WO2020096951A1 - Coulage d'additif tridimensionnel - Google Patents

Coulage d'additif tridimensionnel Download PDF

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Publication number
WO2020096951A1
WO2020096951A1 PCT/US2019/059643 US2019059643W WO2020096951A1 WO 2020096951 A1 WO2020096951 A1 WO 2020096951A1 US 2019059643 W US2019059643 W US 2019059643W WO 2020096951 A1 WO2020096951 A1 WO 2020096951A1
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WIPO (PCT)
Prior art keywords
mold
dimensional object
heating
shaping
liquid
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PCT/US2019/059643
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English (en)
Inventor
Yi-Hsien Harry TENG
Original Assignee
Teng Yi Hsien Harry
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Publication of WO2020096951A1 publication Critical patent/WO2020096951A1/fr

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    • 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
    • B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C23/00—Tools; Devices not mentioned before for moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • 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
    • B22F10/10—Formation of a green body
    • B22F10/14—Formation of a green body by jetting of binder onto a bed of metal powder
    • 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
    • B22F10/10—Formation of a green body
    • B22F10/18—Formation of a green body by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—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
    • B22F10/60—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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/007—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of moulds
    • 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
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/04—Welding for other purposes than joining, e.g. built-up welding
    • B23K9/044—Built-up welding on three-dimensional surfaces
    • 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
    • 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
    • B33Y80/00—Products made by additive manufacturing
    • 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
    • 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
    • B22F10/64—Treatment of workpieces or articles after build-up by thermal 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
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/22—Driving means
    • B22F12/226—Driving means for rotary motion
    • 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
    • B22F12/30—Platforms or substrates
    • 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
    • B22F12/60—Planarisation devices; Compression devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • 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
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/20—Tools
    • 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 disclosure relates generally to the field of additive manufacturing, and more specifically to hybrid additive manufacturing processes that are configured to cast a three- dimensional object layer by layer within an additively constructed shaping structure.
  • additive manufacturing has evolved into a diversified technology domain and become an efficient and increasingly viable path for direct fabrication of high value parts.
  • This new manufacturing approach employs digital manufacturing in free form fabrication, eliminates traditional tooling, replaces subtractive machining, and offers a variety of methods for rapid prototyping whereas limited production of parts from various materials such as but not limited to plastic and metal.
  • the most challenging hurdle to additive manufacturing for widespread production stands in production speed and cost especially for metal part
  • the directed energy deposition processes are capable to produce much larger parts.
  • higher deposition rates create issues of poor geometric accuracy and dimensional resolutions and increased surface roughness due to thick layers, wide metal beads, and lack of deposition precision.
  • significant thermal stresses can build up in metal parts which may cause part distortion and even cracking.
  • the current directed energy deposition techniques can only construct metal parts in relatively simple geometries without supports.
  • casting is an approach to production of metal parts through pouring and solidification of liquid metals in refractory molds.
  • metal parts can be cast in various sizes, geometries, and quantities that cannot be fabricated as feasibly or economically with other conventional metalworking techniques such as powder metallurgy, metal injection molding, forging, and extrusion.
  • preparation of casting molds requires tooling (e.g. patterns, core boxes or dies) that is normally expensive and time consuming to make.
  • Operations like sand casting often require many types of machinery and hardware for preparation and reclamation of foundry sand, mold making, core making, melting, pouring, part finishing, and metal recycling.
  • the casting concept is incorporated into additive manufacturing in the present disclosure, so that a three-dimensional object can be“cast” layer by layer in a quickly, additively constructed shaping structure or mold with good resolutions and surface definition.
  • this approach can offer unique benefits to additive manufacturing of metal, polymer or composite parts especially for medium to large ones in productivity and cost.
  • the present disclosure relates to an additive manufacturing methodology and apparatus configured to construct a shaping structure that is essentially a mold or at least a partial mold and cast a three-dimensional object incrementally in a series of mold cavities generated.
