WO2020173519A1 - Procédé de construction en couches et dispositif de construction en couches pour la fabrication additive d'au moins une zone d'élément structural d'un élément structural, ainsi que produit de programme informatique et support de stockage - Google Patents

Procédé de construction en couches et dispositif de construction en couches pour la fabrication additive d'au moins une zone d'élément structural d'un élément structural, ainsi que produit de programme informatique et support de stockage Download PDF

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Publication number
WO2020173519A1
WO2020173519A1 PCT/DE2020/000034 DE2020000034W WO2020173519A1 WO 2020173519 A1 WO2020173519 A1 WO 2020173519A1 DE 2020000034 W DE2020000034 W DE 2020000034W WO 2020173519 A1 WO2020173519 A1 WO 2020173519A1
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WO
WIPO (PCT)
Prior art keywords
component
layer
layer construction
parameter value
exposure parameter
Prior art date
Application number
PCT/DE2020/000034
Other languages
German (de)
English (en)
Inventor
Alexander Ladewig
Sebastian Rott
Katrin Friedberger
Steffen Schlothauer
Original Assignee
MTU Aero Engines AG
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Filing date
Publication date
Application filed by MTU Aero Engines AG filed Critical MTU Aero Engines AG
Publication of WO2020173519A1 publication Critical patent/WO2020173519A1/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
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • 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
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • 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
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • 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
    • 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
    • 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 invention relates to a layer construction method and a layer construction device for the additive production of at least one component region of a component.
  • the invention further relates to a computer program product, a computer-readable storage medium and a component with at least one additively manufactured component area.
  • Additive layer construction processes describe processes in which geometric data are determined based on a virtual model of a component or component area to be manufactured, which is broken down into layer data (so-called "slicing"). Depending on the geometry of the model, an exposure or irradiation strategy is determined according to which the selective solidification of a material is to take place. In the layer construction process, the desired material is then deposited in layers and selectively scanned and solidified by means of the at least one energy beam in order to additively build up the desired component area. Various irradiation parameters such as the energy beam power and the exposure speed of an energy beam to be used for solidification are important for the resulting microstructure. The arrangement of so-called scan lines is also important.
  • the scan lines which can also be referred to as melting traces or exposure vectors, define the paths along which the at least one energy beam scans and melts the material and can generally run linearly or non-linearly.
  • additive or generative manufacturing processes differ from conventional abrasive or primary forming manufacturing methods.
  • additive manufacturing processes are generative laser sintering or laser melting processes, which can be used, for example, to manufacture components for turbomachines such as aircraft engines.
  • selective laser melting thin powder layers of the material or the materials used are applied to a building platform and melted and solidified locally with the aid of one or more laser beams in the area of a build-up and joining zone.
  • the construction platform is then lowered, another layer of powder applied and locally strengthened again. This cycle is repeated until the finished component or the finished component area is obtained.
  • the component can then be further processed if necessary or without further
  • Confirmation copy re processing steps are used.
  • the component is produced in a similar way by laser-assisted sintering of powdery materials.
  • the energy is supplied here, for example, by laser beams from a CC laser, Nd: YAG laser, Yb fiber laser, diode laser or the like.
  • Electron beam processes are also known in which the material is selectively scanned and solidified by one or more electron beams.
  • a disadvantage of the known layered construction method is the fact that components manufactured with them often have a comparatively high structural anisotropy, which can lead to different mechanical properties depending on the direction. This in turn can lead to reduced strengths and stiffnesses, which have to be taken into account and compensated for in the component design.
  • the object of the present invention is to improve a layer construction method and a layer construction device of the type mentioned at the outset in such a way that it is possible to manufacture components or component areas with more uniform mechanical properties in different spatial directions.
  • Further objects of the invention consist in specifying a computer program product and a computer-readable storage medium which enable a corresponding control of such a layer construction device.
  • a first aspect of the invention relates to a layered construction method for the additive manufacture of at least one component region of a component, in particular a component of a flow machine, comprising at least the following steps:
  • the at least one exposure parameter value can thus be set as a function of the reference false color values, whereby information from the optical tomography of the reference component area and additionally or alternatively the reference component can be used to determine the at least set an exposure parameter value.
