WO2019088963A1 - Appareil et procédé de retrait d'une structure de support d'une pièce imprimée en 3d - Google Patents

Appareil et procédé de retrait d'une structure de support d'une pièce imprimée en 3d Download PDF

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Publication number
WO2019088963A1
WO2019088963A1 PCT/US2017/058950 US2017058950W WO2019088963A1 WO 2019088963 A1 WO2019088963 A1 WO 2019088963A1 US 2017058950 W US2017058950 W US 2017058950W WO 2019088963 A1 WO2019088963 A1 WO 2019088963A1
Authority
WO
WIPO (PCT)
Prior art keywords
support structure
acid solution
printed part
printed
additive manufacturing
Prior art date
Application number
PCT/US2017/058950
Other languages
English (en)
Inventor
Steven M. Brooks
Original Assignee
Florida Turbine Technologies, 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 Florida Turbine Technologies, Inc. filed Critical Florida Turbine Technologies, Inc.
Priority to PCT/US2017/058950 priority Critical patent/WO2019088963A1/fr
Publication of WO2019088963A1 publication Critical patent/WO2019088963A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
    • B08B3/04—Cleaning involving contact with liquid
    • B08B3/10—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
    • 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
    • B22F10/47—Structures for supporting workpieces or articles during manufacture and removed afterwards characterised by structural features
    • 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
    • B22F10/62—Treatment of workpieces or articles after build-up by chemical 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
    • B22F12/10—Auxiliary heating means
    • 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
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/35—Cleaning
    • 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
    • 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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • 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
    • B22F10/43—Structures for supporting workpieces or articles during manufacture and removed afterwards characterised by material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • 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 present invention relates generally to an apparatus and a process for producing a 3D printed part, such as by metal additive manufacturing, and more specifically to an apparatus and a process for removing a support structure deep inside a 3D printed part.
  • the metal additive manufacturing process is a 3D printing process in which a metallic part is printed by progressively depositing thin layers of a metallic powder on a bed and using a laser to solidify certain areas of the metallic powder. As the part builds in an upward direction, a support structure is required for areas such as an overhang where the metallic powder must be supported until the laser can solidify that area.
  • the support structure is typically formed using the same metallic powder, but in a less dense structure, such as a honeycomb structure.
  • this support structure must be removed.
  • the support structure can be removed using a mechanical process of physically breaking the support structure free from the part.
  • a mechanical process such as a tool cannot be used to reach within the internal sections of the part where the support structure is located.
  • An example of a complex part could be an air cooled turbine airfoil with internal cooling passages and features such as trip strips or pedestals.
  • Another example is a shrouded impeller.
  • the present invention advantageously provides an apparatus and a process for removing a support structure from a 3D printed part, where the 3D printed part along with the support structure is placed in an acid solution and the part is surrounded by an induction heater also located within the acid solution.
  • the acid solution is recirculated through the acid tank to prevent the acid solution from heating up too much. Small surfaces of the part are heated up by the induction heater before larger pieces are heated so that the acid will remove the smaller pieces first. After enough time, all of the support structure is removed by the acid and the heater to leave the finished 3D printed part with the support structure removed.
  • the 3D printed part can be a turbopump with a single piece rotor within a single piece housing, and the acid solution can be cooled or diluted hydrochloric acid, and the tank and pipe and pump can be of a ceramic coated copper.
  • the acid tank can be made from a plastic or glass material that does not react with the acid solution.
  • a process for removing a support structure from a 3D printed part formed using an additive manufacturing process comprises the steps of: forming the 3D printed part using an additive manufacturing process in which a support structure is also formed; placing the 3D printed part with the support structure in an acid solution; heating the 3D printed part with the support structure within the acid solution using an induction coil heater submerged within the acid solution such that the support structure is removed by the acid solution; and recirculating the acid solution while the 3D printed part is being heated to limit a temperature rise of the acid solution.
  • the additive manufacturing process is a metal additive manufacturing process and the 3D printed part and the support structure are formed of the same metal material.
  • the support structure is less dense than the
  • the process for removing a support structure from a 3D printed part further comprises the step of heating the 3D printed part within the acid solution using an induction coil heater submerged within the acid solution.
  • the 3D printed part is an air cooled turbine airfoil.
  • an apparatus for removing a support structure from a 3D printed part formed using an additive manufacturing process comprises: an acid solution tank; an acid solution within the acid solution tank; a 3D printed part with a support structure secured within the acid solution; an induction coil heater surrounding the 3D printed part within the acid solution; and an acid solution recirculation system to recirculate the acid solution within the acid solution tank, wherein the induction coil heater heats up the support structure within the 3D printed part to remove the support structure from the 3D printed part while the recirculation system limits a rise of the temperature of the acid solution.
  • the 3D printed part is a metal part formed from a metal additive manufacturing process.
  • the 3D printed part and the support structure are formed from the same material.
  • the acid solution tank and the recirculation system are ceramic coated copper to protect against exposure to the acid solution.
  • the 3D printed part is an air cooled turbine airfoil.
  • FIG. 1 shows a cross-section side view of an apparatus for removing a support structure from a 3D printed part according to the present disclosure
  • FIG. 2 shows a cross-section side view of a 3D printed part with a support structure intact
