WO2019076910A2 - Procédé de fabrication additive d'un composant et dispositif pour la mise en œuvre du procédé - Google Patents

Procédé de fabrication additive d'un composant et dispositif pour la mise en œuvre du procédé Download PDF

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Publication number
WO2019076910A2
WO2019076910A2 PCT/EP2018/078266 EP2018078266W WO2019076910A2 WO 2019076910 A2 WO2019076910 A2 WO 2019076910A2 EP 2018078266 W EP2018078266 W EP 2018078266W WO 2019076910 A2 WO2019076910 A2 WO 2019076910A2
Authority
WO
WIPO (PCT)
Prior art keywords
raw material
base body
workpiece carrier
material layer
additive
Prior art date
Application number
PCT/EP2018/078266
Other languages
German (de)
English (en)
Other versions
WO2019076910A3 (fr
Inventor
Matthias Dahlmeyer
David Grüning
Original Assignee
Hochschule Für Technik Und Wirtschaft Berlin
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 Hochschule Für Technik Und Wirtschaft Berlin filed Critical Hochschule Für Technik Und Wirtschaft Berlin
Priority to EP18789107.2A priority Critical patent/EP3697598A2/fr
Publication of WO2019076910A2 publication Critical patent/WO2019076910A2/fr
Publication of WO2019076910A3 publication Critical patent/WO2019076910A3/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
    • 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
    • B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
    • 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
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • 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
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/66—Treatment of workpieces or articles after build-up by mechanical 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
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • 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 the additive production of a component and to an apparatus for carrying out the method.
  • additive manufacturing means a process of building the component by gradually adding such layers.
  • the geometry of the component to be produced is usually analyzed and a decomposition of the component geometry is carried out in a plurality of layers. By successively building these layers on top of each other from the raw material, it is possible in this way to produce almost arbitrarily shaped geometries.
  • the raw material may, for example, have a paste-like, liquid, film or powdery consistency and, after the production of each raw material layer, be solidified or attached to a layer of the component to be produced.
  • the solidification or attachment can be carried out with a physical or chemical reaction in the raw material, wherein the chemical reaction can be accelerated by means of external influences such as increasing the temperature or introducing radiation such as ultraviolet light.
  • Metal raw materials can be solidified by means of sintering or melting, which can for example be done locally by means of heat input by a laser. All methods have in common that the raw material layer are superimposed with their respective layer thickness along a construction direction, so that with each layer of the already additive produced base body is thickened by a further layer.
  • the disadvantage here is that so far no similar qualities in dimensional tolerances, surface quality and material properties can be achieved as with other manufacturing processes, for example. With machining manufacturing processes or after a Nach- processing with such other manufacturing processes, and that direction-dependent material properties and distortion causing heat input are set to one direction for the entire component.
  • An advantage of additive manufacturing methods lies in the possibility of producing components with high geometric complexity, in particular with undercuts, wherein the components produced by the additive must be aftertreated with other production methods, for example by means of machining or milling, in the case of high locally required accuracies or special local properties.
  • this often turns out to be difficult, since it is difficult or even impossible to clamp the additive-manufactured component due to the nature of its geometry, especially in the case of complex additive-produced component geometries, the regions to be machined for machining processes are not geometrically accessible or only with considerable additional effort.
  • the object is achieved by a method for the additive production of a component having the features of patent claim 1.
  • the method comprises the following steps.
  • first step additive construction of a first base body from a raw material on a workpiece carrier or arrangement of a prefabricated base component as a first base body on the workpiece carrier takes place.
  • second step an additive application and solidification of a raw material layer takes place on the base body.
  • the application and solidification of the raw material layer is in this case achieved in a first procedure, that by means of a selective heat source, the material of the base body is locally liquefied at a Aufschmelzort on a first base body pad such that a locally limited
  • Melting bath is generated in the otherwise fixed first base body pad, and wherein subsequently powdered raw material is introduced to the molten bath.
  • the raw material can be introduced into the melt or adhered to the surface of the melt.
  • This has the advantage that due to the localized surface of the time-variable producible melt bath, the introduction or adhesion of the raw material is correspondingly localized.
  • a localized solidification of the raw material and a simple and cost-effective provision of complex geometries is possible.
  • the application and solidification of the raw material layer is achieved by liquefying the powdery raw material into droplet-like raw material by means of a selective heat source and bringing the liquefied droplet-shaped raw material to a fixed first base body connection surface.