  • zones of the reference component area or of the reference component that are produced during the additive manufacturing and heated to different degrees can be detected.
  • Optical tomography makes it possible, for example, to differentiate between warm and cold zones of the differently heated zones.
  • the intensity maxima can characterize the warmest zones. Accordingly, an uppermost intensity maximum of the intensity maxima can characterize the warmest zone.
  • the invention is based on the knowledge that the warm and cold zones can also be assigned different reference structural structures, that is to say, structural structures of the reference component area and additionally or alternatively of the reference component.
  • a warm zone can arise, for example, through longer exposure to energy beams, which can for example take place through laser irradiation, whereas a In comparison, the cold zone can arise due to a correspondingly shorter application of the energy beam.
  • the duration of the application of the energy beam can, however, have a decisive influence on the reference microstructure, so that larger material grains and greater structural anisotropy can occur with longer exposure to the energy beam (and correspondingly warm zone) than with shorter exposure to the energy beam (cold zone).
  • information about the respective reference microstructure dependent on the corresponding zones can also flow into the setting of the at least one exposure parameter value of the energy beam via the reference false color values.
  • This makes it possible, for example, to avoid larger temperature differences caused by the energy beam at mutually different points in the component area, which means that, for example, differences in structure anisotropy between the various points can be kept low and the component area can accordingly be created with more uniform mechanical properties in different spatial directions, as, for example, the reference component area.
  • the reference false color values can be designed as reference gray values, for example.
  • the reference false color values can be used to identify, for example, respective defects and thus defective structural areas of the reference component area and additionally or alternatively of the reference component. These defects (defective structural areas) can be present in several layers of the reference component area or the reference component and can be detected on the basis of the reference false color values.
  • the present layer construction method by setting the at least one exposure parameter value as a function of the reference monitoring data set, it can be avoided that the respective defects occurring in the reference component area or reference component also occur in the component area or the component. This also contributes in an advantageous manner to the design of the component area or the component with more uniform mechanical properties in different spatial directions compared to the reference component area or the reference component.
  • the at least one reference monitoring data set characterizes a reference structural structure distribution at least in the reference component area and at least one reference exposure parameter value assigned to the reference structural structure distribution.
  • the reference exposure parameter value can correspond, for example, to a reference energy input into the reference component area as a result of the application of an energy beam or an energy beam output, that is to say an energy beam output.
  • the reference exposure parameter value can correspond, for example, to a reference energy input into the reference component area as a result of the application of an energy beam or an energy beam output, that is to say an energy beam output.
  • At least one correction value is determined by which the at least one exposure parameter value is set differently from the at least one reference exposure parameter value, whereby at least the component area with a structure distribution is provided which has a lower defect density and / or a lower number of defects than the reference structure distribution.
  • the exposure parameter value can differ from the reference exposure parameter value by the correction value.
  • an energy input of the at least one energy beam is set as the at least one exposure parameter value. This is advantageous because by adjusting the energy input a particularly direct influencing of a microstructure in the component layer and thus in the component area of the component can take place.
  • the energy input can have the unit J / mm 3 and thus indicate an input of energy per unit volume.
  • a monitoring data set based on optical tomography of at least the component layer is created, which is compared with the reference monitoring data set to monitor the additive manufacturing of at least the component area.
  • the monitoring data set can include false color values recorded by optical tomography during the additive manufacturing of at least the component area. The monitoring can take place in that the false color values are compared with the reference false color values. This makes it possible to recognize if, for example, one of the false color values deviates by an impermissibly large amount from a corresponding reference false color value, which can indicate the presence of pores, cracks or other defects.
  • the false color values can be embodied as gray values, for example.
  • respective defects and thus defective structural areas of the component area and additionally or alternatively of the component can be recognized at an early stage.
  • These defects (defective structural areas) can be present in several component layers of the component area or the component and can be recognized on the basis of the false color values, in particular by comparing the false color values with the reference false color values.
