WO2023083575A1 - Procédé, dispositif de planification et produit-programme informatique de planification d'une exposition localement sélective d'une région de travail au rayonnement d'un faisceau d'énergie, et procédé, dispositif de fabrication et produit-programme informatique pour la fabrication additive de composants à partir d'un matériau en poudre - Google Patents

Procédé, dispositif de planification et produit-programme informatique de planification d'une exposition localement sélective d'une région de travail au rayonnement d'un faisceau d'énergie, et procédé, dispositif de fabrication et produit-programme informatique pour la fabrication additive de composants à partir d'un matériau en poudre Download PDF

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Publication number
WO2023083575A1
WO2023083575A1 PCT/EP2022/079078 EP2022079078W WO2023083575A1 WO 2023083575 A1 WO2023083575 A1 WO 2023083575A1 EP 2022079078 W EP2022079078 W EP 2022079078W WO 2023083575 A1 WO2023083575 A1 WO 2023083575A1
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WO
WIPO (PCT)
Prior art keywords
contour
powder material
irradiation
energy beam
area
Prior art date
Application number
PCT/EP2022/079078
Other languages
German (de)
English (en)
Inventor
Bernhard Gutmann
Dominik Maurer
Wilhelm Meiners
Jeroen Risse
Original Assignee
Trumpf Laser- Und Systemtechnik Gmbh
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Publication date
Application filed by Trumpf Laser- Und Systemtechnik Gmbh filed Critical Trumpf Laser- Und Systemtechnik Gmbh
Publication of WO2023083575A1 publication Critical patent/WO2023083575A1/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
    • B22F10/20—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
    • B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
    • 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
    • B22F10/385—Overhang structures
    • 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
    • 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

Definitions

  • Method, planning device and computer program product for planning a locally selective irradiation of a work area with an energy beam as well as method, manufacturing device and computer program product for the additive manufacturing of components from a powder material
  • the invention relates to a method, a planning device and a computer program product for planning a locally selective irradiation of a work area with an energy beam, and a method, a manufacturing device and a computer program product for the additive manufacturing of components from a powder material.
  • the invention is therefore based on the object of providing a method, a planning device and a computer program product for planning a locally selective irradiation of a work area with an energy beam, as well as a method, a manufacturing device and a To create a computer program product for the additive manufacturing of components from a powder material, wherein the disadvantages mentioned are reduced, preferably avoided.
  • the object is achieved in particular by using a method, also referred to below for short as a planning method, for - in particular computer-implemented - planning a locally selective irradiation of a work area with one, i.e. at least one, energy beam in order to use the energy beam to create a component layer by layer from a plurality of a powder material arranged in a sequence of layers in chronological succession in the work area, is created, wherein for at least one powder material layer of the plurality of powder material layers, a displacement of the energy beam is defined in sections along a contour line of the component to be produced, wherein for the displacement of the energy beam in sections along the A plurality of contour travel vectors is defined for the contour line, with a maximum length of less than 1 mm being defined for the contour travel vectors, and with an irradiation plan for the locally selective irradiation of the work area with the energy beam being obtained.
  • a method also referred to below for short as a planning method, for - in particular computer-impl
  • heat dissipation in an overhang area is lower than in a core area due to the non-solidified powder material arranged at least in some areas below it, so that overheating phenomena, in particular spatter, of a melt pool can easily occur in the overhang area, which can have a negative effect on the component quality.
  • overheating phenomena can advantageously be mitigated, preferably avoided, by displacing the energy beam in sections along the contour line with the plurality of contour travel vectors of limited length. Last but not least will be on this In this way, the amount of scrap is minimized or scrap is avoided altogether.
  • the improved buildability also advantageously means that support structures can be dispensed with, with powder material otherwise used for the construction of support structures being saved on the one hand, and process times associated with the removal of support structures, which would otherwise be required, being saved on the other. As a result, the process is very economical overall.
  • a contour line is understood to mean in particular an imaginary boundary line of the component to be produced in a respective powder material layer, i.e. in particular an imaginary boundary line or border of a cross-sectional area of the component to be produced lying in the powder material layer.
  • a contour travel vector is understood to mean, in particular, a special irradiation vector that extends along the contour line.
  • An irradiation vector is understood to mean, in particular, a continuous, preferably linear displacement of the energy beam over a specific distance with a specific direction of displacement.
  • the irradiation vector includes in particular the direction or orientation of the displacement, i.e. the vector alignment.
  • the radiation vector particularly if it is a contour travel vector, does not have to be in the form of a straight line section; rather, a radiation vector in particular in the form of a contour travel vector can also follow a line or curve that is curved at least in some areas.
  • the contour travel vector preferably follows locally the shape of the contour line in the section of the contour line assigned to the contour travel vector.
  • Additive or generative manufacturing or production of a component means in particular a layered construction of a component from powder material, in particular a powder bed-based method for producing a component in a powder bed, in particular a manufacturing method that is selected from a group consisting of a selective Laser sintering, Laser Metal Fusion (LMF), Direct Metal Laser Melting (DMLM), Laser Net Shaping Manufacturing (LNSM), Selective Electron Beam Melting - (S)EBM), and a Laser Engineered Net Shaping (LENS).
