WO2024013123A1 - Procédé de fabrication additive d'un composant à l'aide d'un mélange de poudres métallique/polymère - Google Patents

Procédé de fabrication additive d'un composant à l'aide d'un mélange de poudres métallique/polymère Download PDF

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Publication number
WO2024013123A1
WO2024013123A1 PCT/EP2023/069097 EP2023069097W WO2024013123A1 WO 2024013123 A1 WO2024013123 A1 WO 2024013123A1 EP 2023069097 W EP2023069097 W EP 2023069097W WO 2024013123 A1 WO2024013123 A1 WO 2024013123A1
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WO
WIPO (PCT)
Prior art keywords
metal
plastic
powder mixture
component
wavelength
Prior art date
Application number
PCT/EP2023/069097
Other languages
German (de)
English (en)
Inventor
Jan SANDER
Original Assignee
Brose Fahrzeugteile SE & Co. Kommanditgesellschaft, Coburg
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Brose Fahrzeugteile SE & Co. Kommanditgesellschaft, Coburg filed Critical Brose Fahrzeugteile SE & Co. Kommanditgesellschaft, Coburg
Publication of WO2024013123A1 publication Critical patent/WO2024013123A1/fr

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20Direct sintering or melting
    • B22F10/28Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/50Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus 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
    • B22F12/40Radiation means
    • B22F12/44Radiation means characterised by the configuration of the radiation means
    • B22F12/45Two or more
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y70/00Materials specially adapted for additive manufacturing
    • B33Y70/10Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10Processes characterised by the sequence of their steps
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the proposed solution relates in particular to a method for the additive manufacturing of a component.
  • powdered printing material in the additive manufacturing of a component and to build the component in layers.
  • the powdered printing material is applied in layers on a printing platform of a 3D printing device.
  • a component that should consist of both a plastic material and a metal.
  • the melting points of plastic and metal are comparatively far apart.
  • metallic printing material is melted or sintered.
  • the temperatures required for this then sometimes considerably exceed the melting temperature of the plastic, so that plastic material that has already been applied may be destroyed.
  • the present solution is therefore based on the task of providing improvements for the additive manufacturing of a component made of metal and plastic. This object is achieved both with a method of claim 1 or 14 and by a 3D printing device of claim 15 or a use of claim 17.
  • the proposed solution it is intended to use a metal-plastic powder mixture with a metal component and a plastic component as the printing material. After the metal-plastic powder mixture has been applied, the plastic component is at least locally evaporated by heat input (and thus locally removed) before an at least locally remaining metal component of the applied metal-plastic powder mixture is connected by heat input.
  • a basic idea of the proposed solution is the approach of using a metal-plastic powder mixture to apply metal components and plastic components together in a printing process, but then subsequently removing a plastic component by evaporation, so that remaining metal (to form a section with solid Meta II structure for the component to be manufactured), i.e. can be melted or sintered, for example.
  • the metal portion can be exposed in a localized manner.
  • only metal-containing powder without plastic will be made available, so that, for example, in a subsequent process step, the metal portion that only remains locally can be melted or sintered, without plastic being melted or sintered.
  • an at least local, in particular only local, i.e. locally limited, evaporation of the plastic component can only take place after several (at least two) layers of the metal-plastic powder mixture have been applied, and in particular in several applied layers.
  • a plastic portion is therefore only evaporated after several layers of metal-plastic powder mixture have been applied.
  • the plastic component can also evaporate in layers, i.e. H. Layer by layer, or over several layers.
  • At least one additional layer of the metal-plastic powder mixture is applied before the at least locally remaining metal portion is connected to that area (one or more layers) of the applied metal-plastic powder mixture in which the Plastic portion was evaporated in a first process step to form a metal structure.
  • the application of at least one additional layer of the metal-plastic powder mixture can serve to compensate for shrinkage.
  • a corresponding reduction in the layer thickness can be compensated for.
  • connection of the metal component takes place in a subsequent second process step, only after the plastic component has also previously been evaporated in the at least one additional layer applied.
  • the metal portion of the additional layer can also be connected in the second process step.
  • a metal portion of one or more applied additional layers can also be melted or sintered in order to create a larger metal structure.