  • a preferred, layer-by-layer comparison of the false color values with the reference false color values advantageously enables a particularly early and particularly precise assessment of whether, for example, rejects are produced during the manufacture of the component area or the component.
  • a layer-by-layer change in the at least one exposure parameter value can be made take place so that the exposure parameter value is set differently, so to speak, in different component layers of the component area.
  • a laser beam is used as the energy beam in step c). This is advantageous since the laser beam enables particularly targeted local solidification of the material.
  • At least one material from the group of steel, aluminum alloys, titanium alloys, cobalt-based alloys, chrome-based alloys, nickel-based alloys, copper alloys, intermetallic alloys or any mixture thereof is used as the material.
  • the material can in principle also be a plastic such as ABS, PLA, PETG, nylon, PET, PTFE or the like, components or component areas with higher mechanical, thermal and chemical loading can generally be used with the help of metallic and / or intermetallic materials to be established.
  • the material can contain elements from the iron, titanium, nickel, chromium, cobalt, copper, aluminum or titanium group.
  • the material can be an alloy from the group consisting of steel, aluminum alloy, titanium alloy, cobalt alloy, chromium alloy, nickel-based alloy or copper alloys.
  • the material can be a high temperature-resistant nickel-based alloy such as Mar M-247, Inconel 718 (IN718), Inconel 738 (IN738), Waspaloy or C263.
  • Intermetallic alloys such as Mg2Si and titanium aluminides can also be provided.
  • a second aspect of the invention relates to a layer construction device for the additive production of at least one component region of a component by an additive layer construction method, comprising:
  • At least one powder feed for applying at least one powder layer of a material to at least one build-up and joining zone of at least one movable
  • Build platform At least one radiation source for generating at least one energy beam for layer-by-layer and local solidification of the material by selective scanning and melting of the material along scan lines; and
  • control device which is designed to:
  • the control device is set up to control the radiation source and thereby set at least one exposure parameter value of the energy beam as a function of at least one reference monitoring data set, the at least one reference monitoring data set being based on at least one reference component area by optical tomography of a reference component is based on reference false color values detected during its additive production and characterizes local intensity maxima of the reference false color values, the control device being set up to set the at least one exposure parameter value of the energy beam as a function of at least one of the local intensity maxima.
  • the layer construction device can for example comprise a camera, in particular a thermal imaging camera, by means of which the reference false color values of the reference component region of the reference component can be recorded.
  • the layer construction device is designed as a selective laser sintering and / or melting device.
  • component areas and complete components can be produced whose mechanical properties are at least essentially direction-independent.
  • CO2 lasers, Nd: YAG lasers, Yb fiber lasers, diode lasers or the like can be provided to generate a laser beam as the energy beam. It can also be provided that two or more electron and / or laser beams are used as the respective energy beams.
  • a third aspect of the invention relates to a computer program product, comprising instructions which, when the computer program product is executed by a control device of a layer construction device according to the second aspect of the invention, cause the layer construction device to execute the layer construction method according to the first aspect of the invention.
  • a fourth aspect of the invention relates to a computer-readable storage medium comprising instructions which, when executed by a control device of a layer construction device according to the second aspect of the invention, cause the layer construction device to carry out the layer construction method according to the first aspect of the invention.
  • a computer-usable or computer-readable medium can be any device that can contain, store, communicate, disseminate, or transport the computer program product for use by or in connection with the instruction execution system or layered device.
  • the medium can be an electronic, magnetic, optical, electromagnetic, infrared or semiconductor system or a propagation medium per se, since signal carriers are not included in the definition of the physical, computer-readable medium.
  • Solid-state or solid-state memory include solid-state or solid-state memory, magnetic tape, a removable computer disk, direct access memory (RAM), read-only memory (ROM), rigid magnetic disk, and an optical disk such as read-only memory (CD-ROM, DVD, Blue-Ray etc.), or a writable optical disc (CD-R, DVD-R).
  • RAM direct access memory
  • ROM read-only memory
  • rigid magnetic disk and an optical disk such as read-only memory (CD-ROM, DVD, Blue-Ray etc.), or a writable optical disc (CD-R, DVD-R).