  • LMF Laser Metal Fusion
  • DMLM Direct Metal Laser Melting
  • LNSM Laser Net Shaping Manufacturing
  • S Selective Electron Beam Melting -
  • LENS Laser Engineered Net Shaping
  • the manufacturing device is therefore set up in particular to carry out at least one of the aforementioned additive or generative manufacturing methods.
  • An energy beam is generally understood to mean directed radiation that can transport energy. This can generally involve particle radiation or wave radiation.
  • the energy beam propagates through the physical space along a propagation direction
  • the energy beam is an optical working beam.
  • An optical working beam is to be understood in particular as directed electromagnetic radiation, continuous or pulsed, which is suitable in terms of its wavelength or a wavelength range for the additive or generative manufacturing of a component from powder material, in particular for sintering or melting the powder material.
  • an optical working beam means a laser beam that can be generated continuously or in a pulsed manner.
  • the optical working beam preferably has a wavelength or a wavelength range in the visible electromagnetic spectrum or in the infrared electromagnetic spectrum, or in the overlap region between the infrared range and the visible range of the electromagnetic spectrum.
  • a working area is understood to mean in particular an area, in particular a plane or surface, in which the powder material is arranged and which is locally irradiated with the energy beam in order to locally solidify the powder material.
  • the powder material is sequentially arranged in layers in the work area and is locally irradiated with the energy beam in order to produce a component—layer by layer.
  • the fact that the work area is locally exposed to the energy beam means, in particular, that the entire work area is not applied globally - neither instantaneously nor sequentially - to the energy beam, but rather that the work area is exposed in places, in particular at individual, connected or separate points, with the Energy beam is applied, wherein the energy beam is shifted in particular by means of the scanner device within the work area.
  • the fact that the energy beam is applied selectively to the work area means in particular that the energy beam is applied to the work area at selected, predetermined points or locations or in selected, predetermined areas.
  • the working area is in particular a layer of powder material or a preferably contiguous area of a layer of powder material, which is scanned by the energy beam with the aid of the scanner device is accessible, that is, it includes in particular those points, locations or areas of the powder material layer that can be acted upon by the energy beam.
  • a locally selective irradiation of a work area with a plurality of energy beams can be planned in order to use the plurality of energy beams to produce a component layer by layer from a plurality of powder material layers of a powder material arranged in a sequence of layers in the work area.
  • a displacement of the energy beam in sections along at least one respective contour line with a plurality of contour travel vectors is defined for a plurality of powder material layers from the plurality of powder material layers, with a maximum length of less than 1 mm or with one of the aforementioned values being defined for the contour travel vectors .
  • such a displacement of the energy beam along at least one respective contour line is defined for all powder material layers of the plurality of powder material layers.
  • the maximum length for the contour travel vectors is 900 pm, preferably 800 pm, preferably 700 pm, preferably 600 pm, preferably 500 pm, preferably 400 pm, preferably 300 pm, preferably 200 pm, preferably 100 pm, preferably 75 pm, preferably 50 pm.
  • a minimum length of 25 ⁇ m, preferably 50 ⁇ m, preferably 75 ⁇ m, preferably 100 ⁇ m is specified for the contour travel vectors.
  • the planning method it is determined for at least one contour travel vector of the contour travel vectors whether the contour travel vector is arranged in an overhang area or in a core area of the component to be produced.
  • a maximum length of less than 1 mm or one of the previously specified maximum and/or minimum lengths is specified for a contour travel vector arranged in an overhang area.
  • only one contour travel vector is defined for the displacement of the energy beam in the core area per contour section.
  • the contour line is irradiated for the core area with a conventional Defined contour travel, the fragmentation of the contour sections into a plurality of contour travel vectors with a limited maximum length being carried out only in the overhang area.
  • an overhanging area is understood in particular to be an area below which, in the direction of the layer sequence, non-solidified powder material is located at least in certain areas, in particular in the area of the contour line or at an outer edge of the overhanging area.
  • Such an overhang area is also referred to as a downskin area.
  • an overhang area is an edge area of a cross-sectional area. It is possible for the overhang portion to be set to be portionwise located over solidified powder material.
  • a core area is understood to mean in particular an area which is arranged at least predominantly, in particular with more than 90% of its area, over solidified powder material in the direction of the layer sequence.
  • Such a core area is also referred to as an inskin area. It is possible for the core area to be defined so that it is completely located over solidified powder material. However, it is also possible for the core area to be defined in such a way that it is arranged in areas above non-solidified powder material, in which case it can protrude a predetermined distance beyond the solidified powder material in the direction of the contour line of an adjacent overhang area.
  • an irradiation sequence is defined for the plurality of contour travel vectors in which a temporally immediately consecutive irradiation of contour travel vectors arranged directly adjacent to one another along their vector orientation is avoided.
  • overheating of the powder material can advantageously be avoided and the buildability of overhangs, especially those with flat overhang angles, can be improved.
  • the fact that two contour travel vectors are immediately adjacent to one another along their vector orientation means in particular that the contour travel vectors are arranged one behind the other along the displacement direction of the energy beam defined by at least one of the two contour travel vectors.
