based on the intended boundary of the layer of the part.
  • the method may furthermore include receiving a model of the path.
  • the substance may be metal. More specifically, the substance may be titanium.
  • a manufacturing apparatus may include a base, a laser movable relative to the base, a nozzle movable relative to the base, and a controller in communication with the laser and the nozzle.
  • the controller may be programmed to receive a model of a part, determine a path based on an intended boundary of a layer of the part, instruct the nozzle to feed a wire having an end, instruct the laser to heat a target point at the end of the wire, and instruct the laser and nozzle in unison to move the target point and the end of the wire along the path.
  • At least one of a start point and a stop point of the path lie outside an intended boundary of the layer of the part, and the path passes more than once through points on a path segment that defines a one-dimensional curve that tracks the intended boundary.
  • the controller may be further programmed to instruct the laser and the nozzle to adjust a first deposition rate of melting the wire along the third path segment to be less than a second deposition rate of melting the substance along a fourth path segment extending from the third path segment.
  • all start points and stop points of the path may lie outside the intended boundary of the layer.
  • the first path segment may extend from the start point to the third path segment
  • the second path segment may extend from the third path segment to the stop point.
  • the manufacturing apparatus may include an articulable arm having a shoulder fixed relative to the base and a wrist, with the laser and the nozzle coupled to the wrist.
  • a controller includes a processor and a memory, and the memory stores instructions executable by the processor such that the controller is programmed to receive a model of a part, determine a path based on an intended boundary of a layer of the part, instruct the nozzle to feed a wire having an end, instruct the laser to heat a target point at the end of the wire, and instruct the laser and nozzle in unison to move the target point and the end of the wire along the path.
  • At least one of a start point and a stop point of the path lie outside an intended boundary of the layer of the part, and the path passes more than once through points on a path segment that defines a one-dimensional curve that tracks the intended boundary.
  • Figure 1 is a perspective view of an example LMD-w manufacturing apparatus.
  • Figure 2 is a perspective view of an example wrist of the manufacturing apparatus of Figure 1.
  • Figure 3 is a side view of an example LMD-w nozzle and an example laser.
  • Figure 4 is a top view of the nozzle and the laser of Figure 3.
  • Figure 5 is a block diagram of an example control system for the manufacturing apparatus of Figure 1.
  • Figure 6 is a process flow diagram of an example process for manufacturing a part.
  • Figures 7A-C are top-view diagrams of example paths of deposition of material by the nozzle and laser.
  • Figure 8 is partial top view of a bead following the path of Figure 7.
  • An additive manufacturing apparatus includes a base, a laser movable relative to the base, a nozzle movable relative to the base, and a controller, i.e., including a processor and a memory, in communication with the base.
  • the apparatus may also include an articulable arm, on the wrist of which the laser and the nozzle are attached.
  • the controller is also in communication with the arm.
  • the manufacturing apparatus is used to manufacture a part.
  • the controller receives in its memory a model of the part.
  • the controller divides the model into layers and determines a deposition path for each layer.
  • the layer path is based on an intended boundary, which is the two-dimensional cross-sectional shape of the part at a particular layer.
  • the path is made of path segments and includes at least one start point on a first path segment and one stop point on a second path segment. The path will pass more than once through points on a third path segment and only once through a fourth path segment.
  • the controller instructs the arm to move the wrist to a start point.
  • the controller determines whether the path passes over the path segment more than once. If so, the controller adjusts to a first deposition rate; if not, the controller adjusts to a second deposition rate. Then the controller simultaneously instructs the nozzle to feed a wire through the nozzle, the laser to heat a target point that is at the end of the wire, and the arm to move the laser and the nozzle along the current path segment. These steps are repeated for each path segment of the path and then for each layer of the part.
  • manufacturing a part 30 includes depositing a bead by melting a substance along a path 32, one or more beads forming a layer of a part, and one or more layers forming the part. Manufacturing the part may further include milling, or other finishing.
  • Each bead includes at least one start point 34 and at least one stop point 36 of deposition of the substance by an additive manufacturing apparatus 50.
  • the start point 34 and the stop point 36 lie on respective first and second path segments 40, 42 that are outside an intended boundary 38 of the part 30, the intended boundary 38 based on specified dimensions of the part 30 when it is finished, e.g., after the part 30 is finished by milling or the like following an additive manufacturing process.