  • CD-ROM read-only memory
  • DVD-R writable optical disc
  • Processors as well as program code for implementing the various aspects of the invention can be centralized or distributed (or a combination thereof).
  • a fifth aspect of the invention relates to a component, in particular a turbine component of a turbomachine, comprising at least one component area which is produced by means of a layer construction device according to the second aspect of the invention and / or by means of a layer construction method according to the first aspect of the invention.
  • the component according to the invention has a highly uniform and at least essentially direction-independent joint structure, which leads to a significantly higher resistance to cyclic loads as well leads to significantly increased strength and stiffness values.
  • the features resulting therefrom and their advantages can be found in the descriptions of the first and second aspects of the invention, with advantageous configurations of each aspect of the invention being regarded as advantageous configurations of the other aspects of the invention.
  • the component can be designed as a turbine blade for a gas turbine, in particular for an aircraft engine.
  • FIG. 1 shows a schematic sectional view of a layer construction device
  • FIG. 2 shows a schematic representation of a layer surface of a reference component region of a reference component during its additive production, with reference false color values of the layer surface determined by optical tomography being shown;
  • FIG. 3 shows a schematic representation of a layer surface of a component region of a component during its additive production, with false color values of the layer surface determined by optical tomography being shown;
  • FIG. 4 shows a schematic detailed view of a surface segment within an area A framed by in FIG. 2;
  • FIG. 5 shows a schematic detailed view of a further surface segment within a region B framed in FIG. 2;
  • Fig. 7 shows a further micrograph showing a further reference microstructure of the reference component area.
  • FIG. 1 shows a schematic sectional view of a layer construction device 10.
  • the layer construction device 10 is used for the additive manufacture of at least one component region 12 of a component 14 by an additive layer construction method.
  • the layer construction device 10 comprises at least one powder feed 16 with a powder container 18 and a coater 20.
  • the powder feed 16 is used to apply at least one powder layer of a material 22 to a construction and joining zone II of a construction platform 24 that can be moved according to arrow B.
  • the coater 20 moved according to arrow III in order to transport material 22 from the powder container 18 to the building and joining zone II.
  • the layer construction device 10 further comprises at least one radiation source 26 for generating at least one energy beam 28, for example in the form of a laser beam, for layer-wise and local solidification of the material 22 by the material 22 with the energy beam 28 along in Fig. 2 and 3 schematically indicated scan lines 40 is selectively scanned and melted.
  • a control device 30 is provided, which is designed to control the powder feed 16 so that it applies at least one powder layer of the material 22 to the building and joining zone II of the building platform 24 and the building platform 24 in layers by a predefined layer thickness according to the arrow B lowers.
  • the layer construction device 10 comprises an optical specific device 32, by means of which the energy beam 28 can be moved over the build-up and joining zone II.
  • the radiation source 26 and the device 32 are coupled to the control device 30 for data exchange.
  • the layer construction device 10 comprises a heating device 34, by means of which the powder bed can be heated to a desired base temperature.
  • the heating device 34 can, for example, have one or more induction coil (s) include. Alternatively or additionally, other heating elements, for example IR radiators or the like, can also be provided.
  • the control device 30 is set up to control the radiation source 26 and thereby set at least one exposure parameter value of the energy beam 28 as a function of at least one reference monitoring data set 50.
  • the reference monitoring data set 50 is based on reference false color values 64 recorded by optical tomography of at least one reference component region 60 of a reference component 62 during its additive production, as can be seen in FIG.
  • the reference monitoring data set 50 characterizes local intensity maxima 66 of the reference false color values 64.
  • the control device 30 is also set up to set the at least one exposure parameter value of the energy beam 28 as a function of at least one of the local intensity maxima 66.
  • the reference monitoring data record 50 can be stored in a memory of the control device 30 and thus made available for the additive production of the component area 12 of the component 14 by the additive layer construction method.
  • the reference component region 60 and the component region 12 can preferably be congruent to one another. Accordingly, the reference component 62 and the component 14 can also be congruent to one another.
  • the layer construction device 10 in the present case comprises a camera 36, in particular a thermal imaging camera, by means of which the reference false color values 64 can be recorded.