  • the first approach and the second approach can be combined so that droplet-shaped raw material is brought to a localized melt pool.
  • the raw material adheres to the surface of the molten bath or is embedded in the molten bath.
  • a base body land is made of a first raw material and thereon is a first raw material layer of a second raw material other than the first raw material.
  • the first raw material can be applied, for example, from a first processing head to the base body connecting surface, in particular the molten bath.
  • the second raw material for example, from a second raw material head on the base body pad, in particular the molten bath, can be applied.
  • non-alloyable raw materials can be used in combination to build the component.
  • layered raw material layers of different materials are solidifiable or a first raw material can be embedded in a molten bath of a second raw material that can not be alloyed with the first raw material.
  • a varying composition of the additive-produced component can be achieved, in particular, gradually changing, stress-adapted properties of the component can be achieved.
  • a first raw material and a second raw material, which can be alloyed with the first raw material can also be used for this purpose.
  • the use of various raw materials in the additive construction of the component is not limited to two materials in any of the variants, but in principle any number of different raw materials can be used and combined, both by layers of different raw materials and by mixing the raw materials.
  • a temperature of the powdery raw material and / or the droplet-shaped raw material and the base body pad or the molten bath for receiving a sintered connection between the applied raw material and the base body is produced.
  • This has the advantage that a firm connection is made between the raw material or the plurality of raw materials and the base body land.
  • the temperature of the powdery raw material and / or the droplet-shaped raw material and the base body connecting surface are matched to one another in this sense such that a desired solidification is achieved.
  • different densities to be achieved, void fractions, elasticities and / or strengths are adjustable by means of the temperatures.
  • the powdered raw material is embedded in the molten bath.
  • unalloyable raw materials can be combined.
  • a first powdered raw material with a high density and optionally brittle plasticity properties may be embedded in a molten bath of a second material of lower density and / or higher plasticity.
  • At least part of the powdered raw material is completely or partially melted in the molten bath.
  • the raw material from a processing head is guided to the base body, in particular to the melt pool and / or to the first base body connection surface, in particular gravity-fed and / or applied to the base body connection surface by means of a nozzle.
  • This has the advantage that a particularly precise local placement of the applied raw material is possible.
  • the raw material in this way from different directions to the base member can be moved.
  • the gravity feed is easy to implement structurally.
  • the application by means of a nozzle, in particular by a pneumatic conveying has the advantage that the raw material impinges with a high momentum on the base body connection surface or the surface of the molten bath and a good adhesion or embedding is ensured.
  • the raw material is liquefied between the machining head and the base body during a flight phase, in particular by means of one or more laser beams. In this way, from the conveyed powder-shaped raw material, a partial area to droplet-shaped raw material can be liquefied, so that only this droplet-shaped raw material adheres to the base body connecting surface. As a result, a spatially precise limited additive construction is possible.
  • the flight phase here is the period between the discharge of the raw material from the processing head and the impact of the raw material on the base body pad.
  • the spreading can be carried out either gravity or pneumatically promoted. That part of the pul deformed discharged raw material to be liquefied is heated, for example by means of one or more laser beams in this phase of flight.
  • two or more laser beams are directed to the raw material in the phase of flight, wherein the laser beams intersect at a focal point and there cause the liquefaction of the powdery raw material with a particularly high thermal power density.
  • the object is likewise achieved by a method having the features of patent claim 7.
  • the method comprises the following steps:
  • the base body may in this case consist of both areas which constitute a component of the component geometry to be generated, as well as a support structure, which is sometimes necessary in additive building, in particular if, in the case of additive construction, higher layers project beyond underlying layers.
  • the workpiece carrier may for example be a bottom plate of an apparatus for additive construction or a support on the bottom plate.
  • a workpiece carrier may have various embodiments of clamping devices, such as chucks.
  • a wall of a powder bath may constitute part of the jig.
  • the cavity is incorporated integrally into the base body such that the construction of the base body takes place in such a way that the geometry of the cavity to be produced in the base body is already taken into account during the production of the layers from the raw material.
  • the first prefabricated insert body is then arranged. In particular, this fixes the insert body substantially stationary relative to the base body.
  • This can take place in that the insert body is adapted to the geometry of the cavity and is supported or positioned and / or oriented by the walls of the cavity.