  • the vector orientation of a contour run vector is given by the direction or orientation of the displacement of the energy beam along the contour run vector. So by just one irradiation from in the direction of displacement of the energy beam immediately one after the other arranged contour travel vectors is avoided in immediate succession, at the same time the typically provided contour travel is quasi broken up, the contour instead being irradiated piecemeal, as it were in a non-contiguous sequence of the individual set pieces of the contour.
  • an irradiation of an irradiation vector is understood in particular to mean that the irradiation vector is processed, ie the powder material in the working area is irradiated in accordance with the definition given by the irradiation vector.
  • contour line preferably along the entire contour line—a plurality of contour travel vectors adjacent to one another perpendicularly to the contour line are defined.
  • a plurality of contour travel vectors that are adjacent to one another perpendicularly to the contour line are defined.
  • only exactly one contour travel vector is preferably additionally defined for each contour section to be irradiated.
  • the contour travel vectors that are adjacent to one another perpendicularly to the contour line are aligned with one another.
  • the beginnings of contour travel vectors that are adjacent to one another perpendicularly to the contour line are arranged next to one another perpendicularly to the contour line.
  • the ends of contour travel vectors that are adjacent to one another perpendicularly to the contour line are arranged next to one another perpendicularly to the contour line.
  • both the beginnings and the ends of contour travel vectors that are adjacent to one another perpendicularly to the contour line are arranged next to one another perpendicularly to the contour line.
  • the contour travel vectors that are adjacent to one another perpendicularly to the contour line are offset from one another.
  • the beginnings of contour travel vectors that are adjacent to one another perpendicularly to the contour line are offset from one another along the contour line.
  • the ends of contour travel vectors that are adjacent to one another perpendicularly to the contour line are offset from one another along the contour line.
  • both the beginnings and the ends of contour travel vectors that are adjacent to one another perpendicularly to the contour line are offset from one another along the contour line.
  • the irradiation sequence is defined in such a way that initially at a fixed location on the contour line, the contour travel vectors that are adjacent to one another perpendicularly to the contour line at the fixed location are irradiated one after the other, with only then contour travel vectors being irradiated at another location - preferably the previous one recorded place along the contour line are not immediately adjacent - place of the contour line are irradiated.
  • the irradiation sequence is defined in such a way that - along the contour line - first the contour travel vectors are irradiated in a fixed radial position to the contour line, with only then the contour travel vectors adjacent to the initially irradiated contour travel vectors perpendicular to the contour line being irradiated in a different radial position to the contour line .
  • a radial position is understood to mean, in particular, a position perpendicular to the contour line.
  • contour travel vectors are first irradiated one after the other that have the same position perpendicular to the contour line, i.e.
  • contour travel vectors with a different radial position only then being irradiated.
  • immediately consecutive irradiation of contour travel vectors that are directly adjacent to one another in the direction of the contour line is avoided.
  • the irradiation sequence is defined such that radially inner contour travel vectors are irradiated locally along the contour line—at least in an overhanging area—before radially outer contour travel vectors.
  • the contour travel vector is referred to as the radially inner contour travel vector that is at a greater distance from a boundary edge or an edge of the component being created than the other contour travel vector, with the contour travel vector that has the smaller distance to the boundary edge being referred to as the radially outer contour travel vector or the edge of the resulting component.
  • the irradiation sequence is therefore advantageously - at least in the overhang region - always defined locally in such a way that the irradiation takes place from an interior of the component in the direction of the boundary edge or the edge, and not vice versa from the boundary edge or the edge in the direction of the interior of the component.
  • This advantageously ensures improved heat dissipation during the irradiation of the working area, in particular if a core area is irradiated first and only then an overhanging area, with the irradiation sequence from the inside of the component ensuring that there is always a thermally conductive connection to already solidified powder material in the overhanging area as well Powder material layer is given.
  • the irradiation sequence is defined in such a way that radially inner contour travel vectors are irradiated locally along the contour line in time before radially outer contour travel vectors.
  • a different irradiation sequence of the contour travel vectors can also be provided in the core area, it also being possible for radially outer contour travel vectors to be irradiated in time before radially inner contour travel vectors.
  • an irradiation of a core area is scheduled before an irradiation of at least one overhang area adjacent to the core area, with in particular a temporal sequence of the irradiation being defined in such a way that first the core area is completely irradiated before the irradiation of the adjacent overhang area is started.
  • a temporal sequence of the irradiation being defined in such a way that first the core area is completely irradiated before the irradiation of the adjacent overhang area is started.
  • contour travel vectors that are directly adjacent to one another perpendicular to the contour line are defined in such a way that their molten pools overlap with one another. In this way, a particularly favorable thermally conductive connection for the contour travel vectors is achieved, so that overheating phenomena are avoided. In addition, a particularly stable, high-quality and sealed component is advantageously obtained.
  • contour travel vectors in powder material layers arranged one above the other along the layer sequence of the powder material layers are arranged one above the other, are offset perpendicular to the layer sequence to each other.
  • the contour travel vectors, which are arranged one above the other in powder material layers arranged one above the other along the layer sequence are defined with different - in particular opposite, in particular alternating from powder material layer to powder material layer - irradiation directions, i.e. vector alignments. In this way in particular, the formation of preferred directions and associated weakening or predetermined breaking points in the resulting component can be avoided.
