WO2019136523A1 - Méthode et appareil pour augmenter la résolution, réduire les taux de défauts et augmenter les taux de production d'articles 3d fabriqués de manière additive - Google Patents

Méthode et appareil pour augmenter la résolution, réduire les taux de défauts et augmenter les taux de production d'articles 3d fabriqués de manière additive Download PDF

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Publication number
WO2019136523A1
WO2019136523A1 PCT/AU2019/050013 AU2019050013W WO2019136523A1 WO 2019136523 A1 WO2019136523 A1 WO 2019136523A1 AU 2019050013 W AU2019050013 W AU 2019050013W WO 2019136523 A1 WO2019136523 A1 WO 2019136523A1
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WIPO (PCT)
Prior art keywords
powder
light source
powdered
build
powdered material
Prior art date
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PCT/AU2019/050013
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English (en)
Inventor
Michael Larkins
Tony Kendal
Original Assignee
Flew Solutions Australia Ltd
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Publication date
Priority claimed from AU2018900085A external-priority patent/AU2018900085A0/en
Application filed by Flew Solutions Australia Ltd filed Critical Flew Solutions Australia Ltd
Publication of WO2019136523A1 publication Critical patent/WO2019136523A1/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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • 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
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
    • 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
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
    • B22F12/42—Light-emitting diodes [LED]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B22F12/45—Two or more
    • 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
    • B22F12/60—Planarisation devices; Compression devices
    • B22F12/67—Blades
    • 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
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/277—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/286—Optical filters, e.g. masks
    • 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
    • B22F12/10—Auxiliary heating means
    • B22F12/13—Auxiliary heating means to preheat the 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
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
    • 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
    • B22F12/52—Hoppers
    • 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
    • B22F12/55—Two or more means for feeding 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
    • B22F2201/00—Treatment under specific atmosphere
    • B22F2201/10—Inert gases
    • 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
    • B22F2201/00—Treatment under specific atmosphere
    • B22F2201/20—Use of vacuum
    • 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
    • B22F2202/00—Treatment under specific physical conditions
    • B22F2202/11—Use of irradiation
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • 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 to a method and apparatus for additive manufacturing of three dimensional articles.
  • Additive manufacturing is a method for forming three-dimensional articles through a process of successive fusion of selected areas of powder layers that have been applied to a build platform.
  • Apparatus for additive manufacturing may comprise a heated build platform on which a three-dimensional article is to be formed, along with at least one powder delivery mechanism with controllable powder release, which is configured to be able to lay down a thin layer of powdered material on the build platform for the formation of a powder bed.
  • An energy beam is also included for delivering energy to the powdered material so that selective fusion of the powdered material takes place, and elements for controlling the energy given off by the energy beam over the bed of powdered material for the formation of a cross section of the three-dimensional article through fusion or union of the parts of the powdered material bed, and a controlling computer that has stored within it information on the cross sections of the three-dimensional article.
  • a three-dimensional article is formed through subsequently fusing together consecutively formed cross sections of powder layers, that are successively laid down by the powder delivery mechanism in conjunction with a sweeping element.
  • the build platform typically moves downwards during operation in increments that define the layer height, e.g. 100 microns. This results in the powder always being swept at the same level, and the incident energy beam always striking the freshly swept powder in the same plane.
  • the charge from the electron beam may flow as an electrical current to ground through the produced part and to some degree through the remaining powder surrounding the produced part.
  • an electrical field having field strength above a critical level will develop around the position where the beam is radiating.
  • the electrical field having electrical field strength above the critical level will be referred to as Ecrit.
  • An electrical field will cause the powder particles to repel each other such that particles leave the uppermost surface layer of the particle and create a distribution of particles floating above the surface. The floating particles resemble a cloud positioned above the surface.
  • the electrical field i.e. the particle cloud or smoke of powder
  • the electrical field i.e. the particle cloud or smoke of powder
  • the electrical field i.e. the particle cloud or smoke of powder
  • the electrical field will influence the resolution of the device in a negative way. This is partly due to the fact that the particles in the particle cloud will diverge the electron beam.
  • the electrical field has field strength below Ecrit, the electrical field, i.e. the particle cloud, will not influence the resolution of the device in a significant way.