  • FIG. 3 shows a cross-section side view of the 3D printed part of FIG. 2 with the support structure removed according to the present disclosure.
  • the present invention is an apparatus and a process for removing a support structure from a 3D printed part such as a metallic part formed using a metal additive manufacturing (MAM) process.
  • a metallic part such as an air cooled turbine airfoil used in a gas turbine engine or a shrouded impeller can be formed from layers of a metallic powder deposited onto a bed and solidified using a laser to melt the metallic powder in certain areas. Some of the metallic powder deposited can be used as a support surface for parts that are overhung.
  • the support structure is formed with less density than the solidified metallic areas in order that it can be removed after the part has been formed. In areas that are too difficult to reach using a mechanical tool to remove the support structure, the apparatus and process of the present invention can be used.
  • the 3D printed part with support structure is placed in an acid bath and the part is heated using an induction coil so that small surfaces of the part are heated first, thus increasing the reaction with the acid and removing the support structure material faster than the lower temperature material.
  • the acid solution is pumped through the acid tank to ensure bulk temperature does not heat up too much. Over time all of the small areas will be removed and the support structure will have been etched away, leaving the finished part without any support structure therein.
  • the apparatus for removing the support structure from a 3D printed part is shown in FIG. 1 and includes an acid solution tank 11, an acid solution 12, a 3D printed part 16 with support structure 18 therein, an induction coil heater 13, an acid solution pump 15, and an acid solution recirculation pipe 14.
  • the acid solution 12 is a cooled or diluted acid solution so that a slow reaction with the less dense support structure 18 occurs.
  • the acid solution recirculation pipe 14 and the acid solution pump 15 are part of an acid solution recirculation system of the apparatus.
  • the acid solution 12 is recirculated through the acid solution recirculation pipe 14, within the acid solution tank 11, and around the 3D printed part 16 to limit the acid solution from heating up too much.
  • the 3D printed part 16 can be an air cooled turbine airfoil made from a nickel superalloy
  • the acid solution 12 could be hydrochloric acid
  • the acid solution tank 11 could be formed from a plastic material or glass material
  • the acid solution tank 11 and the acid solution recirculation 14 pipe and the acid solution pump 15 could be ceramic coated copper to prevent the acid from affecting anything other than the support structure 18 of the 3D printed part 16.
  • the 3D printed part 16 with the support structure 18 is shown in FIG. 2, with the 3D printed part 16 and the support structure 18 having several overhung sections.
  • the 3D printed part 16 with the support structure 18 intact is placed within the acid solution 12 and the induction coil heater 13 is moved to surround the 3D printed part 16.
  • the acid solution 12 is circulated through the acid solution tank 11 so that bulk temperature of the acid solution 12 does not change much.
  • the induction coil heater 13 will then heat up small surfaces of the 3D printed part 16 before the larger surfaces heat up, so that the acid reacts to the smaller and heated surfaces and removes the smaller surfaces first.
  • the support structure 18 may include smaller surfaces than the 3D printed part 16. This process continues until all of the support structure 18 is removed or as much as possible can be removed.
  • FIG. 3 shows the 3D printed part 16 with the support structure 18 removed.
  • the resulting gap that is located where the support structure 18 used to be is indicated in FIG. 3 with reference number 19.
  • the apparatus and process for removing support structure from a 3D printed part can be used for metallic parts such as turbomachinery airfoils or shrouded airfoils, and even plastic parts.
  • One such turbomachinery could be a turbopump with a single piece rotor within a single piece housing in which the single piece rotor is trapped within the single piece housing.
  • the turbopump would be printed in a vertical direction along an axis of the rotor and the housing in which the support structure is printed along with the rotor rand housing, and then the entire assembly is placed in the acid solution and the support structure removed using the induction heater and the acid solution.
  • a process for removing a support structure 18 from a 3D printed part 16 formed using an additive manufacturing process comprises the steps of: forming the 3D printed part 16 using an additive manufacturing process in which a support structure 18 is also formed; placing the 3D printed part 16 with the support structure 18 in an acid solution 12; heating the 3D printed part 16 with the support structure 18 within the acid solution 12 using an induction coil heater 13 submerged within the acid solution 12 such that the support structure 18 is removed by the acid solution 12; and recirculating the acid solution 12 while the 3D printed part 16 is being heated to limit a temperature rise of the acid solution 12.
  • the additive manufacturing process is a metal additive manufacturing process and the 3D printed part 16 and the support structure 18 are formed of the same metal material.
  • the support structure 18 is less dense than the 3D printed part 16.
  • the process for removing a support structure 18 from a 3D printed part 16 further comprises the step of heating the 3D printed part 16 within the acid solution 12 using an induction coil heater 13 submerged within the acid solution 12.
  • the 3D printed part 16 is an air cooled turbine airfoil.
  • an apparatus for removing a support structure 18 from a 3D printed part 16 formed using an additive manufacturing process comprises: an acid solution tank 11; an acid solution 12 within the acid solution tank 11; a 3D printed part 16 with a support structure 18 secured within the acid solution 12; an induction coil heater 13 surrounding the 3D printed part 16 within the acid solution 12; and an acid solution recirculation system to recirculate the acid solution 12 within the acid solution tank 11, wherein the induction coil heater 13 heats up the support structure 18 within the 3D printed part 16 to remove the support structure 18 from the 3D printed part 16 while the recirculation system limits a rise of the temperature of the acid solution 12.
  • the 3D printed part 16 is a metal part formed from a metal additive manufacturing process.
  • the 3D printed part 16 and the support structure 18 are formed from the same material.
  • the acid solution tank 11 and the recirculation system are ceramic coated copper to protect against exposure to the acid solution 12.
  • the 3D printed part 16 is an air cooled turbine airfoil.