  • contour travel vectors arranged one above the other perpendicularly to the layer sequence are set offset to one another and/or with different irradiation directions.
  • irradiation with the energy beam is alternatively or additionally specified for at least a first powder material layer from the plurality of powder material layers in a first overhang region and in a first core region of the first powder material layer, with irradiation for a second powder material layer from the plurality of powder material layers is determined with the energy beam only for a second core area of the second powder material layer assigned to the first core area, it being determined that a second overhang area of the second powder material layer assigned to the first overhang area is not irradiated.
  • the fact that the second overhang area is assigned to the first overhang area means in particular that the second overhang area is at least partially adjacent to the first overhang area along the layer sequence, in particular arranged above it, in particular in such a way that the first overhang area and the second overhang area overlap at least in areas.
  • the fact that the second core area is assigned to the first core area accordingly means in particular that the second core area is at least partially adjacent to the first core area along the layer sequence, in particular above it is arranged, in particular in such a way that the first core region and the second core region overlap with one another at least in regions.
  • the first powder material layer and the second powder material layer are arranged directly one above the other along the layer sequence.
  • the layer sequence for the component to be produced is defined with a plurality of first powder material layers and a plurality of second powder material layers.
  • the first powder material layers and the second powder material layers are arranged in an alternating manner. This means, in particular, that individual first and second powder material layers are arranged one above the other in direct alternation along the layer sequence.
  • first powder material layers and the second powder material layers are arranged alternately in blocks.
  • blocks of first and second powder material layers are arranged alternately one above the other along the layer sequence, with each block having at least one powder material layer, in particular a plurality of powder material layers.
  • each block of the second layers of powder material comprises a plurality of the second layers of powder material, while each block of the first layers of powder material comprises only exactly one first layer of powder material.
  • the first powder material layers and the second powder material layers are arranged alternately in sections and in blocks alternately in sections along the layer sequence one above the other. This represents in particular a sectional combination of the previously presented embodiments along the layer sequence.
  • a parameterization of the contour travel vector is selected depending on whether the contour travel vector is arranged in an overhang area or in a core area.
  • a parameterization of a radiation vector here in particular a contour travel vector, is understood to mean a determination of at least one parameter, in particular a plurality of parameters, for the radiation vector.
  • the at least one parameter is selected in particular from a group consisting of: a power of the energy beam, a diameter of the energy beam on the work area, a displacement speed of the energy beam, a minimum irradiation time for the irradiation vector, and a waiting time before and/or after the irradiation of the irradiation vector.
  • the at least one parameter is a parameter that at least partly determines an energy input into the powder material.
  • the parameterization of the contour travel vector is selected depending on where the contour travel vector is arranged in the overhang area.
  • the buildability of an overhang area in particular in the case of flat overhang angles, can advantageously be further improved.
  • the parameterization of the contour travel vector is selected depending on the radial distance at which the contour travel vector is arranged from the core area.
  • the radial distance is in particular the distance, measured perpendicular to the contour line, from an imaginary boundary line between the core area and the overhang area.
  • the energy input into the powder material can be increased or decreased depending on the radial distance from the core area.
  • the overhang area for contour travel vectors arranged in the overhang area, irradiation with a reduced average temporal energy input compared to the core area—in particular in absolute terms or per unit area.
  • a reduced average temporal energy input compared to the core area in particular in absolute terms or per unit area.
  • overheating phenomena in the overhang area can be avoided and the buildability of the overhang area, in particular in the case of flat overhang angles, can thus be improved.
  • heat dissipation is lower than in the first core area due to the non-solidified powder material arranged at least in some areas below it, so that the overheating phenomena mentioned, in particular spatter, of the melt pool can easily occur in the overhang area, which have a negative effect on the component quality affect can.
  • These overheating phenomena can advantageously be mitigated, preferably avoided, by reducing the average energy input over time.
  • a reduced mean energy input over time in particular in absolute terms or per unit area, means in particular that less energy is introduced in the first overhang region as an average over time, i.e. in particular averaged over time, in particular in absolute terms or per unit area than in the first core area.
  • At least one reduction measure is defined, selected from a group consisting of: reducing a power of the energy beam, increasing a displacement speed of the energy beam, defining shorter irradiation vectors, reducing a vector density of irradiation vectors, and specifying, in particular increasing, waiting times for the irradiation, ie between individual irradiation vectors.
  • these measures are suitable for reducing the average energy input over time.
  • an increased displacement speed of the energy beam is preferably combined with—particularly increased—predetermined waiting times for the irradiation.
  • a waiting time for the irradiation is understood to mean, in particular, a waiting time that is provided between the irradiation of irradiation vectors, in particular locally at a point in the working area between adjacent, in particular immediately adjacent, irradiation vectors, in particular in order to overheat the powder material avoid. It is by no means ruled out that during the waiting time - if necessary by means of the same energy beam - at least one irradiation vector is irradiated at another, thermally slightly coupled or decoupled point of the work area in order to reduce the overall process time.
  • a reduction in a vector density of irradiation vectors leads in particular to a reduced average temporal energy input per unit area.
  • contour travel vectors arranged in the overhang area irradiation with an area-related energy input that is increased compared to the core area is specified.
  • a deeper melt pool is advantageously achieved, which comprises a larger number of powder material layers along the layer sequence.