  • the cavity can be taken into account in the geometry of the prefabricated insert body in the additive construction of the base body and the cavity can be adapted to the insert body.
  • the insert body is supported by filling gaps or gaps between the walls of the cavity and the insert body by means of filler material.
  • the filler is set up for later removal.
  • the cavity is formed, for example, as a hole.
  • the hole may be a blind hole which extends into the base body.
  • the first insert body is in this case introduced into the blind hole and in particular to a floor the blind hole be approached and supported on the ground.
  • the bottom in this case has material of the base body or raw material.
  • the hole may alternatively be a through hole extending through the base body.
  • the first insert body can be introduced into the through hole and can be guided through the through hole with a corresponding length of the first insert body.
  • the through hole may extend through the base body up to the workpiece carrier and the first insert body may be supported on the workpiece carrier.
  • the workpiece carrier has a recess or passage opening into which and / or through which the first insert body extends. As a result, insert body can be arranged in the through hole, which are longer than the height of the arranged on the workpiece carrier or arranged base body.
  • the structural body is connected to the first base body and with the first insert body.
  • the resulting connection between the structural body and the first base body and the insert body may be cohesive, positive or non-positive, depending on the method used for additive construction.
  • the component provided as above thus has at least the first insert body and the body structure in the sense of a single integral body.
  • the base body either wholly or partially, may be part of the integral body.
  • the base body wholly or partially have the function of a support body in the implementation of the method and be removed after building the body structure, so that the finished component comprises the first insert body and the body structure.
  • the finished component has a first part of the base body together with the first insert body and the structural body, wherein a second part of the base body has the function of a support body in the implementation of the method and is removed after building the structural body, so that the finished component has the first insert body, the body and the first part of the base body.
  • the inventive arranging the insert body in the cavity has the advantage that the insert body due to the previous, for example, machining production in a particularly simple way other, non-additive processing method is accessible and thus simply special material properties and / or surface finishes or dimensional tolerances for areas of finished in the final component provides that would not be achievable with additive manufacturing.
  • a precise alignment of the insert body in the cavity and thus relative to the base body is possible.
  • the insert body can be arranged particularly precisely relative to the subsequently to be produced structural body.
  • the base body has a first base body connection surface. This has the advantage that the raw material can be applied to the base body pad and thus to the base body.
  • the base body connection surface can be set up for a particularly simple application or adhesion of the raw material.
  • the first base body by tilting the workpiece carrier relative to a machining head, by means of which the first raw material layer is arranged and / or by means of which the first raw material layer for layer formation, in particular chemically and / or thermally acted, and / or tilting of the machining head relative to the workpiece carrier ,
  • the tilting allows the first raw material layer to be positioned in various possible arrangements relative to the base body and thus to achieve good surface qualities, in particular in cases where the first raw material layer constitutes an outer wall of the component geometry to be produced.
  • An advantage is also that the application of the raw material layer takes place through the processing head and / or by chemical and / or thermal action along the direction of extension of the raw material layer and thus a coherent first raw material layer has good surface and strength properties.
  • the method comprises the following step:
  • the arrangement of the second raw material layer may in this case be carried out in particular after the aforementioned tilting following the production of a first raw material layer.
  • the object is likewise achieved by a method for the additive production of a component according to claim 11 with the following steps:
  • the base body can be built up on the workpiece carrier or an already produced base body can be enlarged on the first base body connecting surface around the first raw material layer.
  • a shaping of the base body is possible.
  • the method also includes a subsequent further step, namely a
  • the second base body pad has the advantage that the second raw material layer can adhere thereto.
  • the base body connection surface can be set up for a particularly simple application or adhesion of the raw material.
  • At least one cavity is introduced into the base body, it is possible in a further step to arrange a first prefabricated insert body in the at least one cavity.
  • the insert body also on the base component, in particular on the first base body connection surface can be arranged.
  • prefabricated insert bodies can be arranged both in a possibly existing cavity or on the base body connection surface and can then be integrated in the base body or the structure body by further construction of the base body and / or can be connected to the structure body.
  • the first insert body has a prefabricated insert body connection surface during insertion or is provided with additive application after it has been arranged with a first insert body connection surface.
  • An insert body connection surface ensures good connection of the structural body to the insert body.
  • precise placement of the insert body in the cavity is possible by aligning the insert body interface as required during positioning.