  • a field strength below Ecrit is thus desirable.
  • a second solution, often used in conjunction with the above-mentioned supplementary gas solution is the use of a pre-sintering process step before the full fusion step. This involves using the same energy beam at a lower power or pixel dwell time, for example the beam spends less time in each position, delivering less energy and only partially heating and partially sintering a portion of, or the entirety of the powder layer prior to the full fusion of the desired part.
  • the problem with said solution is that the time required to perform the relatively gentle pre-sintering significantly increases the time required for each powder layer, reducing production rates.
  • a pre-sintering process step for titanium powder may require 45 seconds whereas the melting step may require 5 seconds.
  • the pre-sintering of the powder makes removal of the un-used powder difficult, especially in complex small included geometries with fine detail. In certain cases, complex geometries that are in principle achievable by the additive
  • the powder particles When an energy beam, being a laser beam, hits the powder surface, the powder particles may also be displaced, but by a different physical phenomena.
  • the build chamber is not typically at vacuum but filled with argon or other inert gas up to and above atmospheric pressure.
  • the laser melting process may generate a plasma of super-heated metal and gas ions at the point where the laser strikes the powder surfaces. This violent interaction increases the efficiency of absorption of the laser light, but creates a local high pressure area, which displaces the powder causing defects.
  • an object of the invention is to provide a method and apparatus for increasing the resolution, reduce defect rates, and increasing production rates in the additive manufacturing process.
  • a method for increasing the resolution, reducing defect rates, and improving production rates when forming a three-dimensional article through successive fusion of selected areas of a powder bed, which selected areas corresponds to successive cross sections of the three- dimensional article.
  • Said method comprising the steps of: providing a build chamber that may be taken to high vacuum by means of, for example, turbo-molecular pumps, providing an electron gun, providing a first powder layer on a build platform inside of said build chamber, directing an electron beam from said electron gun over said build platform causing said first powder layer to fuse in selected locations to form a first cross section of said three-dimensional article, providing a second powder layer on said build platform, directing the electron beam over said build platform causing said second powder layer to fuse in selected locations to form a second cross section of said three- dimensional article, wherein said second layer is bonded to said first layer, directing a light source from 200nm-400nm light emitting diodes (LED’s) or laser diodes mounted outside the build chamber, directing that 200nm-400nm light through a window transparent to these wavelengths onto the powder to eject electrons from the material surface via the photoelectric effect which provides charge mobility and balances the electric charge on the powder to reduce defects due to powder being displaced by electric charge build
  • LED light emitting diodes
  • the window transparent to wavelengths of 200 nm - 400 nm has an ion/particle trap positioned to protect it from particles from within the build chamber.
  • the window transparent to wavelengths of 800 nm - 1500 nm has an ion/particle trap positioned to protect it to protect it from particles from within the build chamber.
  • One advantage of an embodiment of the present invention is the ability to reduce or eliminate the need for a pre-sintering process step prior to the fusion of the freshly swept layer.
  • the reduction of the excessive charge problem via the application of the 200nm-400nm light removes the need for pre-sintering to prevent smoking and powder displacement in some cases.
  • Another advantage of an embodiment of the present invention is the ability to reduce or eliminate the need for a supplementary gas to be introduced into the build chamber to provide positive ions at the powder surface to ameliorate the charging problems created by use of an electron beam.
  • An advantage in one embodiment of using the IR (Infra-Red) and UV (Ultra-Violet) radiation in conjunction with the electron beam during a pre-heating step is to utilize all three energy sources in order to reduce the required time required to preheat, and to sinter the freshly swept powder layer, in instances where the pre-sintering step is still desired. Further the simultaneous application of the UV radiation, IR radiation and electron beam during the melting process step balances radiative heat loss from the top of the part and powder bed into the build chamber and reduces the power required from the electron beam.
  • LED’s are used to generate 365nm UV light for efficient processing of Ti 6 4 powdered material, and 900-1 lOOnm IR radiation is used up to 5kW in order to provide pre-heating in conjunction with the electron beam to minimize the time required for the preheating/pre-sintering process step.
  • the selection of wavelength and power required for both the UV and IR source is dependent on the specific powder material including particle size, morphology, and alloy composition, the size of build area, and what degree of heating may be provided to the work area from a heated bed incorporated into the build platform.