  • a liquid or semi-liquid fill material is delivered into the current shaping cavity to construct one or more layers of the three-dimensional object.
  • the portion of the three-dimensional object built may serve as a build substrate upon which additional layers of the mold or object can be constructed.
  • the construction process continues until the mold and three-dimensional object are completely constructed or built, i.e., until the mold and object are constructed to a completion level desired by a user or operator.
  • the mold and three-dimensional object therein are constructed coordinatively in the additive manufacturing process.
  • the mold defines the geometry of the three-dimensional object and is prepared to control the object dimensions and surface finish, so that the mold is preferably constructed in high resolution and dimensional accuracy settings.
  • a liquid layer thickness up to about 5 to 25 mm depending on the fill material specific gravity applies a negligible or low hydrostatic pressure to the mold, and therefore, a shell mold having a small wall thickness in several millimeters and adequate strength is feasible in order to reduce the mold build time and material consumption. Nevertheless, a larger liquid layer thickness is acceptable with an appropriate wall thickness and strength for the shell.
  • the layer thickness of the three- dimensional object should not be too small, e.g. 1 mm or less since a thin layer design may slow down the additive manufacturing process, nor too large depending on the volumetric shrinkage rate of fill material through solidification to avoid formation of shrinkage cavities or porosity in the three-dimensional object which is a main concern for traditional metal casting involving gating and riser designs. With these considerations, this additive manufacturing process allows a high throughput of liquid or semi-liquid material to fill the mold cavities and construct the three- dimensional object without compromising its dimensional tolerances and surface quality.
  • molds There are two types of molds, i.e.
  • the conjunctive type can be built for a complete mold, or a partial one, or in a combination with the disposable type.
  • a conjunctive mold can be made of a material that is the same as or different from the fill material for construction of the there-dimensional object therein.
  • the three-dimensional object can be designed and constructed with hybrid materials or gradient compositions for special functions or applications.
  • Another objective of the present disclosure is to provide an additive manufacturing method and system that is configured for hybrid manufacturing involving material extrusion, binder jet printing, material jetting, directed energy deposition, sheet lamination, powder bed fusion, or machining to construct a three-dimensional object with enhanced dimensional tolerances and surface quality.
  • a further objective of the present disclosure is to provide an additive manufacturing method and system capable of constructing a mold with cores or inserts to produce a three- dimensional object in complex geometries.
  • An additional objective of the present disclosure is to provide an additive manufacturing method and system capable of producing a three-dimensional object having hybrid or gradient compositions.
  • Still another objective of the present disclosure is to provide an additive manufacturing method and system that is configured with thermal and mechanical means to control the temperature distribution and cooling rate and apply a force to reduce internal stresses and distortion in the manufacturing of a three-dimensional object.
  • Fig. 1 is an exemplary process flowchart of the additive manufacturing method in the present disclosure
  • FIG. 2 is a perspective view of an exemplary additive manufacturing configuration in construction of a shaping cavity and a three-dimensional object therein.
  • Fig. 3 is a perspective view of a mold constructed with a core and inserts for construction of a three-dimensional object.
  • Fig. 4 is a perspective view of an exemplary additive manufacturing configuration in construction of a shaping cavity and a three-dimensional object therein in a wire arc deposition process.
  • FIG. 5 is a schematic view of an exemplary additive manufacturing system and configuration in the present disclosure.
  • an additive manufacturing methodology and system is configured to construct a shaping structure layer over layer and a three-dimensional object incrementally through casting in a series of shaping cavities formed during the construction of the shaping structure.
  • a liquid or semi liquid fill material is delivered into the cavity that quickly solidifies or hardens to form one or more layers of the three-dimensional object.
  • the construction process of the shaping structure and three-dimensional object continues until the object is completely built.
  • shaping structure is essentially a mold designed for shaping the three-dimensional object constructed therein without regard to its geometry details and providing benefits of enhanced geometry accuracy, dimensional tolerance and surface quality along with an increased throughput of build material and reduced cost.