  • second overhanging areas of second powder material layers underneath are also effectively consolidated, so that a stable, sealed component is achieved overall; on the other hand, there is a lowering of the level of the melted and solidified powder material in the region of the currently uppermost layer of powder material, ie in the working area.
  • an increased area-related energy input is understood in particular to mean that more energy is introduced in the first overhang area per unit area, cumulatively over time, ie in particular integrated over time, than in the first core area.
  • an increased surface-related energy input does not contradict a reduced mean energy input over time; For example, increased energy can be introduced over a longer period of time with a lower radiation power over an area and integrated over time, while at the same time reducing the average energy input over time.
  • At least one increase measure is defined, selected from a group consisting of: increasing the power of the energy beam, reducing the diameter of the energy beam on the work area, reducing the displacement speed of the energy beam, increasing a vector density of irradiation vectors, and increasing a number of - repetitive - displacements of the energy beam along a same or adjacent irradiation path.
  • Each of these measures taken individually, but also in combination with one another, is suitable for increasing the area-related energy input.
  • Multiple displacement of the energy beam along the same irradiation path or also along adjacent irradiation paths can advantageously result in multiple melting of the powder material, which is also referred to as remelting.
  • At least one increase measure, selected from the aforementioned group of increase measures, in combination with at least one reduction measure, selected from the aforementioned group of reduction measures, is specified in order to reduce the average temporal energy input - in absolute terms or per unit area - and the area-related increase energy input.
  • the at least one increase measure, selected from the aforementioned group of increase measures is combined with at least one reduction measure, which is selected from a group consisting of: defining shorter irradiation vectors and specifying, in particular increasing, waiting times for the irradiation.
  • the irradiation plan is obtained as a data set for controlling a production device, in particular a production device according to the invention described below or a production device according to one or more of the embodiments described below, for additively manufacturing a component from the powder material becomes.
  • a production device in particular a production device according to the invention described below or a production device according to one or more of the embodiments described below
  • the irradiation plan is obtained in this way in a form that is easy to handle, in particular machine-readable.
  • the object is also achieved by creating a method for additively manufacturing a component from a powder material, which has the following steps: providing a method according to the invention for planning a locally selective irradiation of the work area or using a method according to one or more of those described above Embodiments obtained irradiation plan for the locally selective irradiation of a work area with one, i.e. at least one, energy beam in order to produce the component by means of the energy beam in layers from a plurality of powder material layers of the powder material arranged in a layer sequence in the work area in chronological succession, and manufacturing the component according to the irradiation plan, in particular by means of the manufacturing device according to the invention described below or a manufacturing device according to one or more of the embodiments described below.
  • the method for additive manufacturing there are in particular those advantages that have already been described above in connection with the method for planning the locally selective irradiation.
  • the component can also be manufactured with a plurality of energy beams by locally selectively irradiating the work area with a plurality of energy beams. In this way, the production of the component can advantageously be accelerated, in particular by simultaneously solidifying different cross-sectional areas of the component within a layer of powder material.
  • the irradiation plan is provided by carrying out a method according to the invention for planning a locally selective irradiation of the work area or a method for planning according to one or more of the previously described embodiments.
  • the method for manufacturing the component thus also includes the method for planning the irradiation—in particular in the form of preceding steps.
  • a laser beam or an electron beam is preferably used as the energy beam.
  • the component is preferably manufactured by means of selective laser sintering and/or selective laser melting.
  • a metallic or ceramic powder can preferably be used as the powder material.
  • the object is also achieved by creating a computer program product, comprising machine-readable instructions, on the basis of which a method according to the invention for planning a locally selective irradiation of the work area or a method for planning according to one or more of the embodiments described above is carried out on a computing device if the Computer program product running on the computing device.
  • a method according to the invention for planning a locally selective irradiation of the work area or a method for planning according to one or more of the embodiments described above is carried out on a computing device if the Computer program product running on the computing device.
  • the invention also includes a first data carrier comprising such a first computer program product.
  • the object is also achieved by creating a computer program product, comprising machine-readable instructions, on the basis of which a method according to the invention for additively manufacturing a component from a powder material or a method for additively manufacturing according to one or more of the embodiments described above is carried out on a computing device if the computer program product runs on the computing device.
  • a method according to the invention for additively manufacturing a component from a powder material or a method for additively manufacturing according to one or more of the embodiments described above is carried out on a computing device if the computer program product runs on the computing device.
  • the invention also includes a second data carrier comprising such a second computer program product.
  • the object is also achieved by creating a planning device for planning a locally selective irradiation of a work area with one, i.e. at least one, energy beam in order to use the energy beam to produce a component from a powder material arranged in the work area, the planning device being set up to carry out a method according to the invention for planning a locally selective irradiation of a work area with the energy beam or a method for planning according to one or more of the embodiments described above.
  • the planning device there are in particular those advantages that have already been mentioned in have been described in connection with the planning process and the additive manufacturing process.
  • the planning device can be set up to plan the locally selective irradiation of the work area with a plurality of energy beams.
  • the planning device is designed as a device that is selected from a group consisting of a computer, in particular a personal computer (PC), a plug-in card or control card, and an FPGA board.