  • Another advantage of an embodiment of the present invention is that it can be used in conjunction with the addition of varying levels of gas into the build chamber during the process, as outlined in patent US9079248B2.
  • a combination of electron beam, UV and IR radiation and gas may be used simultaneously to minimise preheating and layer melting times while maintaining optimal resolution.
  • an apparatus for additive manufacturing using an electron beam including: an electron beam source configured to generate a charged beam of electrons; a build chamber having a build area therein configured to achieve a high level of vacuum; at least one powder delivery mechanism to deliver a powdered material to the build area in the build chamber; at least one powder sweeping arm to spread the powdered material on the build area; at least one first light source of 200 nm - 400 nm mounted outside the build chamber, said at least one first light source being directed through a window transparent to wavelengths of 200 nm - 400 nm and onto the powdered material.
  • the at least one first light source of 200 nm - 400 nm is at least one light emitting diode (LED) and / or at least one laser diode.
  • LED light emitting diode
  • the at least one second light source of 800 nm-l500 nm is at least one light emitting diode (LED) and / or at least one laser diode.
  • the at least one first light source directed through the window transparent to 200 nm - 400 nm and onto the powdered material provides management of electric charge in the powdered material, preventing Ecrit from being reached during application of the electron beam.
  • the at least one first light source ejects electrons from the powdered material via the photoelectric effect so as to manage the electric charge on the powdered material and prevent Ecrit from being reached.
  • the powdered material is powdered metal material, powdered metal alloy material, powdered polymer material, powdered ceramic material or combinations thereof.
  • the window transparent to wavelengths of 200 nm - 400 nm has an ion/particle trap positioned to protect it from particles from within the build chamber.
  • the window transparent to wavelengths of 800 nm - 1500 nm has an ion/particle trap positioned to protect it to protect it from particles from within the build chamber.
  • the window is an optical fibre.
  • a discreet window is retained, and optical fibre is used to route the optical energy from a more convenient location to the window into the build chamber.
  • the window is transparent to 200 nm - 400 nm and the window transparent to wavelengths of 800 nm - 1500 nm are the same window.
  • the window is transparent to 200 nm - 450 nm and the window transparent to wavelengths of 800 nm - 1500 nm are separate windows.
  • manufacturing using an electron beam including: providing an electron beam source configured to generate a charged beam of electrons; providing a build chamber having a build area therein; directing at least one powder delivery mechanism to deliver a powdered material to the build area in the build chamber; directing at least one powder sweeping arm to spread the powdered material on the build area; directing at least one first light source of 200 nm-400 nm mounted outside the build chamber, said at least one first light source being directed through a window transparent to wavelengths of 200 nm - 400 nm and onto the powdered alloy material in the build chamber.
  • FIG. 1 shows, the apparatus for an example embodiment of a device for producing a three dimensional article, according to the present invention.
  • FIG. 2 depicts, in schematic view, an example of the surface of the powdery material with a charged particle cloud.
  • FIG. 3 A depicts a power versus time graph for delivered ETV power of the second example embodiment according to the present invention.
  • FIG. 3B depicts a power versus time graph for delivered IR power of the second example embodiment according to the present invention
  • FIG. 3C depicts a power versus time graph for delivered electron beam power of the third example embodiment according to the present invention
  • FIG. 3D depicts a pressure versus time graph for chamber pressure of the forth example embodiment according to the present invention.
  • FIG. 4 depicts an alternative powder delivery mechanism for an example embodiment of a device for producing a three dimensional article, according to the present invention.
  • three-dimensional articles and the like as used herein refer generally to intended or actually fabricated three-dimensional configurations (e.g. of structural material or materials) that are intended to be used for a particular purpose. Such articles, etc. may, for example, be designed with the aid of a three-dimensional CAD system.
  • the term“electron beam” as used herein in various embodiments refers to any charged particle beam.
  • the sources of charged particle beam can include an electron gun, a linear accelerator, a positive or negatively charged ion beam and so on.
  • laser beam refers to any beam of photons, that is, particles of light.
  • the source of the beam of photons may be a solid state laser, a gas laser, a diode array, a pulsed laser, a quantum cascade laser and so on.