  • a shaping structure can be a complete mold constructed layer over layer with formation of a series of enclosed shaping cavities to contain a liquid or semi-liquid fill material regardless of the cavities being open-top or not.
  • the layer thickness of the three-dimensional object is generally larger than that of the mold to speed up the process, but it may be appropriate to change when necessary.
  • the layer thickness of the mold and three-dimensional object can change throughout the construction process.
  • a segment of the mold can be called a“wall”, “barrier” or“enclosure” where appropriate.
  • a mold may include cores or inserts for shaping interior surfaces, cavities, channels, or complex geometries in the three-dimensional object. The difference between the cores and inserts is that the cores are generally removed in post processing, while the inserts are embedded in or joined with the three-dimensional object.
  • a mold having thin walls surrounding its geometry is called a“shell mold”, or simply a“shell”. Its principal wall thickness is a measurement across its 50% or more surface area.
  • the term“build substrate” refers to a support base such as a build plate, a build table, a structure, a component, or an already built portion of mold or three-dimensional object upon which the mold or object can be constructed or further constructed.
  • a liquid fill material refers to a molten metal or alloy, liquid resin, molten polymer, molten inorganic compound, solution, or any other inorganic or organic liquid.
  • a molten metal or alloy can be supplied from a melter or furnace in the operation using feedstock selected from ingots, bars, wires, shots, scrap metals, master alloys, or any other suitable materials that can be useful ingredients in producing the molten metal or alloy.
  • a molten metal or alloy can be deposited from a directed energy deposition device with a wire or powder feedstock by a means of electric arc fusion, laser fusion, electron beam fusion, plasma fusion, electromagnetic induction fusion, fuel combustion fusion, or any other type of energy fusion.
  • a semi-liquid material can be a molten metal or alloy containing precipitates, foreign particles, platelets, short fibers or gas bubbles, a liquid resin mixed with particles, platelets, gas bubbles, short fibers or other types of solids, a slurry, a colloidal suspension, an emulsified suspension, a liquid with bubbles, or any other type of liquid-solid or liquid-gas mixture.
  • references to“one embodiment”,“an embodiment”,“exemplary embodiments”, and the like may indicate that the embodiment(s) of the disclosure so described may include a particular feature, structure or characteristic, but not every embodiment necessarily includes the particular feature, structure or characteristic.
  • a flow chart of an exemplary process is illustrated for construction of a mold 30 and a three-dimensional object 50 therein, which can be further described by an additive manufacturing system 100 and configurations shown in Fig. 2 through Fig. 5 that are again exemplary for the present disclosure.
  • an operator will start the additive manufacturing process 200 by running a program with a job-specific file on a computer 5 for the additive manufacturing system 100, and get the process ready including settings, supplies, accessories, or support equipment.
  • the additive manufacturing process 200 can be part of a broader manufacturing process or have additional steps for production of certain types of parts or products or for support to production of assembled products, depending on the process configurations of different embodiments.
  • a mold or shell 30 can be constructed as a disposable or conjunctive one or a combination thereof for different purposes.
  • the disposable type is to be removed from the three-dimensional object 50 in post processing.
  • molds are made of a refractory material that can withstand the heat from molten metals and be stable chemically and structurally without any failure.
  • the material for a disposable mold can be selected from but not limited to alumina, silica, fused quartz, glass, limestone, feldspar, mullite, kaolin, fire clay, carbon, graphite, zircon, zirconia, chromite, olivine, cordierite, spinel, gypsum, aluminum silicate, calcium silicate, magnesium silicate, or any other suitable mineral or processed inorganic material.
  • construction of the refractory molds often requires an inorganic, organic or polymer binder to hold refractory grains or particles together and develop an adequate strength for use.