  • the insert body is attached to the base member, in particular to the base body pad, a precise alignment by opposing arrangement of the surfaces is possible.
  • the insert body is first placed in the cavity and then provided with the first insert body pad by additive application.
  • the insert body connection surface can be aligned for a good connection with the first base body, wherein in particular the advantages of the aforementioned tilting can come to fruition.
  • the insert body connection surface is produced by additive application to the insert body, any unevenness on the insert body can be compensated for before the insert body is connected in an additive construction of the structure body.
  • At least one of the at least one insert body in particular a part of its prefabricated insert body connection surface and / or a part of its other surface, by means of a non-additive method according to DIN 8580, eg separating or forming, in particular by milling and / or turning and / or embossing and / or Deep drawing and / or sheet metal bending and / or forging and / or master molding, in particular casting, and / or coating, is produced.
  • a prefabricated insert body connection surface a simple alignment of the insert body relative to the component geometry to be produced is possible and can be maintained during the generation of the component geometry.
  • machining in particular by milling and / or by turning, a component with both complex geometries of the base body and / or the body structure and with areas with particularly good surface qualities or dimensional tolerances can be provided.
  • the first base body connection surface is planar. This has the advantage that a further additive production of the structural body subsequent to the first base body connecting surface is possible in a straightforward manner and with a continuous raw material layer.
  • the first insert body connection surface is planar. This has the advantage that the first insert body can be predefined and reliably positioned relative to the base body and / or to the body structure and reliably connected to the base body and / or the resulting body structure.
  • the first insert body connection surface is arranged relative to the first base body connection surface in a common connection plane, or for a first insert body connection surface to be additively shaped to the first insert body already arranged in the cavity in such a way that the first insert body pad is arranged with the base body pad in a common connection plane.
  • a contiguous plane first raw material layer lying in the common connection plane is provided on the first base body connection pad and the first insert body pad, the first raw material layer being orthogonal to the connection plane by its layer thickness in the direction of a first construction direction extends.
  • the cohesive connection can be produced in particular by means of sintering or laser beam melting, in particular when using metal powder as a shapeless raw material.
  • the second raw material layer is arranged inclined relative to the first raw material layer by an inclination angle.
  • This has the advantage that, on the one hand, good surface qualities and dimensional tolerances can be achieved on the additively structured regions.
  • the inclination about the inclination angle allows an additive construction to be reliable and of high quality even if, for example, the insert bodies have undercuts which have to be achieved with raw material, for example if the insert bodies have notches or throat flutes.
  • a prefabricated base component is arranged on the workpiece carrier and forms the base body or the base body has previously been constructed by means of additive manufacturing on the workpiece carrier.
  • the arrangement of a prefabricated base component on the workpiece carrier has the advantage that this provides a base body in a simple and uncomplicated manner, which is advantageous in particular in cases when a body to be built up on the base body is in the foreground and the base body has a carrier function.
  • the necessary time for additive construction is shortened by using a conventionally prefabricated base component.
  • a part of the component to be produced can be formed by the base body and an additive construction of complex structures - possibly with the embedding of insert bodies according to the invention - be made.
  • the overall process is simple and inexpensive to carry out.
  • arranging at least one first insert body on the first base body connection surface or on the workpiece carrier and then respectively arranging the first raw material layer or a second raw material layer is such that the first raw material layer and / or the second raw material layer adjoin the first raw material layer at least one insert body adjacent, provided.
  • This allows embedding of the insert body in the component to be manufactured by the insert body is rebuilt by additive construction.
  • the advantages of inclinability come into play in particular, since in this way the first raw material layer and / or the second raw material layer can be positioned in different orientations relative to the insert body and then be solidified.
  • the continued additive construction of the base body around the insert body and / or the arrangement of the structural body is thus also possible with geometries of the insert body with undercuts.
  • the raw material has a pasty consistency and arranging the raw material layer or the raw material layers by discharging the raw material from the processing head, in particular by extrusion, takes place as a dosing head.
  • This has the advantage that a simple application of the raw material in the form of raw material layers is made possible.
  • the first raw material layer and / or the second raw material layer can be applied by meandering down the connection surface to be provided with a raw material layer, in particular the insert body connection surface and / or the base body connection surface.