  • the at least one (additional) additional layer applied can be dimensioned in terms of the volume of its metal content in such a way that the volume of the evaporated plastic material is balanced.
  • a first laser radiation of a first wavelength is used to evaporate the plastic portion, while a second laser radiation of a second wavelength is used to connect the metal portion, the second wavelength being smaller than the first wavelength.
  • a plastic material and a metal typically absorb laser radiation to different degrees.
  • a plastic material, in particular a polymer absorbs laser radiation of a lower wavelength (for example ⁇ 1 pm) much worse than a metal.
  • laser radiation with a longer wavelength is reflected by a metal and therefore not absorbed, while a plastic material, in particular a polymer, absorbs such laser radiation, optionally through additives provided herein.
  • a first laser radiation which is generated by a first laser, for example a CO2 laser
  • plastic material can be vaporized in a targeted manner, while the corresponding first laser radiation hardly reduces the metal content of the applied metal-plastic powder mixture or not influenced.
  • laser radiation of lower wavelength for example green or blue laser radiation
  • a second Laser which is not absorbed by a plastic material, but by the metal, a connection of the metal portion can be achieved by melting or sintering.
  • a plastic material is provided for the plastic portion of the metal-plastic powder mixture, which incinerates while including an adjacent metal melt.
  • a polymer is provided as a plastic material, optionally by adding appropriate additives, which is ashed under the effect of the high temperatures of an adjacent molten metal to produce a Meta II structure based on the metal content in an area adjacent to the molten metal, so that over an area adjacent to the molten metal adjacent ash area thermal insulation of the molten metal is achieved compared to adjacent, already printed areas of the component.
  • the metal-plastic powder mixture can have metal-plastic particles, in particular consist of metal-plastic particles.
  • metal-plastic particles in particular consist of metal-plastic particles.
  • at least a portion of the metal portion of the metal-plastic powder mixture is formed by a plurality of metal cores of the metal-plastic particles, while at least a portion of the plastic portion of the metal-plastic powder mixture is formed by plastic jackets, each of which encloses a metal core.
  • plastic jackets each of which encloses a metal core.
  • a large number of metal-plastic particles are therefore provided, each of which has a metal core with an enveloping plastic jacket.
  • corresponding metal-plastic particles facilitates the application of printing material containing metal and plastic in a single printing process, with the proposed solution and the different further treatment of the plastic portion on the one hand and the metal portion on the other hand being used in subsequent process steps to create desired plastic and metal structures for the component to be manufactured can be formed.
  • a metal structure for the component to be produced is formed with the connected metal portion and it is additionally provided not to evaporate, at least locally, a plastic portion of the applied metal-plastic powder mixture, but to connect it, in particular by melting, sintering or polymerization.
  • it is therefore provided not only to form an at least locally coherent metal structure from the originally powdery metal portion for the component to be produced, but also to form a plastic structure in which no connection of the powdery metal portion occurs.
  • a plastic structure of the component can be formed, for example, by a hardened polymer matrix
  • a targeted connection of the powdery plastic component to form a solid plastic structure can be carried out using appropriate laser radiation, as explained above.
  • (further) polymerization can also be provided, especially in the case of a metal-plastic powder mixture that already contains a polymer.
  • Polymerization here is understood in particular to mean that polymerization is stimulated by laser light in such a way that a molecular weight of the resulting polymer is greater than the molecular weight of the starting materials, which are due, for example, to plastic jackets of the metal-plastic particles that have been applied and therefore printed in layers.
  • the plastic portion can be formed by a thermoplastic polymer, in which shorter polymer chains are linked to form longer ones.
  • the mechanism can be activated either directly by the energy introduced with the laser radiation or by at least one additive contained in the plastic component, which is activated by the laser radiation and acts as a linker.
  • Thermoset polymers can also be used, particularly in conjunction with photoactivators, such as those used in resins for stereolithography 3D printing (SLA).
  • the additives for linking can be activated thermally or via a photoreaction.
  • anchor structures are formed for the component to be produced by connected metal components applied metal-plastic powder mixture, which are embedded in the finished component in a plastic section - formed by connected plastic components.