  • Such binders include but not limited to colloidal silica, ethyl silicate, sodium silicate, potassium silicate, lithium silicate, clay, lime, cement, gypsum, phosphoric acid, aluminum phosphate, magnesium phosphate, starch, dextrin, phenolic resin, novolac resin, furan resin, urea resin, acrylic resin, polyvinyl acetate, polyvinyl alcohol, polyvinyl butyral, polyester acrylate, urethane acrylate, epoxy acrylate, and styrene butadiene.
  • a conjunctive mold as an addition to the three-dimensional object can be made of a material that is the same as or different from the fill material used for construction of the three- dimensional object.
  • a shell in some embodiments, it can become a surface layer completely or partially surrounding the three-dimensional object, which can provide surface protection under hostile working conditions against wear, impact, excessive loading, oxidation, corrosion, reaction or heat exposure, or a solution for weight adjustment or cost reduction in combination of suitable shell and fill materials.
  • step 204 mold construction starts on a build substrate which can be a build plate 10, build table, structure or component to build the first shaping cavity 31 in layers corresponding to a set of cross-section geometries.
  • a suitable additive manufacturing method or a combination of methods is selected from, but not limited to material extrusion, binder jet printing, material jetting, directed energy deposition, sheet lamination, powder bed fusion, machining, and assembling or joining of mold layers or segments produced separately.
  • An embodiment employs extrusion of a slurry, paste or filament 20 to construct a mold 30 with multiple extruding devices 21, 22, 23 and 24 as shown in Fig. 2.
  • An extruder may have a slot- shaped nozzle for an increased wall thickness without sacrificing the build time.
  • Another embodiment prints a mold with a binder in a powder bed wherein a three-dimensional object is to be constructed incrementally after loose powder is removed from its shaping cavities, while in a different embodiment a section or segment of mold is printed in a separate powder bed and then transferred to the mold construction location for assembly by stacking, adhering, fastening, clamping, welding, interlocking, or other suitable means.
  • step 204 powder bed fusion, sintering or heating is adopted in some embodiments to construct shells or molds with a laser, electron beam, electric arc, radiant heat beam, or another type of energy beam which can join powder particles or sand grains together and develop the mold strength.
  • a laser, electron beam, electric arc, radiant heat beam, or another type of energy beam which can join powder particles or sand grains together and develop the mold strength.
  • an embodiment utilizes powder or sand coated or mixed with a polymer binder which is fused to adhere the particles or grains together by scanning of an energy beam in a powder bed.
  • a metal powder is sintered or fused together to produce a metal shell with laser powder bed fusion or electron beam powder bed fusion.
  • a wire-fed or powder-fed directed energy deposition approach is followed in construction of metal shells or molds with a laser, electron beam, electric arc, resistance heating, or different energy source.
  • Some of these embodiments have the shaping cavities formed by metal deposition undergo machining or surface finishing such as but not limited to milling, turning, grinding, polishing, cutting, drilling, and boring to improve the surface quality and dimensional accuracy of the molds.
  • a metal shell or mold can become a surface layer or portion of the three-dimensional object constructed therein, and it is possible to have hybrid material designs or gradient compositions by joining the shell/mold and the three- dimensional object together.
  • sheets or layers of material in a lamination approach to form shaping cavities in construction of a mold, which are cut or machined according to a set of cross-section geometries of the shaping cavities and assembled together by stacking, clamping, interlocking, adhering, fastening, or welding.
  • Such sheets or layers are made of a metal, polymer, ceramic, refractory material, inorganic material, composite, or building material including but not limited to lumber, cement board, gypsum board, fiber board, foam board, plywood and oriented strand board.
  • the mold 30 is constructed by stackingjoining or assembling an already built mold layer or segment on a build substrate that was made in a separate additive manufacturing operation.
  • the mold layer has a reasonable thickness about 1 mm at least, and is strong enough with or without a fixture holding it for transferring and assembling. After casting a layer of three-dimensional object in its cavity, another mold layer is constructed in continuation of the process in a similar or different manner.