  • the advantage is also achieved not only of bringing the first raw material layer and / or the second raw material layer orthogonally to the connection surface, but also of being able to introduce the raw material laterally, in particular to the insert body, and thereby the respective raw material layer in or under undercuts of the insert Insert insert body where this by orthogonal approach to the pad would not be possible.
  • an embedding of the insert body with undercuts is allowed or increases the variety of usable insert body.
  • the raw material has a liquid consistency and is arranged in a liquid bath, wherein the arranging of the raw material layers on the surface of the liquid bath by tilting the workpiece carrier and / or by varying the filling level in the liquid bath and / or by Variation of the height position of the workpiece carrier takes place relative to the liquid bath.
  • the workpiece carrier is disposed within the liquid bath or the liquid bath is connected to the workpiece carrier.
  • the position of the base component arranged on the workpiece carrier is set such that the liquid level caused by the gravitational movement is arranged around the layer thickness of the raw material layer above eg the first base body connection surface and / or the insert body connection surface, in particular the connection plane.
  • the raw material layer can be positioned in a variety of ways and can be stretched into undercuts of insert bodies.
  • a processing head has a radiation source, in particular a light source for generating ultraviolet light, for initiating or accelerating a chemical reaction, in particular a polymerization reaction, of the raw material.
  • a radiation source in particular a light source for generating ultraviolet light, for initiating or accelerating a chemical reaction, in particular a polymerization reaction, of the raw material.
  • Any inclinability of the machining head with the radiation source has the advantage that also undercuts of the base body and / or insert bodies can be achieved locally with the radiation or the light and thus an initiation or acceleration of a chemical reaction, in particular a polymerization reaction, is possible.
  • the raw material has a powdery consistency and the machining head has at least one machining head, in particular a machining head, arranged for producing a composite, in particular for heating and / or sintering and / or melting the raw material Radiation source, for example.
  • a laser light source having.
  • a powdery raw material layer can be solidified by thermal action of the radiation source, in particular of the laser light source.
  • a layer-wise additive shaping of the component, in particular of the base body, and / or the structural body is possible from the powdery raw material.
  • the raw material is arranged as a powder bath, wherein the arrangement of the raw material layers on the surface of the powder bath by tilting the workpiece carrier and / or by varying the filling level in the powder bath and / or by varying the height position of the workpiece carrier takes place relative to the powder bath.
  • a raw material layer of the powdery raw material is arranged by positioning the workpiece carrier having the base body and / or the insert body and / or the structural body already disposed thereunder below the surface of the powder bath so that the powdery raw material having a layer thickness above the is arranged to be connected component component.
  • vibrations are generated on the powder bath and thereby the surface of the powder bath, in particular during or after arranging in a raw material layer, is smoothed.
  • This has the advantage that a mechanical smoothing of the surface of the powder bath, for example by means of a squeegee, can be dispensed with.
  • the vibrations are arranged to prevent slippage of the powder To ensure particles relative to each other in such a way that the powder bath in the gravitational field assumes a flat and horizontal surface.
  • Another advantage is that even complex geometries of the base body and / or the insert body and / or the body structure in the powder bath can be further built additive, even if components protrude from the surface of the powder bath, since the vibration is a processing by a sweeping the surface Makes tool expendable.
  • the arrangement of the raw material layer or the raw material layers partially or completely by discharging the raw material from the processing head, in particular by gravity-assisted scattering or by blowing out of a nozzle of the machining head occurs.
  • the raw material layer can be placed at selected locations.
  • a step is provided according to which a partial or complete removal of the base body is made.
  • This has the advantage that at least a part of the base body can have the function of a support material for the component to be created. As a result, in particular the production of overhanging geometries of a structural body is made possible.
  • the partial or complete removal of the base body in the form of the support material takes place in particular as the last method step.
  • a device for carrying out one of the aforementioned methods according to claim 27 has a workpiece carrier and a machining head.
  • the device for tilting the machining head in particular for tilting a nozzle or a light beam of the machining head, is arranged relative to the workpiece carrier.
  • the device for tilting the workpiece carrier in particular relative to the machining head, in particular relative to a nozzle or a light beam of the machining head.
  • the machining head is arranged to be movable relative to the workpiece carrier or the workpiece carrier along a first axis relative to the machining head along a first axis and / or the machining head is movable relative to the workpiece carrier or the workpiece carrier along a second axis relative to the machining head. and that the device is arranged to vary the orientation of the first axis and / or the second axis relative to the workpiece carrier or to change the orientation of the workpiece carrier relative to the first axis and / or the second axis.
