WO2021018329A1 - Procédé et dispositif de construction en couches pour la fabrication additive d'au moins un segment d'élément structural d'un élément structural, ainsi que produit-programme informatique et support de stockage - Google Patents

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

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Publication number
WO2021018329A1
WO2021018329A1 PCT/DE2020/000165 DE2020000165W WO2021018329A1 WO 2021018329 A1 WO2021018329 A1 WO 2021018329A1 DE 2020000165 W DE2020000165 W DE 2020000165W WO 2021018329 A1 WO2021018329 A1 WO 2021018329A1
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WIPO (PCT)
Prior art keywords
component
energy beam
segment
surface roughness
relative angle
Prior art date
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PCT/DE2020/000165
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German (de)
English (en)
Inventor
Sebastian Rott
Katrin Friedberger
Karl-Heinz Dusel
Alexander Ladewig
Christian Liebl
Steffen Schlothauer
Johannes Casper
Original Assignee
MTU Aero Engines AG
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Application filed by MTU Aero Engines AG filed Critical MTU Aero Engines AG
Publication of WO2021018329A1 publication Critical patent/WO2021018329A1/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
    • 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
    • B22F12/37—Rotatable
    • 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
    • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • 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
    • B22F12/33—Platforms or substrates translatory in the deposition plane
    • 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
    • B22F12/40—Radiation means
    • B22F12/46—Radiation means with translatory movement
    • B22F12/47—Radiation means with translatory movement parallel to the deposition plane
    • 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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • 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
    • B22F12/40—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
    • 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
    • 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