  • the planning device is an RTC5 or RTC6 control card from SCANLAB GmbH, in particular in the configuration currently available on the date determining the seniority of the present property right.
  • the planning device can be provided externally or separately from a production device, with the planning device preferably creating a data record which is then stored in a suitable manner, for example by means of a data carrier or via a network, in particular via the Internet, or via another suitable wireless or wired form of transmission, is transmitted to a manufacturing device, in particular a control device of a manufacturing device.
  • a manufacturing device in particular a control device of a manufacturing device.
  • the planning device it is possible for the planning device to generate CAM data from CAD data, ie in particular a command sequence, in particular an NC program, for controlling the production device, with this command sequence then being transmitted to the production device for its control.
  • CAD data of a component to be transferred to the planning device, with the planning device generating the command sequence for the production device from this.
  • the planning device can also be integrated into a manufacturing device.
  • the planning device can be integrated into the control device of the production device, or the control device of the production device can be designed as a planning device, in particular by providing a suitable hardware component and/or by implementing a suitable computer program product, in particular software.
  • CAD data of a component can be produced to be transferred to the production device, with the production device itself, in particular the planning device implemented in the control device, generating corresponding CAM data or a command sequence for controlling the production device from the CAD data.
  • the planning device it is also possible for the planning device to comprise a plurality of computing devices, in which case they are in particular designed to be physically distributed is.
  • the planning device then preferably comprises a plurality of computing devices that are networked with one another.
  • the planning device can be embodied as a data cloud or so-called cloud, or the planning device is part of a data cloud or cloud.
  • the planning device it is also possible for the planning device to comprise on the one hand at least one computing device external to the manufacturing device and on the other hand the manufacturing device, in particular the control device of the manufacturing device, with steps carried out by the planning device being carried out partly on the external computing device and partly on the manufacturing device, in particular on the control device.
  • the planning device does not take over the complete planning of the locally selective irradiation of the work area, but only parts thereof; In particular, it is possible for the planning device to take over only that part of the planning of the locally selective irradiation of the work area that relates to the steps and/or definitions described above.
  • other parts of the planning of the locally selective irradiation can be carried out in other computing devices, in particular in computing devices external to the manufacturing device, or also in the manufacturing device itself, in particular its control device, or else in a data cloud or cloud.
  • the planning device to change, adapt or correct CAM data generated by another computing device or a command sequence, in particular an NC program.
  • the object is also achieved by creating a manufacturing device for the additive manufacturing of components from a powder material, which has a beam generating device that is set up to generate one, ie at least one, energy beam.
  • the production device has a scanner device that is set up to locally and selectively irradiate a work area with the energy beam in order to use the energy beam to produce a component from the powder material arranged in the work area.
  • the manufacturing device has a control device that is functionally connected to the scanner device, optionally also to the beam generating device, and set up to control the scanner device and, if necessary, the beam generating device.
  • the control device is set up to carry out a method according to the invention for the additive manufacturing of components or a method for the additive manufacturing of components according to one or more of the embodiments described above.
  • a method according to the invention for the additive manufacturing of components or a method for the additive manufacturing of components according to one or more of the embodiments described above.
  • the beam generating device is set up to generate a plurality of energy beams and/or the manufacturing device has a plurality of beam generating devices for generating a plurality of energy beams. It is possible that a plurality of scanner devices are provided for the plurality of energy beams. However, it is also possible for the scanner device to be set up to displace a plurality of energy beams—in particular independently of one another—on the work area. In particular, the scanner device can have a plurality of separately controllable scanners, in particular scanner mirrors, for this purpose.
  • the scanner device preferably has at least one scanner, in particular a galvanometer scanner, piezo scanner, polygon scanner, MEMS scanner, and/or a working head or processing head that can be displaced relative to the work area.
  • the scanner devices proposed here are particularly suitable for shifting the energy beam within the working area between a plurality of irradiation positions.
  • a working head or processing head that can be displaced relative to the work area is understood here in particular to mean an integrated component of the production device which has at least one radiation outlet for at least one energy beam, the integrated component, i.e. the working head, as a whole along at least one displacement direction, preferably along two mutually perpendicular directions of displacement, is displaceable relative to the work area.
  • a working head can, in particular, be designed in the form of a portal or be guided by a robot.
  • the working head can be designed as a robot hand of a robot.
  • the control device is preferably selected from a group consisting of a computer, in particular a personal computer (PC), a plug-in card or control card, and an FPGA board.
  • the control device is an RTC5 or RTC6 control card from SCANLAB GmbH, in particular in the embodiment currently available on the date determining the seniority of the present property right.
  • the beam generating device is preferably designed as a laser.
  • the energy beam is thus advantageously generated as an intensive beam of coherent electromagnetic radiation, in particular coherent light.
  • irradiation preferably means exposure.
  • the production device is preferably set up for selective laser sintering.
  • the manufacturing device is set up for selective laser melting.
  • FIG. 1 shows a schematic representation of an exemplary embodiment of a manufacturing device for the additive manufacturing of components from a powder material with an exemplary embodiment of a planning device;
  • FIG. 2 shows a schematic representation of a first embodiment of a method for planning a locally selective irradiation of a work area with an energy beam
  • FIG. 3 shows a further schematic representation of the method for planning a locally selective irradiation of a work area with an energy beam
  • FIG. 4 shows a schematic representation of further exemplary embodiments of the method for planning a locally selective irradiation of a work area with an energy beam.