  • the path 32 typically passes more than once through points on a third path segment 44, the points substantially defining a one-dimensional curve that tracks the intended boundary.
  • Locating the start point 34 and the stop point 36 outside of the intended boundary of the part 30 reduces the likelihood of voids and defects that can result from the start point 34 and/or the stop point 36 overlapping or being within the intended boundary 38.
  • the reduced likelihood of voids and defects translates to reduced scrap and reduced reworking costs. Consequently, it is possible to achieve greater freedom in generating paths 32 to fit various cross-sectional shapes of parts 30 while increasing the manufacturing quality of the parts 30.
  • an additive manufacturing apparatus 50 can include a base 52 and an articulable arm 54 fixed relative to the base 52.
  • a laser 56 and a nozzle 58 are coupled to the arm 54, as is a measurement device 55, as is known.
  • the base 52 is provided to support a substrate 60, on top of which the part 30 may be constructed.
  • the base 52 provides stable support for the part 30 during manufacture.
  • the articulated arm 54 may have a shoulder 62 fixing its position relative to the base 52 and a wrist 64 onto which equipment may be coupled.
  • the arm 54 may have multiple degrees of freedom in order to position and orient its wrist 64 in three- dimensional space.
  • the articulated arm 54 may be a six-axis industrial robot, in which case the arm 54 has six degrees of freedom: angle and rotation of a shoulder joint 66, angle of an elbow joint 68, rotation of a forearm 70, and angle and rotation of a wrist joint 72.
  • the laser 56 is movable relative to the base 52. Specifically, the laser 56 may be coupled to the wrist 64, and the arm 54 may move and orient the laser 56 in three-dimensional space. The laser 56 may be oriented to aim at a target point 74. The laser 56 produces a beam of collimated light directed toward the target point 74, which heats the target point 74. The laser 56 is capable of melting the substance that will form the part 30.
  • the nozzle 58 is movable relative to the base 52. Specifically, the nozzle 58 may be coupled to the wrist 64, and the arm 54 may move and orient the nozzle 58 in three-dimensional space.
  • the nozzle 58 feeds the substance that is constructed into the part 30.
  • the nozzle 58 may be a wire feeder.
  • the wire feeder may have a push-pull system with closed-loop control having two wire-feeding units (not pictured) in communication, such as are known, to maintain the correct rate of feeding the wire 76 through the nozzle 58.
  • the substance may be a wire 76, and the wire 76 may be formed of metal, e.g., titanium.
  • a controller 80 may be in communication with the laser 56, the nozzle 58, and the arm 54, i.e., with actuators and or sensors thereof, as is known.
  • the controller 80 may be a microprocessor-based controller.
  • the controller 80 may include a processor, memory, etc.
  • the memory of the controller 80 may store instructions executable by the processor. Communications between the controller 80 and the laser 56, nozzle 58, and arm 54 may take place via a communication bus and/or wired or wireless network such as is known. Manufacturing Process
  • Figure 6 is a process flow diagram illustrating an exemplary process
  • the process 600 for manufacturing the part 30.
  • the process 600 or particular steps thereof may be carried out according to programming of the controller 80.
  • the process 600 begins in a process block 605, in which the controller 80 receives a model of the part 30.
  • the part 30 is typically specified in a computer file such as is known, for example, a computer-aided design (CAD) file.
  • CAD computer-aided design
  • the CAD file or the like will typically specify a three-dimensional shape for the part 30 upon completion of the process 600.
  • the controller 80 divides the model of the part 30 into layers, typically of uniform height. As is known, the height of each layer, and thus the number of layers, typically depends on the height of a bead of the substance that will be deposited to form the part 30. Further, the controller 80 can determine an intended boundary 38 for each layer of the part 30 based on the model of the part 30.
  • the intended boundary 38 is the two-dimensional cross-sectional shape of the part 30 at a particular layer.
  • the controller 80 determines a path 32 for each layer.
  • Example paths 32 are shown in Figures 7A-7C.
  • the path 32 is based on the intended boundary 38 of each layer for the part 30, and can include points for deposition of the substance, and formation of the part 30 layer, within and without the intended boundary 38 for the layer.
  • the path 32 may depend on the width of the bead of the substance and on the desired offset between two adjacent beads.
  • the path 32 may also depend on a pattern of depositing the bead, for example, straight line or zig-zag.
  • Example paths 32 are shown in Figures 7A-C and 8 as a solid line with directional arrowheads.
  • the start point 34 and the stop point 36 of the path 32 lie on respective first and second path segments 40, 42 that are outside the intended boundary 38 (shown in dashed lines) of the layer of the part 30.
  • the path 32 crosses more than once through points on the third path segment 44 and only once through points on a fourth path segment 46.
  • the crossed-dashed lines indicate an overlapped edge of a bead.