  • Method and layer construction device for the additive manufacture of at least one component segment of a component as well as computer program product and storage medium
  • the invention relates to a method and a layer construction device for the additive manufacture of at least one component segment of a component. Further aspects of the invention relate to a computer program product, a computer-readable storage medium and a component.
  • a powdery material is usually deposited in layers and selectively solidified by means of at least one energy beam in order to additively build up a desired component segment.
  • Such a process which can also be referred to as an additive or generative manufacturing process, thus differs from conventional abrasive or primary forming manufacturing methods.
  • Examples of the process for additive manufacturing are generative laser sintering or laser melting processes, which can be used, for example, to manufacture components for turbo machines such as aircraft engines. With selective laser melting, thin powder layers of the material or materials used can be 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 can be lowered, another layer of powder applied and locally solidified again. This cycle can be repeated until the finished component or the finished component segment is obtained.
  • the component or component segment can then be processed further if necessary or used without further processing steps.
  • selective laser sintering the component or component segment is produced in a similar manner 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 solidified by one or more electron beams.
  • the object of the present invention is to create a method and a layered construction device of the type mentioned at the outset, by means of which at least one component segment of a component can be manufactured with little effort with at least locally improved quality. Further tasks
  • CONFIRMATION COPY The invention consists in specifying a computer program product and a computer-readable storage medium which enable such a layered construction device to be controlled. Finally, it is the object of the invention to specify a component with at least one component segment having an improved quality.
  • a first aspect of the invention relates to a method for the additive manufacture of at least one component segment of at least one component, in particular for a turbo machine, comprising at least the following steps:
  • the relative angle between the energy beam and the surface normal of the segment surface at the point of impact represents a setting variable that can be controlled and set with little effort, whereby the method can be used, for example, with high reproducibility of the target surface roughness, for example in mass production of the component.
  • the invention is based on the knowledge that the nominal surface roughness is directly proportional to the relative angle between the energy beam and the surface normal, whereby a specific angular value or angular amount of the relative angle can be assigned to a specific roughness value of the nominal surface roughness.
  • the target surface roughness can be generated in a targeted manner as a function of the relative angle.
  • the target surface roughness can also be generated in a predetermined manner without complex regulation of an irradiation duration and additionally or alternatively a radiation intensity of the energy beam.
  • the method enables, in particular, the targeted generation of the target surface roughness without varying the duration of the irradiation and additionally or alternatively the radiation intensity of the energy beam.
  • the predetermined target surface roughness can be generated as a function of the setting of the relative angle without changing the radiation intensity and / or the irradiation time of the energy beam.
  • step b) a translational and / or rotary relative movement is carried out between the at least one energy beam and the at least one building platform in order to direct the energy beam onto a second point of impact different from the point of impact, one of the predetermined target surface roughness different, second predetermined target surface roughness at least the segment surface is generated by a, the second surface roughness associated, second relative angle between the energy beam and a, the second point of impact of the energy beam on the material associated second surface normal of the Segment surface is set.
  • This is advantageous because it allows the second target surface roughness, which is different from the target surface roughness, to be set in a targeted manner at the second point of impact of the energy beam.
  • the further steps take place: c) lowering the at least one building platform layer by layer and d) repeating steps a) to c).
  • This advantageously enables a successive, layered build-up of the component segment or the component, the target surface roughness being able to be generated during the build-up and without complex post-processing of the component segment or the component. As a result, time can be saved when manufacturing the component.
  • a laser beam or an electron beam is used as the energy beam.
  • the component segment or the entire component can be produced, with its mechanical properties being able to correspond at least essentially to those of the material.
  • the relative angle is set in that a radiation source emitting the energy beam is moved translationally and / or rotationally relative to the at least one building platform.
  • the radiation source can be, for example, a CO2 laser, Nd: YAG laser, Yb fiber laser, diode laser or the like.
  • the relative angle is set by moving the at least one building platform translationally and / or rotationally relative to the at least one energy beam. This is advantageous, since it gives increased flexibility when setting the relative angle.
  • the building platform can be inclined, for example, in order to set the relative angle. By tilting the construction platform, an angle of inclination of the component can be set relative to the energy beam and, additionally or alternatively, relative to a radiation source emitting the energy beam.
  • the powder layer is irradiated according to step b) by means of at least two energy beams, the energy beams each being emitted by means of an assigned radiation source and with different predetermined target surface roughness between a relative angle assigned to the respective energy beam the respective energy beam and the respective The point of impact of the energy beam on the surface normal assigned to the material of the segment surface is set.
  • the at least two energy beams are used to produce different nominal surface roughness of a component or to produce different nominal surface roughness of at least two different components. This means that the process can also be used with so-called "multi-laser systems".
  • a component with different nominal surface roughness can be produced with several lasers or different components with different nominal surface roughness can be produced on a construction platform with an assigned laser.
  • the construction time of a single component or a number of different components can be reduced overall.
  • the assigned relative angle of which has a smaller relative deviation from a predetermined relative angle in order to achieve a predetermined target surface roughness is also leads to a shortening of the construction times, since the setting times of the individual radiation sources can be shortened with regard to their angle of incidence.