  • the variability of the orientation of the axes can also be realized by means of one or more pivoting kinematics devices and / or by means of one or more parallel kinematic devices. As a result, for example, a continuous shutdown of non-Cartesian trajectories during application and / or solidification of raw material is possible.
  • FIG. 1 show a lateral cross-sectional view of various successive stages in a first embodiment of a method according to the invention, a lateral cross-sectional view of a construction process of a component according to a second embodiment of a method according to the invention, a lateral cross-sectional view through various stages of a component to be constructed according to a third embodiment of the method according to the invention, a side cross-sectional view through a component to be built up in various stages according to a fourth exemplary embodiment, a lateral cross-sectional view through a component to be built up in different process stages and associated arrangements, a lateral cross-sectional view through a component to be constructed according to a sixth embodiment of the invention.
  • FIG. 1 a to 1 d shows a process stage in the manufacture of a component according to a first embodiment of the invention.
  • Figure 1 a shows a side cross-sectional view of a workpiece carrier 2, on which a base body 4 has been constructed in the form of a support structure.
  • the base body 4 is thereby constructed of powdery raw material by locally sintering the raw material 6.
  • a shapeless raw material layer is applied on the side of the base body facing away from the workpiece carrier, which is subsequently solidified at the desired regions of the raw material layer.
  • the the Workpiece carrier 2 side facing away from the base body 4 thus has a base body pad 8, applied to the raw material and then both solidified by selective laser sintering or melting, and at the same time with the already up to the base body pad 8 extending base body 4 is connectable.
  • the basic body 4 shown in FIG. 1 a has the function of a support structure above which a structural body 10 is to be produced in further process steps.
  • the support structure is in this case solidified by sintering relative to the formless state of the raw material 6 to such a degree that the base body 4 is dimensionally stable, in particular resistant to gravitational forces of the later to be built body 10, but is less strongly solidified than in the body structure 10th the case will be.
  • the support structure in the form of the base body 4 after the completion of the structure is removable to finally provide the actual component geometry.
  • a first cavity 12 and a second cavity 14 have been arranged in the base body 4.
  • the raw material 6 remained in powder form and can then be removed from the base body 4, for example by suction or other mechanical removal.
  • the cavities can also be introduced into an existing support structure of the base body 4 by mechanical processing, for example by drilling or milling.
  • a first insert body 16 is then brought to the base body 4 and the first base body is arranged in the first cavity 12.
  • the first insert body 16 is hereby manufactured separately and thus has special properties of the surface quality and / or the material properties and / or the dimensional accuracy.
  • the first insert body 16 has been machined by machining processes, such as turning and / or milling.
  • the first insert body 16 in this case has a smaller size than the dimension of the first cavity 12, so that the first insert body 16 is aligned in the first cavity 12 is and then fixed by introducing powdery raw material 6 in the first cavity 12.
  • the first insert body 16 has a first insert body connection surface 18 which, when the first insert body 16 is arranged, is aligned parallel to the base body connection surface 8 and is oriented in such a way that the first insert body connection surface 18 engages with the base body connection surface 8 in one common connection level 20 lie.
  • a second insert body 22 is arranged in the second cavity 14.
  • the second insert body extends with its length through the entire base body 4 and through the workpiece carrier 2 and is fixed to the workpiece carrier 2 by a fastening device 24 relative to the base body 4.
  • the second insert body 22 in this case has a second insert body connection surface 26.
  • the second insert body connection surface 26 is arranged parallel to the base body connection surface 8 and parallel to the first insert body connection surface 18 in the connection plane 20.
  • the alignment of the first insert body 16 and the second insert body 22 is optionally carried out with the aid of measuring and / or calibration devices, in order to ensure a particularly precise alignment of the first insert body 16 and the second insert body 22 to each other.
  • a body structure 10 can be built by means of the additive method.
  • a first layer of raw material above the connection plane 20 in contact with the base body 4 and the insert bodies 16, 18 is applied and smoothed, in particular with the aid of a doctor blade.
  • the raw material layer is fixed by means of the laser. and thus creates a continuous first layer of the structural body 10.