  • the light may be coherent or incoherent, and of a broad range of wavelengths beyond the preferences stipulated here.
  • FIG. 1 depicts an embodiment of an additive manufacturing apparatus 10 in which an embodiment of the inventive method may be implemented.
  • the apparatus 10 comprising an electron beam gun 15; powder distributor 20, a powder delivery mechanism consisting of two powder hoppers 25 and 30, although in some embodiments a single hopper, or an entirely alternative powder delivery mechanism may be utilised; a build platform or build plate 35; a powder bed 40; and a build chamber 45, a UV light source, 50 an IR light source, 55 and two ion / particle traps 60 and 65.
  • the build chamber 45 is capable of maintaining a vacuum environment by means of a vacuum system (not shown), which system may comprise one or more turbomolecular pumps, a scroll pump or backing pump, an ion pump and one or more valves which are well known to a skilled person in the art and therefore need no further explanation in this context.
  • the vacuum system is controlled by a control unit 70.
  • the electron beam gun 15 is generating an electron beam which is used for melting or fusing together powder material provided on the build platform 35. At least a portion of the electron beam gun 15 may be provided in the build chamber 45.
  • the control unit 70 may be used for controlling and managing the electron beam emitted from the electron beam gun 15.
  • An ion trap may be provided around the electron gun to prevent powder ejected from the process degrading the crystal or filament acting as the cathode.
  • At least one focusing coil (not shown), at least one deflection coil (not shown), an optional coil for astigmatic correction (not shown) and an electron beam power supply (not shown) may be electrically connected to the control unit 70.
  • the electron beam gun 15 generates a focusable electron beam with an accelerating voltage of about 10-80 kV and with a beam power in the range of 0-20 kW.
  • the pressure in the build chamber may be 10-3 mbar or lower when building the three- dimensional article by fusing the powder layer by layer with the energy beam.
  • the powder hoppers 25, 30 contain the powdered material to be provided on the build platform 35 in the build tank.
  • the powdered material may for instance be pure metals or metal alloys such as titanium, titanium alloys, aluminum, aluminum alloys, titanium aluminide, copper, copper alloys, stainless steel, cobalt-chromium alloys, nickel based superalloys, a ceramic material, polymer material or mixtures of these as required.
  • the powder distributor 20 is arranged to lay down a thin layer of the powder material on the build platform 35.
  • the build platform 35 will be lowered successively in relation to a fixed point in the build chamber 45.
  • the build platform 35 is in one embodiment of the invention arranged movably in vertical direction, i.e., in the direction indicated by arrow 51. This means that the build platform 35 starts in an initial position, in which a first powdered material layer of necessary thickness has been laid down.
  • Means for lowering the build platform 35 may for instance be through a servo engine equipped with a gear or linear actuator, such as the rack and pinion 80, adjusting screws etc.
  • An electron beam may be directed over the build platform 35 causing the first layer of powdered material to fuse in selected locations to form a first cross section of said three-dimensional article.
  • the beam is directed over said build platform 35 from instructions given by the control unit 70.
  • instructions for how to control the electron beam for each layer of the three-dimensional article are stored.
  • a second powder layer is provided on the build platform 35.
  • the second powder layer is preferably distributed according to the same manner as the previous layer.
  • a first layer may be provided by means of a first powder distributor 20, a second layer may be provided by another powder distributor.
  • the action of the powder distributor is automatically controlled according to instructions from the control unit 70.
  • a powder distributor 20 may in an exemplary embodiment take the form of a single rake system, i.e., where one rake is catching powdered material 37 from the powder hopper 25 and the powder hopper 30.
  • the height of each swept powder layer is determined by the distance between the rake and the previously melted surface. This distance and therefore the layer height is controlled by changing the height of the build platform.
  • the energy beam from the electron beam gun 15 is directed over the build plate 35 causing the second powder layer to fuse in selected locations to form a second cross section of the three-dimensional article 100.
  • Fused portions in the second layer may be bonded to fused portions of said first layer.
  • the fused portions in the first and second layer may be melted together by melting not only the powder in the uppermost layer but also remelting at least a fraction of a thickness of a layer directly below said uppermost layer.