  • Fig. 1 shows a schematic representation of an embodiment of a manufacturing device 1 for the additive manufacturing of a component 3 from a powder material 5 with an embodiment of a planning device 7.
  • the manufacturing device 1 has a beam generating device 9, preferably in the form of a laser, which is set up to generate an energy beam 11, in particular a laser beam, and also a scanner device 13, which is set up to locally and selectively irradiate a work area 15 with the energy beam 11. in order to produce the component 3 from the powder material 5 arranged in the working area 15 by means of the energy beam 11 .
  • the production device 1 also has a control device 17, designed in particular as a computing device 8, which is connected to the scanner device 13 and is preferably also operatively connected to the beam generating device 9 and set up to control the scanner device 13 and optionally the beam generating device 9 .
  • the control device 17 is set up to carry out a method, described in more detail below, for planning the locally selective irradiation of the work area 15 with the energy beam 11, also referred to as a planning method for short.
  • control device 17 has the planning device 7 embodied in particular as a further computing device 10 which is set up accordingly for carrying out the planning method.
  • control device 17 itself to be in the form of the planning device 7 .
  • planning method it is also possible for the planning method to be carried out on a planning device 7 provided separately from the production device 1 .
  • the production device 1 is set up, in particular, to build up the component 3 layer by layer from a plurality of powder material layers 19 arranged in a sequence in time in the working area 15 .
  • the working area 15, in particular in the form of a powder bed, is arranged on a construction platform 21, which is gradually lowered counter to a vertical direction Z in the course of the provision of the temporally successive powder material layers 19 in the working area 15.
  • the powder material 5 that forms the next powder material layer 19 is conveyed from the area of a storage cylinder 25 to the work area 15 by means of a coating element 23, designed in particular as a wiper or pusher, and is smoothed there by the coating element 23, so that the current powder material layer 19 is provided.
  • a platform 27 is arranged in storage cylinder 25, which—in this respect corresponding to the lowering of construction platform 21—is gradually raised in the vertical direction Z, as shown schematically by an arrow 29, in order to move the powder material 5 out of storage cylinder 25 to the level of work area 15 to promote.
  • Excess powder material 5 is preferably conveyed through the coating element 23 into a receptacle 31 .
  • component 3 is built up layer by layer, ie in layers.
  • the layer sequence of the powder material layers 19 extends along the vertical direction Z.
  • irradiation plan for locally selective irradiation of the work area 15 with the energy beam 11 is provided, and the component 3 is manufactured according to the irradiation plan provided.
  • the irradiation plan is preferably provided in that the planning method is carried out—in particular by the planning device 7 .
  • Fig. 2 shows a schematic representation of a first embodiment of a method for planning a locally selective irradiation of the work area 15 with the energy beam 11.
  • FIG. 2 shows a section of the working area 15 in a plan view, ie viewed from above along the vertical direction Z according to FIG. 1, with a powder material layer 19 .
  • the displacement of the energy beam 11 is defined in sections along a contour line 33 for the powder material layers 19 .
  • Figure 2 schematically shows a cross-sectional area 35 of the component 3, which is divided into a core area 37 and an overhang area 39.
  • An imaginary boundary line L separates the core area 37 from the overhang area 39.
  • the contour line 33 extends along a circumference of the cross-sectional area 35 in the plane of the powder material layer 19.
  • a plurality of contour travel vectors 300 are defined, in particular first contour travel vectors 310 for the overhang region 39 and second contour travel vectors 320 for the core region 37.
  • contour travel vectors 300 are for the sake of clarity, only individual ones are marked with the corresponding reference symbols.
  • a plurality of irradiation vectors 41 are preferably defined, of which only two are provided with a corresponding reference symbol for the sake of better clarity.
  • a maximum length of less than 1 mm is defined for the contour travel vectors 300, in particular for the first contour travel vectors 310 in the overhang area 39.
  • no maximum length is specified for the second contour travel vectors 320 in the core area 37 .
  • an otherwise with contour travel typically associated long, continuous irradiation is avoided.
  • overheating of the powder material 5 in the area of the contour line 33 can be avoided in this way.
  • the buildability of the overhang area 39 is improved by the determination of the maximum length for the first contour travel vectors 310 .
  • An irradiation plan for the locally selective irradiation of the work area 15 with the energy beam 11 is obtained as part of the planning method.
  • the irradiation plan is preferably obtained as a data record for controlling the manufacturing device 1 .
  • contour travel vectors 300 for the plurality of contour travel vectors 300, in particular for the plurality of first contour travel vectors 310 in the overhang region 39, irradiation of contour travel vectors 300 that are arranged directly adjacent to one another directly along their vector orientation is avoided in direct succession in terms of time, for example by using a symbol here schematically denoted by the letters A, B and C-marked irradiation sequence is selected, with contour travel vector 300 marked with A being irradiated first, then contour travel vector 300 marked with B, and then contour travel vector 300 marked with C.
  • an irradiation sequence can also be specified for the second contour travel vectors 320 in the core region 37 in which second contour travel vectors 320 arranged directly adjacent to one another along their vector orientation are irradiated at least in sections in immediate succession, in particular in such a way that a continuous contour travel results for the section of contour line 33 located in core region 37.