  • This first solidified layer of the structural body 10 has been bonded to both the base body 4, as well as with the first insert body 16 and the second insert body 22 by means of a material fit by means of sintering.
  • FIG. 1 c A completed structural body, which was added above the structure according to Figure 1 b by additive finishing, can be seen in Figure 1 c.
  • the component 28 is already completely assembled, but still connected to the base body 4.
  • the base body 4 After removal of the component 28 from the workpiece carrier and after any necessary removal of any remaining raw material is the base body 4 - which in the present case only forms a support structure - easily removable from the component 28 by mechanical processing.
  • 1 d shows that the component 28 resulting as a result, in which, on the one hand, the first insert body 16 and the second insert body 22 are arranged precisely aligned with each other and are also connected as now integral components of the finished component 28 with the body 10, which in turn is part of the component 28 is.
  • first insert body 16 and the second insert body 22 successively in the base body 4 at different height levels.
  • first cavity 12 is first introduced into the base body 4 and another raw material layer connected to the base body 4 and the first insert body pad 18 and thus the base body and / or the body structure 10 constructed.
  • second cavity 14 can be introduced, as far as this has not been made integral with the further construction of the base body and in this second cavity 14 of the second insert body 22 can be used and in this base body connecting surface 8 by means of another raw material layer with the base body and / or connectable to the body structure.
  • Figures 2a to 2e show a second embodiment of the inventive method.
  • a base body 30 is constructed until the stage according to FIG. 2a is reached.
  • the base body 30 around un-solidified powdery raw material 6 is arranged on the workpiece carrier 2.
  • the base body 30 is already part of the overall geometry to be produced of the component 32 to be produced as a result according to FIG. 2 e.
  • the base body 30 according to FIG. 2a again has a base body connection surface 34, which is configured as a result by the previous layer-wise additive structure.
  • FIG. 2b shows that a powder bath 36 in which the powdery raw material 6 is present is arranged on the workpiece carrier 2 for the further procedure.
  • the surface 38 of the powder bath 36 is arranged horizontally.
  • vibrations can be generated on the powder bath 36 by means of which a smooth surface 38 can be generated.
  • a smoothing of the surface 38 by means of mechanical means such as a doctor is dispensable.
  • the workpiece carrier 2 with the base body 30 arranged thereon is also inclined according to FIG. 2 b, so that the base body connection surface 34 of the base body 30 already produced and the surface 38 of the powder bath 36 are now inclined relative to one another by an angle of inclination 40.
  • a raw material layer is arranged obliquely relative to the base body 30.
  • FIG. 2c shows a corresponding inclination of the workpiece carrier 2 with the base body 30 in a different direction, but otherwise in accordance with FIG. 2b.
  • components 32 having as many as desired inclines 42 arranged at arbitrary inclination angles 40 can thus be produced in principle.
  • polyhedron-like surfaces can thus be produced and thus continuous curved contours can be approached very well with a high surface quality, in particular with avoidance of stair structures on the outer walls.
  • a base body 44 is possible on a workpiece carrier 2 by means of additive manufacturing or by inserting the base body 44.
  • a first insert body 46 and a second insert body 48 are placed on the base body connection surface 50 on such a base body 44 as shown in FIG.
  • the first insert body 46 has a first insert body connection surface 52.
  • the second insert body 48 has a second insert body connection surface 54.
  • the arrangement of the first insert body 46 is carried out by oppositely placing the first insert body pad 52 on the base body pad 50, and the laying of the second insert body 48 is carried out by oppositely arranging the second insert body pad 54 on the base body pad 50.
  • the insert body 46, 48 is possible in a simple manner.
  • the further additive construction of the base body 44 and the additive arrangement of a first raw material layer on the base body connection surface 50 are then carried out starting from the process stage according to FIG. 3b.
  • This first raw material layer thus extends over the base body connection surface 50 and laterally adjoins the first insert body 46 and to the second insert body 48 at.
  • the first insert body 46 and the second insert body 48 are integrated into the finished component 56 after this method step according to the method stage 3e.
  • the added in relation to the figures 3a and 3b height range of the component 56 of the additively structured and with the first base body 44 and the insert bodies 46, 48 connected body 58 is.
  • the construction of the structural body 58 according to the technique of the second embodiment (see Figures 2a to 2e) by corresponding tilting of the workpiece carrier and / or a machining head 60 can be carried out.