  • the electrical conductivity of the powder can gradually be increased by increasing the temperature of the powder.
  • a powder that has a high temperature obtains a considerably higher conductivity that results in a lower density of the charge distribution since the charges quickly can diffuse over a large region. This effect is enhanced if the powder is allowed to be slightly sintered during the pre-heating process.
  • the powder can be fused together, i.e. melted or fully sintered, with predetermined values of the beam current and beam scanning velocity.
  • Figure 2 shows the upper layer 41 of the powder bed 40 of the powdered material with a charged particle cloud 110, with UV light rays 130, from the UV light source 50, on one side and IR light rays 140, from the IR light source 55, on the other side.
  • the charged particle cloud 110 is concentrated around the position where the electron beam 115 irradiates the powdered material. With a higher electrical field, a larger charged particle cloud and more particle displacement will occur around the irradiated point 118.
  • the number of UV photons introduced into the build chamber 45 or created in the build chamber 45 should be above a predefined level in order to mobilize enough of the charge on the surface of the powdered material.
  • the predefined level should be selected such that it keeps the electrical field strength below Ecrit. In doing so, enough of the powdered material is neutralized and lifting and displacement of powder is prohibited.
  • UV light is used to manage the charge distribution within the powdered material via the photoconduction and photoelectric effects. As both of these effects are dependent on the material to be fused and the temperature of the material, the UV radiation power, the IR-light power, and bed pre-heating and the electron beam power, must be considered together for a given powder material.
  • FIG. 1 depicts a first example embodiment of how the method according to the present invention may be implemented in which there is a UV (Ultra Violet) light source 50 in the form of a LED or laser diode, and an IR (Infra Red) light source 55 in the form of LED or laser diode.
  • the UV and IR light sources 50 and 55 are connectable to the additive manufacturing apparatus 10 via an optical fibre 56, a transparent window 72, which in this embodiment is made from a fused silica material, and an ion/particle trap 60.
  • the UV and IR light sources 50 and 55 are in this embodiment controlled by the control unit 70.
  • the UV light source 50 in this embodiment is an array of diodes arranged in square grid.
  • the UV light source may be air or water cooled.
  • the individual diodes of the array have a lens attached to the output of each diode.
  • the UV light from light source 50 passes through an optical arrangement 76, which may contain a collimation lens and one or more micro-lens array or a plurality of micro-lens arrays.
  • the light then passes through a further optical arrangement 75 which is in preference a focusing lens to direct light onto the work area appropriately and an optical filter to prevent light outside of the range 200-400nm propagating back from the build chamber into the diode array where it will cause unwanted heating.
  • the UV and IR light sources 50 and 55 and their associated optical elements may be mounted at an angle with respect to the normal of the plane of the build area in order to efficiently illuminate the build area.
  • a plurality of UV and IR light sources may be mounted concentrically and symmetrically around the electron beam in order to ensure homogeneous illumination of the build area.
  • the micro-lens array incorporated into 76 may instead be an optical diffuser such as frosted glass, although this will cause a loss in the optical power transmitted to the build area.
  • the focusing lens, diffusing element or filter may serve as the build chamber window 74.
  • the ion/particle traps 60 and 65 prevent coating of the transparent windows 72 and 74 by any particles in the build chamber 45.
  • the ion/particle trap may be a sacrificial transparent material that is replenished continuously or intermittently by means of a powered mechanical movement.
  • the ion/particle trap may be formed by an electrical ion trap that will be familiar to persons skilled in the art.
  • the IR source 55 is directed into the additive manufacturing device 10 through the optical fibre 56, transparent window 72 and ion/particle trap 72.
  • the IR and UV light sources 50 and 55 may be engaged at any power level from 0 to 100%.
  • the transparent windows 72 and 74 provide a vacuum seal and can be constructed from quartz, sapphire or fused silica.
  • the UV and IR light sources 50 and 55 may be located external to the additive manufacturing system 10, or incorporated into its structure. If incorporated into the structure, the optical fibre 56 in some cases becomes redundant.
  • the UV source may have integrated electro-mechanical or solid state scanning and lens systems (not shown), or utilize separate lens systems to direct the output light onto powder bed and the build platform 35 in a homogeneous manner.