  • a plurality of contour travel vectors 300, in particular first contour travel vectors 310, adjacent to one another perpendicularly to the contour line are preferably defined along the contour line 33, in particular in the overhang region 39.
  • a first, first contour travel vector 311, a second, first contour travel vector 312, and a third, first contour travel vector 313 that are adjacent to one another perpendicularly to the contour line 33 are drawn in here by way of example.
  • the contour travel vectors 311, 312, 313 that are adjacent to one another perpendicularly to the contour line can be aligned with one another or offset from one another.
  • only exactly one second contour travel vector 320 is preferably defined for each section of the contour line 33 .
  • the irradiation sequence is preferably defined such that initially at a fixed location D of the contour line 33, the contour travel vectors 311, 312, 313 that are adjacent to one another perpendicularly to the contour line 33 at the fixed location D are successively irradiated are, only then contour travel vectors 300 at a - are irradiated other location E of the contour line 33 - along the contour line 33.
  • contour travel vectors 300 are first irradiated in a fixed radial position relative to contour line 33, for example first all contour travel vectors 300 that are arranged along contour line 33 in front of and behind the first first contour travel vector 311 that is drawn in - in particular including the first first contour travel vector 311 -, where Only then are contour travel vectors 300 adjacent to initially irradiated contour travel vectors 300 perpendicular to contour line 33 irradiated in a different radial position relative to contour line 33, for example next all contour travel vectors 300 arranged along contour line 33 in front of and behind the second first contour vector 312 - in particular including the second first contour travel vector 312.
  • the irradiation sequence is preferably defined in such a way that radially inner contour travel vectors 300 are always irradiated locally along the contour line 33—at least in the overhang region 39—before radially outer contour travel vectors 300 in time.
  • the first first contour travel vector 311 is irradiated before the second first contour travel vector 312
  • the second first contour travel vector 312 is irradiated before the third first contour travel vector 313 .
  • the irradiation therefore takes place from the inside of the component 3 to the outside.
  • contour travel vectors 311, 312, 313, which are directly adjacent to one another perpendicularly to the contour line 33, are preferably defined in such a way that their molten pools overlap one another.
  • each of the contour travel vectors 300 determines whether they are located in the overhang area 39 or in the core area 37, with a parameterization for a respective contour travel vector 300 being selected depending on whether the respective contour travel vector 300 is in the overhang area 39 or in the core area 37 is arranged.
  • the parameterization of a respective first contour travel vector 310 is preferably selected depending on where the first contour travel vector 310 is arranged in the overhang region 39 .
  • FIG. 3 shows a further schematic representation of the planning method.
  • FIG. 3 also shows a section of the working area 15 in a plan view, that is to say seen from above along the vertical direction Z according to FIG. 1, with a powder material layer 19 .
  • FIG. 2 which shows an outer contour line 33 of component 3
  • FIG. 3 For the application of the planning method, it does not matter whether the contour line 33 is an outer or inner contour line 33 of the component 3 .
  • FIG. 4 shows a schematic representation of further exemplary embodiments of the planning method.
  • the contour travel vectors 311, 312, 313 that are adjacent to one another perpendicularly to the contour line 33 are aligned with one another.
  • the contour travel vectors 311, 312, 313, which are adjacent to one another perpendicularly to the contour line 33, are offset from one another.
  • the two configurations according to a) and b) can of course also be combined with one another with respect to different locations along the contour line 33 .

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Automation & Control Theory (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Powder Metallurgy (AREA)

Abstract

La présente invention concerne un procédé de planification d'une exposition localement sélective d'une région de travail (15) au rayonnement d'un faisceau d'énergie (11), afin de fabriquer un composant (3) couche par couche à partir d'une pluralité de couches de matériau en poudre (19) d'un matériau en poudre (5) disposées dans la région de travail chronologiquement les unes après les autres dans une succession de couches au moyen du faisceau d'énergie (11). Pour au moins une couche de matériau en poudre (19) de la pluralité de couches de matériau en poudre (19), un décalage du faisceau d'énergie (11) dans des sections le long d'une ligne de contour (33) du composant à produire est déterminé, une pluralité de vecteurs de trajectoire de contour (300) sont déterminés pour le décalage du faisceau d'énergie (11) dans des sections le long de la ligne de contour (33), et une longueur maximale inférieure à 1 mm est déterminée pour les vecteurs de trajectoire de contour (300), un plan d'exposition au rayonnement est obtenu pour l'exposition localement sélective de la région de travail (15) au rayonnement du faisceau d'énergie (11).
PCT/EP2022/079078 2021-11-11 2022-10-19 Procédé, dispositif de planification et produit-programme informatique de planification d'une exposition localement sélective d'une région de travail au rayonnement d'un faisceau d'énergie, et procédé, dispositif de fabrication et produit-programme informatique pour la fabrication additive de composants à partir d'un matériau en poudre WO2023083575A1 (fr)

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EP3115182A1 (fr) * 2014-03-05 2017-01-11 Panasonic Intellectual Property Management Co., Ltd. Procédé de production d'un objet de forme tridimensionnelle
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