Abstract

La présente invention concerne un appareil et un procédé de retrait d'une structure de support d'une partie imprimée en 3D, la partie imprimée en 3D avec la structure de support étant placée dans une solution acide et la pièce étant entourée par un dispositif de chauffage par induction. La solution acide est recirculée à travers le réservoir d'acide pour empêcher la solution acide de chauffer excessivement. Des petites surfaces de la pièce sont chauffées par le dispositif de chauffage par induction avant que les pièces plus grandes soient chauffées de sorte que l'acide enlève les pièces plus petites en premier. Après un temps suffisant, la totalité de la structure de support est retirée par l'acide et le dispositif de chauffage pour laisser la pièce imprimée en 3D finale avec la structure de support retirée.
PCT/US2017/058950 2017-10-30 2017-10-30 Appareil et procédé de retrait d'une structure de support d'une pièce imprimée en 3d WO2019088963A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2017/058950 WO2019088963A1 (fr) 2017-10-30 2017-10-30 Appareil et procédé de retrait d'une structure de support d'une pièce imprimée en 3d

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2017/058950 WO2019088963A1 (fr) 2017-10-30 2017-10-30 Appareil et procédé de retrait d'une structure de support d'une pièce imprimée en 3d

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WO2019088963A1 true WO2019088963A1 (fr) 2019-05-09

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3652322A (en) * 1970-09-03 1972-03-28 Continental Oil Co Method for controlling the heating of a metal immersed in a plating solution
KR20000031617A (ko) * 1998-11-09 2000-06-05 박철순 내외면에 세라믹층을 코팅한 동관 및 그 코팅방법
KR200424342Y1 (ko) * 2006-05-25 2006-08-18 옥재섭 비철금속용기의 표면코팅구조
US20130075957A1 (en) * 2011-09-23 2013-03-28 Stratasys, Inc. Support Structure Removal System
US8881397B1 (en) * 2012-10-16 2014-11-11 Florida Turbine Technologies, Inc. Method for testing variable cooling geometries in a turbine vane
US20150197862A1 (en) * 2014-01-13 2015-07-16 Incodema3D, LLC Additive metal deposition process
US9828679B1 (en) * 2016-06-23 2017-11-28 Florida Turbine Technologies, Inc. Apparatus and process for removing support structure from a 3D printed part

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3652322A (en) * 1970-09-03 1972-03-28 Continental Oil Co Method for controlling the heating of a metal immersed in a plating solution
KR20000031617A (ko) * 1998-11-09 2000-06-05 박철순 내외면에 세라믹층을 코팅한 동관 및 그 코팅방법
KR200424342Y1 (ko) * 2006-05-25 2006-08-18 옥재섭 비철금속용기의 표면코팅구조
US20130075957A1 (en) * 2011-09-23 2013-03-28 Stratasys, Inc. Support Structure Removal System
US8881397B1 (en) * 2012-10-16 2014-11-11 Florida Turbine Technologies, Inc. Method for testing variable cooling geometries in a turbine vane
US20150197862A1 (en) * 2014-01-13 2015-07-16 Incodema3D, LLC Additive metal deposition process
US9828679B1 (en) * 2016-06-23 2017-11-28 Florida Turbine Technologies, Inc. Apparatus and process for removing support structure from a 3D printed part

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
MILLSAPS, BB: "Researchers Are Able to Dissolve Support Structures in Metal 3D Printing", OFFERING GREAT POTENTIAL FOR FUTURE, 15 July 2016 (2016-07-15), Retrieved from the Internet <URL:https://3dprint.com/142332/dissolving-support-structures> [retrieved on 20171212] *

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