  • the ion/particle traps 60 and 65 prevents coating of the transparent window 72 and 74 by any ions, atoms, or powder particles in the build chamber 45.
  • the IR assembly 200 is provided IR light from the IR light source 55 via the optical fibre 56.
  • the IR assembly 200 includes water cooled initial optics 210, a water cooled hot mirror 215, a camera 220, optical saturation filters 225, water cooled final optics 230, a water cooled quartz, sapphire or otherwise visible and IR-transparent window 72 and ion/particle trap 60.
  • the initial optics 210 may have integrated electro-mechanical or solid state scanning systems.
  • the IR assembly 200 is configured to allow imaging through the transparent window 72 simultaneously with the passage of the IR light provided from IR light source 55. As the ion/particle trap 60 is located within or abutting the build chamber 45 it is exposed to the vacuum, as is the ion/particle trap 65.
  • Figure 3 A depicts a UV power versus time graph of the first example embodiment according to the embodiment of the present invention as shown in figure 1.
  • figure 3B depicts a IR power versus time graph for the first example embodiment of the present invention.
  • process steps 300, 310 and 320 in figure 3 A and 330, 340 and 350 respectively are marked above the power graph.
  • Powder distribution is the first process step denoted by 300 in figure 3A and 330 is figure 3B, during this time powdered material is provided on the build platform 35 (clean build platform or a build platform provided with one or several cross sections of fused material), the UV power, inside the additive manufacturing apparatus 10 may be increased from an initial power level (which may be 0%) UV-P1 when the powder distribution is underway and switched to a power level UV-P2 when the powder distribution is finalized.
  • the IR power may be switched from an initial power level (which may be 0%) IR-P1 when powder distribution is underway, and switched to a power level IR-P2 when the powder distribution is finalized.
  • the next process step is the preheating step 310 and 340.
  • This preheating step 310/330 is performed by scanning the electron beam from the electron beam gun 15 over the powder bed 40 in an appropriate manner for heating the powder bed 40 without creating powder smoke.
  • the manufacturing apparatus 10 is at a first power level UV-P2, which is high enough for suppressing or eliminating any excessive charge accumulation and smoking of the powdered material.
  • the first UV power level P2 may be around 10-200 Watts at 385nm for Ti-6Al-4V powdered material dependant on build area size and the electron beam current and voltage used.
  • the UV and IR power levels may be at a constant high level throughout the preheating stage 310/340. Alternatively, the UV and IR power level is varying during said preheating stage 310/340 but always high enough in order to suppress any smoking of the powdered material.
  • the UV power is at a high level, the first power level UV-P2, during preheating 310/340.
  • the UV power is instantaneously increased to the second power level UV-P3, where the second power level UV-P3 is higher than the first power level UV-P2 and the initial power level UV-P1.
  • smoke of powder is most likely to be present in the beginning of the preheating when no powder is sintered at all. The more the powder is sintered the less is the likelihood of creating smoke of powder.
  • the IR power is also at a high level IR-P2 during pre-heating 310/340, and in general may be brought to a different power level at the finalization of the pre- heating step, however in the current preferred embodiment, it is kept at the same constant power IR-P2 as depicted in Figure 3B.
  • the UV and IR power in the additive manufacturing apparatus 10 may be kept constant at the power levels UV-P3 and IR-P2 respectively.
  • the UV power level UV-P3 is higher than the UV-P2 as higher average beam current is used during the melting step 320/350 as compared to the pre-heating step 310.
  • the UV and IR power may be varied during the fusion or melting step, but always in such a manner as to prevent powder displacement and smoke.
  • the UV power levels of this influx from a first power level, here indicated by said first power level UV-P2, to a second power level, here indicated by UV-P3, between the steps of providing said first powder layer and said second powder layer.
  • the preheating of the powder bed 40 may be performed at least partially with the first UV power level UV-P2 which is lower than said second power level UV-P3.
  • the powder bed 40 may be fused in said selected locations at least partially while under illumination by said second power level UV-P3.
  • the required preheating temperature at stage 310/330 is material dependent, which means that different materials require different preheating temperature intervals and UV, IR, and electron beam powers.
  • the temperature chosen for the preheating may affect the internal stresses and fatigue properties of the final three dimensional article.