  • a minimum roughness value of the target surface roughness is generated by minimizing the relative angle. This is advantageous because the segment surface can thus be made smoother the smaller the relative angle between the energy beam and the surface normal is set. In addition, the target surface roughness can become greater the greater the relative angle is set.
  • a second aspect of the invention relates to a layer construction device for the additive production of at least one component segment of at least one component, in particular for a fluid flow machine, comprising:
  • At least one movable building platform which has a build-up and joining zone which is designed to hold at least one powder layer of a material that can be applied to the build-up and joining zone;
  • At least one radiation source for generating at least one energy beam for at least partially solidifying the powder layer while forming the at least one component segment
  • -at least one movement device which is set up to move the energy beam and / or the building platform
  • At least one control device which is designed to control the movement device for moving the energy beam and / or the construction platform.
  • control device is configured to control the movement device in such a way that a relative angle between the energy beam and a surface normal of a segment surface of the component segment assigned to a point of impact of the energy beam on the material is set to a predetermined target surface roughness to generate the at least one segment surface of the at least one component segment, the relative angle being assigned to the target surface roughness.
  • the layer construction device can in particular be set up to carry out a method according to the first aspect of the invention.
  • the layer construction device is designed as a selective laser sintering and / or melting device.
  • component segments and complete components can be produced whose mechanical properties at least essentially correspond to those of the material.
  • CO2 lasers, Nd: YAG lasers, Yb fiber lasers, diode lasers or the like can be provided as the radiation source to generate a laser beam. It can also be provided that two or more electron and / or laser beams are used, the exposure or solidification parameters of which can be varied.
  • the layered construction device can have at least two radiation sources for generating at least two energy beams for at least partially solidifying the powder layer with the formation of at least two component segments with different target surface roughness of a component or with the formation of at least two components with different target values - Include surface roughness.
  • This embodiment of the invention is advantageously a so-called "multi-laser system".
  • a component with different nominal surface roughness can be produced with several lasers or different components with different nominal surface roughness can be produced on a construction platform with an assigned laser. This advantageously increases the possible areas of application of the inventive layer construction device.
  • the construction time of a single component or several different components can be reduced overall.
  • 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 carry out the 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 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, distribute, or transport the computer program product for use by or in connection with the instruction execution system, device, or 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.
  • a fifth aspect of the invention relates to a component, in particular for a turbomachine, comprising at least one component segment, which by means of a layer construction device according to the second aspect of the invention and / or by means of a method according to the first aspect of the invention.
  • FIG. 1 shows a schematic perspective view of a layer construction device, by means of which a component is produced by a method for additive manufacturing, an energy beam impinging on an impact point;
  • FIG. 2 shows a schematic side view of the layer construction device, the energy beam impinging on the point of impact parallel to an x-z plane;
  • FIG. 3 shows a further schematic side view of the layered construction device, the energy beam impinging on a second point of impact in parallel to the x-z plane;
  • FIG. 4 shows a schematic side view of the layer construction device according to a second embodiment.
  • FIG. 1, FIG. 2, FIG. 3 and FIG. 4 each show a schematic representation of a layer construction device 50 for the additive production of at least one component segment 12 of a component 10.
  • the component 10 can be used for a turbo-engine, in particular a jet engine.
  • the layer construction device 50 is embodied in the present case as a selective laser sintering and / or melting device.
  • FIG. 1 In FIG. 1, FIG. 2, FIG. 3 and FIG. 4, coordinate systems related to the component 10 are specified, which are defined by an axis x, by an axis y and by an axis z of the component 10.
  • the layer building device 50 comprises a movable building platform 70 which has a building and joining zone 60.
  • the build-up and joining zone 60 is designed to hold a powder layer 20 of a material 22 applied to the build-up and joining zone 60.
  • a nickel-based alloy with the short name NiCrl 9NbMo, for example, can be used as the powdery material 22, which can have the following composition:
  • Individual particles formed from this material 22 can have a spherical basic shape and a diameter between 15 mm and 45 mm.
  • the layer construction device 50 also includes a radiation source SQ for generating an energy beam 80 for at least partially solidifying the powder layer 20 while forming the component segment 12.
  • a radiation source SQ for generating an energy beam 80 for at least partially solidifying the powder layer 20 while forming the component segment 12.
  • a laser beam or an electron beam is used as the energy beam 80, which is emitted by the radiation source SQ.
  • the layer construction device 50 comprises a movement device 90, which is set up to move the energy beam 80 and the construction platform 70.
  • the movement device 90 can, for example, comprise a plurality of actuators, with the aid of which a respective relative movement RB of the radiation source SQ and the building platform 70 can be brought about.
  • the layer construction device 50 comprises a control device 100 which is designed to control the movement device 90 for moving the energy beam 80 and the construction platform 70.
  • the control device 100 is configured to control the movement device 90 in such a way that a relative angle z between the energy beam 80 and a surface normal 17 of a segment surface 14 of the component segment 12 assigned to a point of impact 16 of the energy beam 80 on the material 22 is set in order to to generate a predetermined nominal surface roughness Ra i of the at least one segment surface 14 of the at least one component segment 12, the relative angle z being assigned to the nominal surface roughness Ra_l.
  • the control device 100 can include a model of the component 10.
  • the model of the component 10 can include geometry data characterizing the component 10.
  • the control device 100 can now be set up to determine the relative angle z between the energy beam 80 and the surface normal 17 during the production of the component segment 12 or the component 10 using the movement device 90 in this way by the relative movement RB of the radiation source SQ and additionally or alternatively the Set the construction platform 70 so that the relative angle z is kept as small as possible during the additive production of the component segment 12 or the component 10 as a function of a changing orientation of the surface normals 17.