  • step 206 can start, if necessary, to process or prepare the shaping cavity 31 to meet the requirements for its conditions, properties, dimensions or quality by a means of heating, cooling, curing, reacting, hardening, solidifying, sintering, consolidating, phase transforming, joining, shaping, machining, surface finishing, coating, impregnating, cleaning, or a combination thereof.
  • Certain embodiments require heating or cooling of the shaping cavity 31 constructed to a certain temperature range before a fill material is deposited. Machining or surface finishing is preferred in some embodiments which is selected from but not limited to milling, turning, grinding, polishing, drilling, boring and cutting to improve the dimensional accuracy or surface quality of the shaping cavity 31.
  • a core 36 is placed in a shaping cavity for forming a cavity, channel, interior surfaces, or a complex geometry in the three-dimensional object constructed, which is normally removed from the finished object or part in post processing.
  • an insert 90 or 91 can be set in a shaping cavity to be embedded in or joined with the three-dimensional object for bridging, cavity forming, channel forming, lining, coupling, hybrid material incorporation, local hardening, strengthening, temperature adjustment, thermal stress correction, weight adjustment, cost reduction or other purposes.
  • metal bridging utilizes a piece of metal plate as a build substrate across a space or cavity for metal deposition thereon, which can be secured to the base metal layer 53 or the preceding base metal layer 52 by welding.
  • An insert can be a shaped metal piece includes but no limited to a piece of tubing, bar, cylinder, arch, box, sheet metal shape, metal component, or any other metal shape.
  • a core is made of a refractory material such as but not limited to alumina, silica, fused quartz, glass, mullite, kaolin, fired clay, feldspar, chromite, olivine, cordierite, spinel, limestone, carbon, graphite, zirconia, zircon, and gypsum along with an inorganic or polymer binder such as colloidal silica, sodium silicate, potassium silicate, lithium silicate, ethyl silicate, lime, cement, gypsum, clay, phosphoric acid, aluminum phosphate, magnesium phosphate, phenolic resin, novolac resin, furan resin, urea resin, starch, dextrin, acrylic resin, polyvinyl acetate, polyvinyl alcohol, polyvinyl butyral, polyester acrylate, urethane acrylate, epoxy acrylate, and styrene butadiene.
  • a refractory material such as but not limited to alumina
  • Step 208 can start during or after step 204 or step 206, in which a dispensing device 41 delivers a liquid or semi-liquid fill material 40 in a form of droplet, continuous stream or discontinuous stream into the current shaping cavity 31 by a means of pouring, extruding, spraying, jetting, pump feeding, gravity feeding, or any other gravity-driven dispensing, pressure-driven dispensing or metering method.
  • a molten material 40 is used, the material is either melted in the dispensing device 41 equipped with a heater, or melted in a separate furnace or melter and transferred to the dispensing device 41.
  • the dispensing device 41 is capable of motion in horizontal two- dimensional (“2D”) directions or in horizontal and vertical three-dimensional (“3D”) directions.
  • the motion path, speed, material feed rate of the dispensing device 41 is programmed and optimized by the computer 5.
  • the liquid or semi-liquid fill material 40 is delivered by a directed energy deposition device using a wire or powder feedstock to fill the shaping cavity 31.
  • Fig. 4 illustrates wire arc deposition devices 45A and 45B depositing a molten metal or different molten metals 51 A and 51B in the shaping cavity 31, such that a hybrid metal part with two or more metals or alloys can be produced this way in some embodiments.
  • a metal wire of a large diameter, bar, or band can be used to increase the feedstock throughput.
  • other directed energy deposition methods can be used to deposit a liquid or semi-liquid metal in the shaping cavity for construction of a metal part.
  • step 210 the portion of the three-dimensional object 50 constructed undergoes processing or adjustment, if necessary, to meet its requirements for its conditions, properties, microstructures, dimensions or quality by a means of heating, cooling, curing, hardening, reacting, solidifying, sintering, consolidating, heat treating, phase transforming, joining, shaping, pressing, machining, surface smoothening, cleaning, or a combination thereof.