  • the path 32 follows the first path segment 40, the third path segment 44, the fourth path segment 46, the third path segment 44 again, and the second path segment 42, in that order.
  • the path 32 follows the first path segment 40, the fourth path segment 46, the third path segment 44, another fourth path segment 46, and the second path segment 42, then restarts at another start point 34 and follows another first path segment 40, another fourth path segment 46, the third path segment 44, another fourth path segment 46, and another second path segment 42.
  • controller 80 instructs the arm 54 to move the wrist 64 to the start point 34.
  • the controller 80 determines whether the next path segment in the path 32 is a path segment that the path 32 passes over more than once, that is, whether the path segment is a third path segment 44 or a fourth path segment 46. If the path 32 passes over the path segment more than once, then in a block 630 the controller 80 adjusts the deposition rate to a first deposition rate. If not, then in a block 635, the controller 80 adjusts the deposition rate to a second deposition rate. The controller 80 adjusts the deposition rate by adjusting the power of the laser 56, the wire feed rate of the nozzle 58, the traverse speed of the wrist 64, and so on to enable overlapping path segments without negatively affecting layer height parameters.
  • the path 32 will pass more than once through points on each third path segment 44.
  • the points define a one-dimensional curve that tracks the intended boundary 38.
  • the one-dimensional curve may be curved or straight.
  • the two passes of the third path segment 44 may overlap or substantially coincide.
  • the first deposition rate i.e., the speed at which the nozzle deposits the substance for melting
  • the third path segment 44 is typically slower than the second deposition rate along the fourth path segment 46.
  • Using the first deposition rate for the third path segment 44 and the second deposition rate for the fourth path segment 46 ensures uniformity of the height of the layer.
  • the third path segment 44 and the fourth path segment 46 are typically inside the intended boundary 38 for a majority of their lengths, although material near an edge of the third path segment 44 or the fourth path segment 46 may be removed when manufacturing the part 30, as illustrated in Figure 8.
  • the controller 80 instructs the nozzle 58 to feed the wire 76 through the nozzle 58 toward the target point 74 of the laser 56.
  • the nozzle 58 feeds additional wire 76 to be melted by the laser 56.
  • the rate of feeding the wire 76 through the nozzle 58 may depend on the selected deposition rate.
  • the controller 80 instructs the laser 56 to melt the wire 76 by aiming the laser 56 at the target point 74, as shown in Figures 3 and 4.
  • the target point 74 is selected to be at an end 78 of the wire 76.
  • the intensity of the laser 56 may depend on the selected deposition rate.
  • the controller 80 determines whether more path segments remain to deposit in that layer. If so, the controller 80 repeats the steps beginning in decision block 625.
  • the manufacturing apparatus 50 thus melts the substance (which in this exemplary process 600 is the wire 76) along the entire path 32 in the layer.
  • the arm 54 moves the end 78 of the wire 76 and the target point 74 of the laser 56 along the path 32.
  • the nozzle 58 is feeding additional wire 76 and the laser 56 is melting the wire 76.
  • a bead of melted wire 76 is deposited along the path 32.
  • the controller 80 determines whether one or more layers are to be deposited for the part 30. If so, the controller 80 returns to the block 620.
  • material outside the intended boundary 38 for each layer is removed from the part 30.
  • a mill or other tool may be used to machine away material that is outside the intended boundary 38 for each layer.
  • the wire 76 was deliberately deposited so as to exceed by a predetermined amount the intended boundary 38, as shown in Figure 8, in which the intended boundary 38 is shown in dashed lines and the bead following the path is shown in solid lines.
  • the part 30 is complete and does not contain any voids attributable to start points 34 or stop points 36.
  • the controller 80 may be programmed to perform some or all of the steps of manufacturing the part 30 using the types of paths 32 described herein. Specifically, the controller 80 may be programmed to receive the model of the part 30, determine the path 32 based on the intended boundary 38 of a layer of the part 30, instruct the nozzle 58 to feed the wire 76, instruct the laser 56 to heat the target point 74 at the end 78 of the wire 76, and instruct the laser 56 and nozzle 58 in unison to move the target point 74 and the end 78 of the wire 76 along the path 32.
  • the controller 80 may be further programmed to instruct the laser 56 and the nozzle 58 to adjust the first deposition rate of melting the wire 76 along the third path segment 44 to be less than the second deposition rate of melting the substance along the fourth path segment 46.
  • the adverb "substantially" modifying an adjective means that a shape, structure, measurement, value, calculation, etc. may deviate from an exact described geometry, distance, measurement, value, calculation, etc., because of imperfections in materials, machining, manufacturing, sensor measurements, computations, processing time, communications time, etc.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Automation & Control Theory (AREA)
  • Robotics (AREA)
  • Laser Beam Processing (AREA)