  • a supplementary gas provided into the build chamber may be capable of providing ions when irradiated by the electron beam during said preheating which to some degree ameliorates the charge distribution problem.
  • Said first supplementary gas may be at least one inert gas.
  • Said inert gas is one or more in the group of: helium, argon, carbon dioxide, nitrogen, neon, krypton, xenon, radon.
  • a supplementary gas may be introduced into the build chamber 45 from an initial gas pressure Pl during the powder distribution process step, to a higher gas pressure P2 during the pre-heating step as described in figure 3D.
  • supplementary gas for the preheating step is in addition to the simultaneous application UV, IR, and electron beam powers as described in figures 3A, 3B, and 3C respectively.
  • the powder provided on the build platform is about to be brought to an appropriate temperature before a fusing/melting step.
  • This preheating step is performed by scanning the electron beam over the powder bed, with simultaneous application of UV and IR light, in an appropriate manner for heating the powder bed without creating powder smoke.
  • the UV, IR and electron beam power level in the additive manufacturing apparatus 10 is at the first power level UV-P2, IR-P2 and EB-P2 respectively, which in combination is satisfactory for suppressing displacement and smoke of powder.
  • the first power level for UV light UV-P1 may be around 10W-200W of UV light and the first power level of IR light, IR-P2 may be around l-5kW of IR light power depending on the material and size of the build area.
  • the UV and IR light sources can be switched relatively quickly ( ⁇ lms) and therefore the UV light let into the build chamber may be increased from the first power level UV-P2 to the second power level UV-P3 quickly at the end of the pre-heating step, as indicated by the vertical line in the figure 3 power versus time graphs.
  • the supplementary gas may be either held constant, or decreased, over the duration of the pre-heating step from a pressure level Pl to a pressure level P2 as depicted on figure 3D.
  • the gas pressure in the additive manufacturing apparatus 21 may be kept as lower and in FIG. 3D it is kept at the initial pressure level Pl such that the gas pressure does not affect the resolution of the electron beam.
  • the preheating of the powder bed may be performed at least partially with decreasing pressure level, from a high pressure, the first pressure level P2, to a low pressure level, which may be the initial pressure level Pl.
  • the powder bed may be fused in said selected locations at least partially with said initial pressure level Pl.
  • the gas pressure may be kept at the initial lower pressure Pl during the powder distribution process step as depicted in figure 3D, or it may be gradually increased from initial pressure level Pl to the higher first pressure level P2 over the duration of the powder distribution step.
  • the UV light source may be provided from sources other than diodes or laser diodes, for instance excimer lasers, arc discharge lamps, mercury lamps etc.
  • the light source may be directed onto the build platform by solid state or electro-mechanical optical beam scanning components (not shown), controlled by the control system 70.
  • light sources ⁇ 200nm may be used to induce the photoelectric effect in the powder material, but a person skilled in the art will appreciate that some modification to the optical arrangement detailed in this invention will need to be made at these wavelengths, to prevent the absorption of the ⁇ 200nm light by air. For example, if an excimer laser was used as the UV source, with ⁇ 200nm wavelength, optical fibre cannot be used and further the entire light path must be kept at vacuum.
  • the IR light source may be provided from sources other than diodes or laser diodes, for instance incandescent lamps, solid state and fibre lasers, and gas lasers including C02 lasers.
  • sources other than diodes or laser diodes for instance incandescent lamps, solid state and fibre lasers, and gas lasers including C02 lasers.
  • C02 laser source significant changes to the optical elements are required for the C02 laser wavelength.
  • the powder hopper and powder delivery mechanism detailed in Figure 1 may be replaced by the arrangement shown in Figure 4.
  • the powder 437 is delivered from rising plates 440 on one or a plurality of sides of the build area, and the fresh powder layer is similarly swept across the build platform 435 by a sweeper or roller 420.
  • a sweeper or roller 420 A person skilled in the art will appreciate that this and other methods of delivering the powder material to the part, for example, selectively by a CNC controlled nozzle, will not have a detrimental impact on the function of the apparatus and method presented here.
  • Such modifications may, for example, involve using a different source of energy beam than the exemplified electron beam such as laser beam.
  • Other materials than metallic powder may be used such as powder of polymers or powder of ceramics.