  • good accessibility of undercuts of the first insert body 46 and of the second insert body 48 is again possible.
  • such undercuts are in the form of fillets 62 in the geometry of the first insert body 46 and of the second insert body 48.
  • the fillets 62 of the first insert body 46 and the second insert body 48 have in connection with the procedure according to the method the advantage that the insert bodies 46, 48 are stably and safely arranged in the component 56 by the lining of the additively stacking raw material layers and by their solidification.
  • the base body 64 is formed by a prefabricated base component, which in its prefabricated state is brought to the workpiece carrier 2 and arranged there.
  • the base component can be produced by means of other production methods, in particular by means of chip-removing production methods, for example turning, milling or primary shaping methods, for example casting.
  • the base body 64 formed by a base member is basically comparable to the base body 4, 30, 44 produced according to the other embodiments, in particular, the base body 64 also has a base body connecting surface 66.
  • the analogous application of the procedure according to the other exemplary embodiments is possible.
  • the method according to this embodiment is more time-effective, since the comparatively simple geometry of the prefabricated base component used as the base body 64 renders the construction of this base component unnecessary by means of additive methods and thus increases the efficiency.
  • a structural body 68 can now be produced additively based on the base body connecting surface 66.
  • the fifth exemplary embodiment according to FIGS. 5 a to 5 e shows a complex-shaped base body 76, which has undercuts 78.
  • a liquid raw material 6 is used, which is arranged in the form of a liquid bath 80 on the workpiece carrier 2 is.
  • a surface 82 of the liquid bath 80 also sets in the liquid bath 80.
  • the processing head in this case has a radiation source in the form of a light source for generating the ultraviolet light 86. Due to the inclinability of the processing head 84, the ultraviolet light 86 can be introduced into the undercuts 78 for selective solidification of the raw material 6.
  • the arrangement of the raw material layer (s) takes place by discharging the raw material out of the machining head 88.
  • the inclinability of the machining head 88 comes into play, is applied by the powder verförmiges raw material 6 locally and in undercuts or under projections.
  • a laser light beam 90 can be generated in the processing head 88 or deflected by it, or alternatively arranged separately from the processing head 88.
  • the laser light beam 90 is in turn tilted relative to the workpiece carrier 2 for selective solidification of the raw material layers in undercuts 78 o under protrusions.
  • This is also possible on the basis of powdery raw materials 6 in a simple and cost-effective manner, in particular with the dispensability of a powder bath 36, a complex geometry as a body buildable.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne un procédé de fabrication additive d'un composant, selon lequel les étapes suivantes sont requises : a. Application additive et solidification d'une couche de matière première sur un corps de base (4, 30, 44, 64, 76), - le matériau du corps de base (4, 30, 44, 64, 76) étant liquéfié localement à un point de fusion sur une première surface de liaison du corps de base (8, 34, 50, 66) à un bain de fusion et ensuite une matière première en poudre (6) est amenée au bain de fusion, et/ou - la matière première en poudre (6) étant liquéfiée en matière première (6) du type gouttelette et est amenée à une première surface de liaison solide (8, 34, 50, 66) du corps de base. L'invention concerne en outre un procédé de fabrication additive d'un composant (28, 32, 56, 74), selon lequel au moins une cavité (12) est intégrée dans le corps de base (4, 30, 44, 64, 76) par montage additif et/ou est introduite par usinage ultérieur du corps de base (4, 30, 44, 64, 76) et un premier corps rapporté préfabriqué (16) est disposé dans au moins une cavité (12). L'invention concerne également un procédé de fabrication additive d'un composant (28, 32, 56, 74) qui permet l'inclinaison du corps de base (4, 30, 44, 64, 76) par inclinaison du porte-pièce (2) et/ou par inclinaison d'une tête de traitement (60, 70, 84, 88) et par disposition d'une seconde couche de matière première. L'invention concerne en outre un dispositif pour la mise en oeuvre du procédé.
PCT/EP2018/078266 2017-10-17 2018-10-16 Procédé de fabrication additive d'un composant et dispositif pour la mise en œuvre du procédé WO2019076910A2 (fr)

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DE102017124124.8A DE102017124124A1 (de) 2017-10-17 2017-10-17 Verfahren zur additiven Fertigung eines Bauteils sowie Vorrichtung zur Durchführung des Verfahrens
DE102017124124.8 2017-10-17

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