  • the nominal surface roughness Ra_l can also have the smallest possible amount.
  • the radiation source SQ and additionally or alternatively the construction platform 70 can be moved, in particular pivoted, using the movement device 90 in accordance with the relative movement RB that the energy beam 80, which in the present case is a laser beam, impinges on the point of impact 16 almost parallel to an xy plane spanned by the axis y and the axis y.
  • the energy beam 80 can then enclose an angle of less than 10 °, preferably 5 °, with the xy plane, for example, and thus be oriented almost parallel to the xy plane.
  • a minimum roughness value of the target surface roughness Ra_l can be generated by minimizing the relative angle z.
  • a computer-readable storage medium 110 is integrated into the control device 100, which storage medium comprises a computer program product with commands for the corresponding control of the layer construction device 50.
  • the relative angle z can be set in that the radiation source SQ emitting the energy beam 80 is moved, in particular pivoted, relative to the construction platform 70. Additionally or alternatively, the relative angle z can be set by moving the construction platform 70, in particular pivoting it, relative to the energy beam 80.
  • step a) the at least one powder layer 20 of the material 22 is first applied to the build-up and joining zone 60 of the building platform 70 which is movable, in particular pivotable, by means of the movement device 90 takes place, as is shown by way of example in FIG.
  • a step b) the powder layer 20 is irradiated by means of the energy beam 80 for partial solidification of the powder layer 20 with the formation of the component segment 12, the predetermined target surface roughness Ra_l of the segment surface 14 of the component segment 12 is generated by setting the relative angle z, assigned to the nominal surface roughness Ra_l, between the energy beam 80 and the surface normal 17 of the segment surface 14 assigned to the point of impact 16 of the energy beam 80 on the material 22.
  • the relative movement RB between the energy beam 80 and the construction platform 70 is carried out in order to direct the energy beam 80 onto a second impact point 18 different from the point of impact 16, as is shown by way of example in FIG .
  • the building platform 70 is lowered in layers.
  • steps a) to c) are repeated until the component 10 is completely additive manufactured.
  • a construction angle which can correspond to a polar angle of the surface normal 17
  • e angle of incidence which can correspond to a polar angle of the energy beam 80, x azimuth angle of the surface normal 17
  • the angles a, e, x, c represent variables that can be set particularly precisely, so that a particularly precise setting of the relative angle z can also take place on the basis of these variables. Equation (1) also applies to the relative angle z_2 shown in FIG. 3, so that with reference to FIG.
  • (x - c) corresponds to the value “0”, for example the angles x and c are each 0 °.
  • Equation (2) represents a two-dimensional view and is valid on the assumption that the angle of incidence e of the energy beam 80 and the surface normals 17 (Surface normal) lie in the xy plane and thus parallel to the z axis.
  • the term with the two azimuth angles x, c "cos (x - c)" is equal to "1", since the difference between the two azimuth angles x, c gives the value "0” or both azimuth angles x, c the value " 0 ".
  • equation (1) can be simplified to the equation (2).
  • equation (2) can represent a special case of equation (1).
  • the invention is based on the knowledge that the respective target surface roughness Ra_l, Ra_2 is directly proportional to the relative angle z.
  • the nominal surface roughness Ra_l, Ra_2 can be predicted and possibly minimized or at least reduced depending on the installation space position and geometry of the component 10.
  • an Ra value of 5 gm can be achieved for the nominal surface roughness Ra_l, Ra_2 if the relative angle z has a value of 0 °.
  • an increase in the relative angle z per 1 ° an increase in roughness of the respective target surface roughness Ra_l, Ra_2 by 0.65 mm can be achieved.
  • the associated Ra value can correspond to about 35 mm.
  • significantly smoother surfaces can be achieved by setting the relative angle z such as the segment surface 14 are formed.
  • a preset parameter setup assigned to the model of the component 10 can preferably be used for irradiating the powder layer 20 by means of the energy beam 80.
  • different angular amounts of the relative angle z can generally be determined, it being possible for a roughness value to be assigned to each of the angular amounts.
  • a relative angle roughness value function determined therefrom in other words a function which expresses the roughness values as a function of various relative angles z, can be stored in the storage medium 110 and additionally or alternatively in the control device 100.
  • the various roughness values to be expected in additive manufacturing can initially be determined using the model of component 10.
  • the various roughness values of the nominal surface roughness Ra_l, Ra_2 can then be generated using equations (1) or (2) and additionally or alternatively the relative angle roughness value function when the component segment 12 or the component 10 is additively manufactured .
  • the use of the relative angle roughness value function in additive manufacturing enables the target surface roughness Ra_l, Ra_2 to be generated quickly and in line with requirements.
  • the radiation source SQ which can also be referred to as an exposure unit, can be moved and inclined with the aid of the movement device 90, thereby making it possible to minimize the relative angle z.
  • the nominal surface roughness Ra_l or the second surface roughness Ra_2 can be generated and thus a predetermined surface quality of the segment surface 14 can be set.
  • the present method represents a significant advantage over conventional production methods. With these conventional production methods, surface roughness Ra of up to 45 mm can arise depending on the parameters, installation space position and geometry of a workpiece to be produced. Especially when designing target components for fatigue strength, with conventional manufacturing methods, due to this relatively poor surface roughness, high reductions in the respective material properties have to be accepted. Many workpieces manufactured additively using these conventional manufacturing methods must therefore either be reworked or oversized for use in aviation.
  • the present method or the present layer construction device 50 enables a specific formula-technical setting of the target surface roughness Ra i, Ra_2 of the component that can be achieved for the component 10, the target surface roughness Ra_l, Ra_2 depending on the construction space position and the The geometry of the component 10 can be predicted and possibly reduced by its model.
  • FIG. FIG. 4 shows a schematic illustration of a second embodiment of the layered construction device 50.
  • the layered construction device 50 shown here has two radiation sources SQ, SQ 1.
  • the radiation sources SQ, SQ 1 each generate an energy beam 80, 82 for irradiating the powder layer 20 of the material 22 on the movable building platform 70.
  • the energy beams 80, 82 strike the powder layer 20 in the area of the points of impact 16, 16 ', the points of impact 16, 16 'are spatially separated from one another and can be assigned to different components in the exemplary embodiment shown. However, it is also possible that the points of impact 16, 16 'can be assigned to different areas of an individual component.