  • the anchor structures are connected to a subsequently created metal structure made of further metal components that are also interconnected, so that the metal structure and the anchor structures form a metallic solid body anchored in plastic material.
  • an anchor structure on the finished component then engages behind a section of plastic material in order to hold the metal structure without distortion during the To produce the manufacturing process and to keep it properly positioned and locked in the plastic material.
  • At least one metal insert, at least one conductor track or at least one circuit can be formed with connected, originally powdery metal components in the component to be produced.
  • corresponding components made of a plastic, in particular a polymer can be printed comparatively easily with corresponding metallic components.
  • the 3D printing process which has been improved in accordance with the proposed solution, allows components with metallic components to be produced, in particular with comparatively complex geometries, without the need for special tools, in particular casting molds.
  • a further independent aspect of the proposed solution provides a method for the additive manufacturing of a component, in which a plastic material and a metal are used to build up the component in layers and for the formation of a plastic structure (and therefore a first solid body section) from applied plastic material first laser radiation of a first wavelength is used, while a second laser radiation of a second wavelength, which is smaller than the first wavelength, is used to form a metal structure (and thus a second solid section) from applied metal.
  • the plastic material and the metal are applied via a metal-plastic powder mixture, each of which comprises metal cores encased in a plastic jacket.
  • a metal-plastic powder mixture each of which comprises metal cores encased in a plastic jacket.
  • the proposed solution further includes a 3D printing device for the additive manufacturing of a component, which is suitable for carrying out one of the proposed methods.
  • a proposed 3D printing device can be set up to use a metal-plastic powder mixture with a metal component and a plastic component as a printing material and can also be set up to at least locally produce a plastic component of the metal-plastic material after the metal-plastic powder mixture has been applied by applying heat.
  • a metal-plastic powder mixture in an additive manufacturing process, which has metal-plastic particles, each with a metal core and a plastic jacket surrounding the metal core, in particular consisting of corresponding metal-plastic particles.
  • a corresponding metal-plastic powder mixture has not yet been used in the additive manufacturing of a component.
  • the plastic jacket is formed by a polymer.
  • the use of a polymer is particularly suitable in view of the different absorption abilities of a metal depending on a wavelength of laser radiation generated and hitting the respective material.
  • Laser radiation of a specific wavelength or a specific wavelength range can be used to specifically heat the polymer portion or the metal portion of the applied powder.
  • Figure 1 several layers of additively applied metal-plastic
  • FIG. 1 shows an absorption wavelength diagram for different
  • Figures 3A to 3F show different phases in an embodiment variant of a proposed method in which plastic structures and metal structures for a component to be produced are produced in a 3D printer device using the two different lasers of Figure 2;
  • Figure 4 shows a manufactured component in which a surface-accessible
  • Meta II structure is anchored in a polymer matrix via anchor structures.
  • Figure 1 shows schematically printed layers S1, S2 and S3 for a component to be produced additively during a 3D printing process.
  • a metal-plastic powder mixture consisting of metal-plastic particles 1 is used to produce the layers S1, S2 and S3.
  • the metal-plastic particles 1 of the powder mixture each have a metal core 10 which is completely covered by a plastic jacket 11.
  • the circular cross section of a metal-plastic particle 1, which can be seen in particular in the sectional view of FIG. 1, and a resulting spherical shape, for example, are merely exemplary. Of course, another cross-sectional shape can also be provided.
  • both a metal component via the metal cores 10 and a plastic component via the plastic jackets 11 are applied to a printing platform of the 3D printer device in a printing process in each layer S1, S2 and S3. Consequently, a plastic material is printed on the plastic jackets 11 at the same time as the metal cores 10.
  • the plastic material for the plastic jackets 11 can be formed, for example, by a polymer. In the following we will also speak of a polymer jacket 11. As illustrated by diagram D in FIG. 2, in which an absorption capacity is plotted over a wavelength for different materials, different materials absorb (laser) light to different extents depending on the wavelength. This is used for selective heat input into the different materials of the metal-plastic particles 1.