  • Machining, preferably CNC machining and surface smoothening include but not limited to milling, turning, cutting, drilling, boring, grinding, blasting, and polishing.
  • Some embodiments require heating or cooling of the portion of the three-dimensional object to a certain temperature range for its further construction, adjustment of internal thermal stresses, layer adhesion improvement, or other purposes of property or microstructure development.
  • step 208 or step 210 is carried out under a reduced atmospheric pressure or a protective or reactive atmosphere comprising argon, nitrogen, carbon dioxide, carbon monoxide, hydrogen, water vapor, ammonia, or a combination thereof to avoid material oxidation or promote a reaction such as oxide reduction.
  • a protective or reactive atmosphere comprising argon, nitrogen, carbon dioxide, carbon monoxide, hydrogen, water vapor, ammonia, or a combination thereof to avoid material oxidation or promote a reaction such as oxide reduction.
  • Step 212 directs the operation to repeat step 204 through step 210 until the construction of mold 30 and three-dimensional object 50 is completed.
  • step 212 directs the operation to repeat step 204 through step 210 until the construction of mold 30 and three-dimensional object 50 is completed.
  • a variety of combinations of additive and subtractive methods are adopted in different embodiments in order to meet the quality requirements and goals of high speed, low cost and capability to produce large or complex parts.
  • the additive manufacturing system in the present disclosure comprises a computer that is integrated, standalone or network-based of all types including but not limited to a controller, processor and mobile device, an apparatus for mold construction, and a dispensing device to deposit a fill material in a series of shaping cavities formed in the course of mold construction.
  • a controller processor and mobile device
  • an apparatus for mold construction an apparatus for mold construction
  • a dispensing device to deposit a fill material in a series of shaping cavities formed in the course of mold construction.
  • the functional tools include but not limited to software programs, controllers, simulators, devices and instruments for measuring, monitoring, analyzing, simulating, optimizing, or controlling the system functions, operating conditions, process performance and quality.
  • the operating conditions, process and physical parameters involved include but not limited to temperature, heating or cooling rate, throughput, flow rate, viscosity, composition, atmosphere, humidity, pressure, load, XYZ position, rotation angle, speed, motion path, geometry deviation, dimensional change, surface roughness, density, hardness, strength, load, pressure, thermal stress, etc.
  • Preferred embodiments have any of these conditions or parameters measured, analyzed and adjusted automatically in real time and closed-loop control.
  • the processing tools refer to those devices or machinery units for preparing, machining, or treating the molds and three-dimensional objects constructed and materials used, so as to produce finished including net-shape parts of high quality and reduce subsequent processing cycles and costs.
  • the additive manufacturing system is configured with devices, tools or machinery units for heating, cooling, curing, reacting, solidifying, sintering, consolidating, melting, phase transforming, milling, grinding, polishing, drilling, turning, cutting, pressing, transferring, assembling, welding, adhering, fastening, clamping, or cleaning, or any combination thereof.
  • the machining or surface treating process is under computer numerical control (CNC).
  • the mold construction apparatus in the additive manufacturing system of the present disclosure is configured with at least one device for additive manufacturing of a series of shaping cavities in a mold by a means of material extrusion, binder jet printing in a powder bed, material jetting, sheet lamination, powder bed fusion or directed energy deposition.
  • the mold construction apparatus comprises devices or tools for assembling mold layers or sections fabricated in separate operations in order to construct a series of shaping cavities in a mold.
  • the mold construction apparatus comprises one or more extruders operating to build the walls of the shaping cavities, preferably in fine resolutions.
  • An extruder may have a slot-shaped nozzle for an improved productivity.
  • the mold construction apparatus is configured with a binder jet printer or selective laser melting/sintering device and a powder bed to construct a mold layer by layer. When a shaping cavity is ready, a cleaning device using compressed air or vacuum removes the loose powder from the shaping cavity before it is filled to construct a layer of the three-dimensional object.