  • the camera 36 is coupled to the control device 30 for data exchange.
  • FIG. 2 shows a schematic representation of a layer surface of the reference component region 60 and thus at least a section of the reference component 62 during its additive production using the layer construction device 10.
  • the reference false color values determined using the camera 36 by optical thermography are shown in FIG 64 and the various local intensity maxima 66 of the reference false color values 64 can be seen.
  • the reference monitoring data set 50 characterizes a reference structure distribution in the entire reference component 62 and in the reference component area 60.
  • the reference monitoring data set 50 characterizes at least one reference exposure parameter value assigned to the reference structure distribution.
  • the reference exposure parameter value can for example correspond to an energy input, which can be caused by the energy beam 28 to produce the reference component 62 from the material 22 during the additive production of the reference component 62.
  • the energy input can also be referred to as energy input.
  • the energy can be introduced as a function of location and additionally or alternatively as a function of the geometry.
  • the control device 30 is also set up to determine at least one correction value as a function of the reference structure distribution and the at least one reference exposure parameter value.
  • the at least one exposure parameter value is then set to differ by the at least one correction value from the at least one reference exposure parameter value, whereby at least the component region 12 is provided with a structure distribution which has a lower defect density and / or a lower number of defects than the reference structure distribution.
  • FIG. 3 shows, in a schematic representation, the layer surface of the component region 12 and thus at least a section of the component 14 during its additive manufacture by the layer construction method.
  • Fig. 3 also respective false color values 74 determined by means of the camera 36 by optical thermography can be seen.
  • the false color values 74 are also recorded and stored in layers with the aid of the camera 36.
  • the monitoring data record 70 is created, which is compared with the reference monitoring data record 50 for monitoring the additive manufacturing of at least the component region 12.
  • the monitoring data record 70 is stored in the memory of the control device 30.
  • FIG. 4 and 5 each show schematic detailed views of different surface segments of the reference component area 60.
  • FIG. 4 shows an enlarged illustration of an area A outlined in FIG. 2
  • FIG. 5 shows an enlarged illustration of an area B outlined in FIG .
  • area A during additive manufacturing, a greater amount of energy was introduced using the energy beam 28, with one of the intensity maxima 66 increasing in area A recognize is. Accordingly, a greater number of defects 76 (number of defects) in the form of pores and cracks and a greater density of defects 76 (defect density) can be seen in area A than in area B, as can be seen from a synopsis of FIGS. 4 and 5 .
  • FIG. 6 shows a micrograph of the region B shown in FIG. 5, whereas FIG. 7 shows a further micrograph of the region A shown in FIG.
  • the representations shown in FIG. 6 and FIG. 7 can be obtained, for example, by electron backscattering (EBSD).
  • EBSD electron backscattering
  • the present layer construction method or the present layer construction device 10 enables an effective estimation of an expected defect distribution in the form of a defect frequency and defect size or the defect density and additionally or alternatively the number of defects depending on the component geometry using the determined reference false color values 64 or false color values 74 , which can be, for example, respective gray values.
  • Optical tomography can use the reference false color values 64 or
  • False color values 74 a respective evaluation of an orientation and distribution of material grains of medium and maximum size take place.
  • a heat balance in the component 14 or in the component area 12 influenced by the melting using the energy beam 28 can also be optimized.
  • Optical tomography makes it possible to identify respective partial areas on the basis of the reference false color values 64 or false color values 74, in which different temperatures prevail.
  • the optical tomography can, for example, take into account heat conduction conditions in the component area 12 or in the reference component area 60 due to the respective component geometry and thus avoid unwanted changes in influencing variables such as a scan vector length and a track overlap. As a result, undesired, essential changes in the respective reference microstructure or microstructure and associated changes in the material properties (static and cyclic strength, defect density) of the melted material 22 can be avoided.
  • the layer construction method or the layer construction device 10 make it possible to use the local intensity maxima 66 in order to set the heat balance in a targeted manner.
  • a reference false color mean value can also be formed from the reference false color values 64 in order to keep the additive manufacturing of the component region 12 or the component 14 based on the reference false color mean value, which can be designed as a gray value position mean value, layer by layer.