  • the object of the invention, apparatus and method remains consistent, excepting the application of an inert gas rather than vacuum to the build chamber, and different beam steering and focusing requirements which will be obvious to persons skilled in the art.
  • Suppression of the powder displacement for embodiments utilising a laser beam as the energy source is achieved through absorption or reduction of the laser intensity required for fusing of the powdered material. This is achieved by the heating of the freshly swept powder layer with the UV and / or IR irradiation, as well as modifying the optical absorption characteristics of the powder due to the elevated temperature and

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Abstract

L'invention concerne une méthode et un appareil permettant d'augmenter la résolution, de réduire les taux de défauts et d'augmenter les taux de production lors de la formation d'un article tridimensionnel par fusion successive de parties d'un lit de poudre, ladite méthode comprenant la fourniture d'une chambre de construction, la fourniture d'un canon à électrons, la fourniture d'une couche de poudre sur une plateforme de construction à l'intérieur de ladite chambre de construction, l'orientation d'un faisceau d'électrons à partir dudit canon à électrons sur ladite plateforme de construction, ce qui amène la couche de poudre à fondre dans des emplacements sélectionnés pour former une section transversale dudit article tridimensionnel, simultanément à l'utilisation du canon à électrons éclairant la plateforme de construction avec une lumière ultraviolette et une lumière infrarouge pour éjecter des électrons de la couche de poudre pour empêcher un mouvement de poudre résultant de forces de charges statiques sur les particules de poudre et pour fournir un chauffage supplémentaire à la couche de poudre respectivement.
PCT/AU2019/050013 2018-01-11 2019-01-11 Méthode et appareil pour augmenter la résolution, réduire les taux de défauts et augmenter les taux de production d'articles 3d fabriqués de manière additive WO2019136523A1 (fr)

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AU2018900085A AU2018900085A0 (en) 2018-01-11 Method and apparatus for increasing the resolution, reducing defect rates and increasing production rates in additively manufactured 3D articles
AU2018900085 2018-01-11

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Publication number Priority date Publication date Assignee Title
CN110802839A (zh) * 2019-11-26 2020-02-18 华南理工大学 一种适用于粘接剂喷射成型的下送粉装置及方法
WO2021003256A1 (fr) * 2019-07-02 2021-01-07 Nikon Corporation Décharge améliorée de lit de poudre
CN112903548A (zh) * 2019-12-04 2021-06-04 西门子股份公司 对烟雾事件的识别和电子束熔炼设备
US11305355B2 (en) 2020-05-21 2022-04-19 Kilncore Inc. High temperature, high pressure, powder-based, 3D printed object manufacturing

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US20150064047A1 (en) * 2013-08-28 2015-03-05 Elwha Llc Systems and methods for additive manufacturing of three dimensional structures
WO2016051163A1 (fr) * 2014-10-01 2016-04-07 Renishaw Plc Appareil et procédé de fabrication additive
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US20090017220A1 (en) * 2007-05-25 2009-01-15 Eos Gmbh Electro Optical Systems Method for a layer-wise manufacturing of a three-dimensional object
US20150064047A1 (en) * 2013-08-28 2015-03-05 Elwha Llc Systems and methods for additive manufacturing of three dimensional structures
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Publication number Priority date Publication date Assignee Title
WO2021003256A1 (fr) * 2019-07-02 2021-01-07 Nikon Corporation Décharge améliorée de lit de poudre
CN110802839A (zh) * 2019-11-26 2020-02-18 华南理工大学 一种适用于粘接剂喷射成型的下送粉装置及方法
CN112903548A (zh) * 2019-12-04 2021-06-04 西门子股份公司 对烟雾事件的识别和电子束熔炼设备
EP3831515A1 (fr) * 2019-12-04 2021-06-09 Siemens Aktiengesellschaft Détection des événements de fumée et installation de fusion par bombardement électronique
US11642740B2 (en) 2019-12-04 2023-05-09 Siemens Aktiengesellschaft Identifying smoke events and electron beam melting installation
US11305355B2 (en) 2020-05-21 2022-04-19 Kilncore Inc. High temperature, high pressure, powder-based, 3D printed object manufacturing

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