  • the dispensing device is a storage of a liquid or semidiquid material that can dispense it to fill the shaping cavities by a means of gravity-driven discharging, pumping, extruding, spraying, or any other type of mechanical or pressure-driven feeding.
  • the dispensing device has a metering capability such as gravimetric metering or volumetric metering under computer control to deliver the right amount of fill material as needed.
  • the dispensing device is equipped with a heater for melting feedstock or keeping the melt in a specified temperature range after its transfer from a separate melter. Driven by motor drives associated with a gantry-type, jib-type or robotic arm motion mechanism, the dispensing device is capable of running in horizontal 2D directions or in horizontal and vertical 3D directions, preferably with its path, speed and feed rate controlled by a computer program.
  • the dispensing device is configured with one or more directed energy deposition devices selected from but not limited to wire arc fusion, laser fusion, electron beam fusion, plasma fusion, electromagnetic induction fusion, resistance heat fusion, which uses a large-caliber feedstock of wire, shot, pellet, bar or band material to increase the deposition throughput.
  • directed energy deposition devices selected from but not limited to wire arc fusion, laser fusion, electron beam fusion, plasma fusion, electromagnetic induction fusion, resistance heat fusion, which uses a large-caliber feedstock of wire, shot, pellet, bar or band material to increase the deposition throughput.
  • Fig. 5 demonstrates an exemplary additive manufacturing system and its configuration in operation to construct a mold 30 and a three-dimensional object 50 therein layer over layer on a build plate 10.
  • a liquid or semi-liquid fill material 40 is delivered to fill the shaping cavity and forms a layer of the three-dimensional object 50.
  • a dispensing device 41 is depositing a liquid or semi-liquid fill material 40 in the current shaping cavity 33 to construct the current layer 53 of the three-dimensional object 50 over the preceding layer 52.
  • a heater 75 is provided to keep the shaping cavity 33 and the preceding metal layer 52 in an appropriate temperature range when necessary to achieve an adequate metallic bond between the metal layers 53 and 52.
  • a platen 60 comes in to apply a load P and chilling to the metal layer 53 that is solidifying or has just solidified for the purpose of decreasing the hot metal spot dimensions and thermal stresses under mechanical pressing or restriction to avoid distortion of the metal part 50.
  • the build plate 10 is configured with a heating device for raising the temperature of the“cold” zone. Additionally, packing the“cold zone” in a thermal insulation material such as fiberglass insulation, ceramic fiber insulation, foam insulation, sand or refractory granule can be adopted to reduce the local heat loss and keep the temperature distribution more uniform in the three-dimensional object 50.
  • the exemplary additive manufacturing system 100 in Fig. 5 is configured with a comprehensive temperature measurement package having temperature sensors 81, 82, 83, 84, 85 and 86, or more if necessary, in selected locations of the build plate 10, current layer 53 and preceding layer 52 of three-dimensional object 50, platen 60, mold 30, and heating device 71, respectively.
  • the temperature distribution and variation data provide feedback to the system control in real time for selective heating or cooling.
  • metal molds or parts are constructed under a reduced atmospheric pressure or vacuum.
  • a protective or reducing atmosphere is used which is selected from but not limited to argon, nitrogen, hydrogen, carbon dioxide, carbon monoxide, ammonia, water vapor, or a combination thereof.
  • the embodiments of the additive manufacturing system in the present disclosure comprise a variety of apparatus, devices or tools that require motion or rotation under control of a computer program, so that they are configured and integrated with a gantry -type mechanism, jib-type mechanism or robotic arm having different degrees of freedom for 2D or 3D motion or rotation around one or more axes.