Abstract

La fabrication d'une pièce comprend la fusion d'une substance le long d'un chemin dans une couche. Un point de départ et/ou un point d'arrêt du chemin se trouvent à l'extérieur d'une limite prévue de la couche de la pièce. Le chemin passe plus d'une fois par des points sur un segment de chemin qui définit une courbe unidimensionnelle qui suit la limite prévue.
PCT/US2016/027244 2016-04-13 2016-04-13 Système et procédé de fabrication d'additifs WO2017180116A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2016/027244 WO2017180116A1 (fr) 2016-04-13 2016-04-13 Système et procédé de fabrication d'additifs

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2016/027244 WO2017180116A1 (fr) 2016-04-13 2016-04-13 Système et procédé de fabrication d'additifs

Publications (1)

Publication Number Publication Date
WO2017180116A1 true WO2017180116A1 (fr) 2017-10-19

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Cited By (8)

* Cited by examiner, † Cited by third party
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EP3663032A4 (fr) * 2018-10-24 2020-06-10 Mitsubishi Electric Corporation Procédé de mise en forme de stratification, procédé de génération de chemin de traitement et dispositif de mise en forme de stratification
CN112888525A (zh) * 2018-10-24 2021-06-01 三菱电机株式会社 层叠造形方法、加工路径生成方法及层叠造形装置
RU2805914C1 (ru) * 2020-04-22 2023-10-24 Аесс Шанхай Кемешл Эйркрафт Энджин Мэньюфэкчуринг Ко., Лтд. Способ предварительного формирования дефекта несплавления путем управления процессом lmd при аддитивном производстве металлических деталей
WO2021212888A1 (fr) * 2020-04-22 2021-10-28 中国航发上海商用航空发动机制造有限责任公司 Procédé de préfabrication de défauts de fusion médiocre par commande de processus lmd

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