  • a correlation between the local intensity maxima 66 of the reference false color values 64 and the material properties of the material 22 and the defect distribution can be used to additively produce the component region 12 or the component 14.
  • the reference component area 60 or the reference component 62 can initially be built up with a constant reference exposure parameter value of the energy beam 28 and recorded by optical tomography, whereby the reference false color values 64 can be recorded in layers, for example as reference gray values.
  • a normalization and adjustment of the recorded reference false color values 64 to a defined reference target value can be an input variable for calculating a parameter related to the component geometry of the component region 12 or the component 14 be in the form of the at least one exposure parameter value which, as the target, provides a more uniform microstructure and defect distribution in the component region 12 or in the component 14.
  • the at least one exposure parameter value for the additive manufacture of the component area 12 or the component 14 can be set in this way that the energy input during the production of the component region 12 or the component 14 is reduced by 20% compared to the additive production of the reference component region 60 or the reference component 62.
  • the analysis of the local reference false color values 64 (for example the local reference gray values) enables a local and thus location-dependent evaluation of the heat balance and the resulting material properties in the reference component 62 or the component 14.
  • the analysis of the local reference false color values 64 can be carried out as Input variable can be used for the structural geometry-dependent adaptation of the exposure parameter value.
  • Input variable By means of a three-dimensional analysis of a reference image stack composed of respective individual layers of the reference component region 60 or the reference component 62, particularly relevant regions for a destructive test can be identified.
  • the possibility of monitoring the reference false color values 64 can also be used to secure parameters for specific structural settings with specific mechanical properties.

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

L'invention concerne un procédé de construction en couches pour la fabrication additive d'au moins une zone d'élément structural (12) d'un élément structural (14), notamment un élément structural (14) d'une turbomachine. Le procédé de construction en couches comprend au moins les étapes suivantes : a) fourniture d'au moins un jeu de données de surveillance de référence (50), lequel se base sur des valeurs de fausses couleurs de référence (64) acquises par tomographie optique d'au moins une zone d'élément structural de référence (60) d'un élément structural de référence (62) pendant sa fabrication additive et caractérise des maxima d'intensité locaux (66) des valeurs de fausses couleurs de référence (64), b) application d'au moins une couche de poudre d'un matériau (22) sur au moins une zone de construction et de liaison (II) d'au moins une plate-forme de construction mobile (24), c) solidification locale du matériau (22) en vue de former une couche d'élément structural en balayant et en faisant fondre sélectivement le matériau (22) avec au moins un faisceau d'énergie (28) le long de lignes de balayage (40), au moins une valeur de paramètre d'éclairement du faisceau d'énergie (28) étant réglée en fonction dudit jeu de données de surveillance de référence (50) et ainsi réglée en fonction d'au moins l'un des maxima d'intensité locaux (66), d) abaissement couche par couche de la plate-forme de construction (24) d'une épaisseur de couche prédéfinie, et e) répétition des étapes b) à d) jusqu'à ce que la zone d'élément structural (12) soit terminée. L'invention concerne en outre un dispositif de construction en couches (10) pour la fabrication additive d'au moins une zone d'élément structural (12) d'un élément structural (14), un produit de programme informatique, un support de stockage lisible par ordinateur ainsi qu'un élément structural (14) comportant au moins une zone d'élément structural (12) fabriquée par procédé additif.
PCT/DE2020/000034 2019-02-26 2020-02-24 Procédé de construction en couches et dispositif de construction en couches pour la fabrication additive d'au moins une zone d'élément structural d'un élément structural, ainsi que produit de programme informatique et support de stockage WO2020173519A1 (fr)

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DE102019001349.2 2019-02-26
DE102019001349 2019-02-26
DE102019219327.7A DE102019219327A1 (de) 2019-02-26 2019-12-11 Schichtbauverfahren und Schichtbauvorrichtung zum additiven Herstellen zumindest eines Bauteilbereichs eines Bauteils sowie Computerprogrammprodukt und Speichermedium
DE102019219327.7 2019-12-11

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