  • Some embodiments operate with Cartesian coordinates, while others with polar coordinates for 3D positioning in construction or processing of a mold or three- dimensional object.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
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Abstract

La présente invention concerne une méthodologie et un système de fabrication additive conçus pour construire une structure de mise en forme et un objet tridimensionnel en son sein dans un processus hybride faisant appel à une variété de procédés de fabrication. La structure de mise en forme est essentiellement un moule, de préférence une coque qui est construite de manière additive pour y générer une série de cavités de mise en forme. Chaque fois qu'une cavité de mise en forme est prête, un matériau de remplissage liquide ou semi-liquide y est déposé pour couler l'objet tridimensionnel de manière incrémentielle. Le moule ou l'objet tridimensionnel peut en outre être traité pour améliorer ses propriétés, la précision dimensionnelle et la qualité de surface. Dans l'objet tridimensionnel, des compositions hybrides ou à gradient peuvent être produites et les contraintes thermiques peuvent être réduites pour éliminer la distorsion par des moyens thermiques et mécaniques.
PCT/US2019/059643 2018-11-05 2019-11-04 Coulage d'additif tridimensionnel WO2020096951A1 (fr)

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DE102020114657A1 (de) 2020-06-02 2021-12-02 HS 3D Performance GmbH Verfahren zur Reparatur oder Modifikation einer modularen Betonsteinform
CN113941832A (zh) * 2021-09-30 2022-01-18 江苏烁石焊接科技有限公司 一种异质异构厚壁件封边式高效增材方法
CN113953625A (zh) * 2021-11-05 2022-01-21 上海和达汽车配件有限公司 一种控制cmt电弧增材制造熔池流动的装置和方法
FR3123234A1 (fr) * 2021-05-25 2022-12-02 Institut De Recherche Technologique Jules Verne procédé de fabrication additive d’une pièce tridimensionnelle
DE102021122727A1 (de) 2021-09-02 2023-03-02 Bayerische Motoren Werke Aktiengesellschaft Vorrichtung zum additiven Fertigen eines Kraftfahrzeugbauteils
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EP4227027A1 (fr) 2022-02-09 2023-08-16 Fundación Tekniker Production d'une couche additive de moules
EP4374990A1 (fr) * 2022-10-31 2024-05-29 UniTech3DP Inc. Appareil d'impression tridimensionnelle
EP4420852A1 (fr) 2023-02-21 2024-08-28 Embraer S.A. Structures d'outillage hybrides en thermoplastiques fabriqués de manière additive renforcés par des supports métalliques rigides et leurs procédés de conception et de fabrication

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Publication number Priority date Publication date Assignee Title
DE102020114657A1 (de) 2020-06-02 2021-12-02 HS 3D Performance GmbH Verfahren zur Reparatur oder Modifikation einer modularen Betonsteinform
CN113305301A (zh) * 2021-05-18 2021-08-27 北京工业大学 一种基于熔化沉积与半固态搅拌的复合制造设备及方法
FR3123234A1 (fr) * 2021-05-25 2022-12-02 Institut De Recherche Technologique Jules Verne procédé de fabrication additive d’une pièce tridimensionnelle
DE102021122727A1 (de) 2021-09-02 2023-03-02 Bayerische Motoren Werke Aktiengesellschaft Vorrichtung zum additiven Fertigen eines Kraftfahrzeugbauteils
CN113941832A (zh) * 2021-09-30 2022-01-18 江苏烁石焊接科技有限公司 一种异质异构厚壁件封边式高效增材方法
CN113953625A (zh) * 2021-11-05 2022-01-21 上海和达汽车配件有限公司 一种控制cmt电弧增材制造熔池流动的装置和方法
EP4227027A1 (fr) 2022-02-09 2023-08-16 Fundación Tekniker Production d'une couche additive de moules
EP4374990A1 (fr) * 2022-10-31 2024-05-29 UniTech3DP Inc. Appareil d'impression tridimensionnelle
EP4420852A1 (fr) 2023-02-21 2024-08-28 Embraer S.A. Structures d'outillage hybrides en thermoplastiques fabriqués de manière additive renforcés par des supports métalliques rigides et leurs procédés de conception et de fabrication
CN116038349A (zh) * 2023-03-01 2023-05-02 四川航天长征装备制造有限公司 一种电弧增材制造筋宽筋高稳定成形装置与方法

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