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Abstract

L'invention concerne un procédé pour la fabrication additive d'au moins un segment (12) d'élément structural d'au moins un élément structural (10), en particulier pour une turbomachine. Le procédé selon l'invention comprend au moins des étapes suivantes consistant à : a) appliquer au moins une couche de poudre (20) d'un matériau (22) sur au moins une zone de construction et d'assemblage (60) d'au moins une plate-forme de construction (70) mobile ; b) exposer la couche de poudre (20) à au moins un faisceau d'énergie (80) pour solidifier au moins en partie la couche de poudre (20) en réalisant le ou les segments (12) d'élément structural. Une rugosité superficielle théorique (Ra_1) prédéfinie d'au moins une surface (14) de segment du ou des segments (12) d'élément structural est produite en ce qu'un angle relatif (ζ) associé à la rugosité superficielle théorique (Ra_1) entre le faisceau d'énergie (80) et une normale de surface (17), associée à un point d'impact (16) du faisceau d'énergie (80) sur le matériau (22), de la surface (14) de segment est réglé. D'autres aspects de l'invention concernent un dispositif de construction en couches (50) pour la fabrication additive d'au moins un segment (12) d'élément structural d'un élément structural (10), un produit-programme informatique, un support de stockage (110) lisible par ordinateur ainsi qu'un élément structural (10).
PCT/DE2020/000165 2019-08-01 2020-07-22 Procédé et dispositif de construction en couches pour la fabrication additive d'au moins un segment d'élément structural d'un élément structural, ainsi que produit-programme informatique et support de stockage WO2021018329A1 (fr)

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DE102019211549.7A DE102019211549A1 (de) 2019-08-01 2019-08-01 Verfahren und Schichtbauvorrichtung zur additiven Herstellung zumindest eines Bauteilsegments eines Bauteils sowie Computerprogrammprodukt und Speichermedium
DE102019211549.7 2019-08-01

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102015216402A1 (de) * 2015-08-27 2017-03-02 MTU Aero Engines AG Vorrichtung und Verfahren zur Herstellung oder Reparatur eines dreidimensionalen Objekts
DE102016105097A1 (de) * 2016-03-18 2017-09-21 Cl Schutzrechtsverwaltungs Gmbh Vorrichtung zur additiven Herstellung eines dreidimensionalen Objekts
US20170341183A1 (en) * 2014-12-12 2017-11-30 Velo3D, Inc. Control Systems for Three-Dimensional Printing
DE202018000735U1 (de) * 2018-02-14 2018-03-01 MTU Aero Engines AG Vorrichtung, konfiguriert zur Ausführung eines Verfahrens zur Auslegung eines Bauteils
DE102016222261A1 (de) * 2016-11-14 2018-05-17 Trumpf Laser- Und Systemtechnik Gmbh Verfahren zur schichtweisen additiven Fertigung von Bauteilen und zugehöriges Computerprogrammprodukt

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170341183A1 (en) * 2014-12-12 2017-11-30 Velo3D, Inc. Control Systems for Three-Dimensional Printing
DE102015216402A1 (de) * 2015-08-27 2017-03-02 MTU Aero Engines AG Vorrichtung und Verfahren zur Herstellung oder Reparatur eines dreidimensionalen Objekts
DE102016105097A1 (de) * 2016-03-18 2017-09-21 Cl Schutzrechtsverwaltungs Gmbh Vorrichtung zur additiven Herstellung eines dreidimensionalen Objekts
DE102016222261A1 (de) * 2016-11-14 2018-05-17 Trumpf Laser- Und Systemtechnik Gmbh Verfahren zur schichtweisen additiven Fertigung von Bauteilen und zugehöriges Computerprogrammprodukt
DE202018000735U1 (de) * 2018-02-14 2018-03-01 MTU Aero Engines AG Vorrichtung, konfiguriert zur Ausführung eines Verfahrens zur Auslegung eines Bauteils

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