  • a first laser LP is provided, for example in the form of a CO2 laser, which generates laser radiation with a higher wavelength in the range of 8-12 pm. Due to the comparatively low absorption capacity of a metal in this wavelength range, such as stainless steel or structural steel, but the high absorption capacity of a polymer, the first laser LP can be used for the targeted introduction of heat into a polymer.
  • the laser radiation from the first laser LP with a wavelength in the range of, for example, 10 pm is reflected by the metal and therefore not absorbed, while it is absorbed by the polymer material in the polymer jackets 11.
  • a corresponding absorption capacity of the polymer can also be adjusted using additives added to the polymer material.
  • a second laser LM in turn generates laser radiation of a lower wavelength, in the present case for example in the range of 0.4-0.6 pm.
  • the second laser LM is a laser for generating green or blue laser light. Laser radiation of this smaller wavelength is well absorbed by a metal and is therefore suitable for heating it.
  • the polymer material of the polymer jackets 11 is transparent to laser light of this wavelength.
  • Figures 3A to 3E show an exemplary sequence of a proposed method for forming different solid body sections made of polymer material on the one hand and metal on the other hand using the metal-plastic particles 1 in a component B to be produced.
  • the respective laser LP can be operated with different power or a single laser LP for heat input into the polymer material of the polymer jackets 11, although always laser radiation identical wavelength, but with different power depending on how the polymer material is to be processed in a certain area.
  • the component section shown is divided into three areas or groups G1, G2, G3.
  • the laser LP is operated with lower power in order to melt, sinter or (further) polymerize polymer material of the polymer jackets 11, so that the individual polymer jackets 11 connect to one another and form a closed polymer structure 3 according to FIG. 3B.
  • the metal cores 10 are then embedded in a resulting polymer matrix of the polymer structure 3 without being connected to one another (and therefore without the formation of an electrically conductive path).
  • polymer material of the polymer jackets 11 is evaporated in layers using the laser LP.
  • the laser LP is operated with greater power than for producing the polymer structure 3 in the area G1.
  • the evaporation of the polymer jackets 11 in the area G2 ultimately leads, as shown in FIG. 3D, to the fact that only the metal cores 10 without plastic are present in this area G2.
  • one or more additional layers 100 with additional metal-plastic particles 1 are applied in the area G2 in which the polymer jackets 11 were previously evaporated, as shown in FIG. 3C.
  • the shrinkage is therefore compensated for by one or more additional layers.
  • the polymer jackets 11 of the additional layers 100 are evaporated again in the area G2 using the laser LP, so that only metal cores 10 are then present again in the area G2.
  • the (optional) application of the additional layers 100 thus compensates for the shrinkage that occurred due to the evaporation of the polymer jackets 11, with only metal cores 10 or metal powder formed with the metal cores 10 being present in the area G2.
  • the loose metal powder formed by the exposed metal cores 10 is sintered or melted using the other, second reader LM.
  • the laser radiation generated by the 2nd laser is LM transparent, so that deeper layers are not damaged by transmission.
  • a Meta II structure 4 is formed in the area G2, which - after appropriate cooling - forms a solid section made of metal in the component to be produced. In the present case, this solid section is present adjacent to a solid section made of polymer material in the area G1.
  • the polymer material used is of such a type that it ashes in the environment of the molten metal generated using the laser LM and then the ash generated in this way provides thermal insulation from the molten metal.
  • a previously produced section of plastic material or a corresponding plastic structure 3 can be formed in the area G1, which ashes at least locally under the influence of the subsequently produced molten metal in order to form thermal insulation from the molten metal for the metal structure 4 to be produced.
  • a metal insert, a conductor track or a circuit, for example, can be defined in the finished component B.
  • a finished component B can be seen in FIG. 4, in which a produced metal structure 4E is present in a polymer matrix of a polymer structure 3.
  • the metal structure 4E - which is accessible on an upper side as an example - is anchored in a form-fitting manner in the polymer material of the polymer structure 3 via additional anchor structures 4A, 4B, 4C and 4D made of metal.
  • Corresponding anchor structures 4A to 4D are produced by molten metal in comparatively small areas, in particular smaller areas than the Meta II structure 4E, in order to avoid deformation of the component B due to distortion.
  • the metal structure 4E is then melted onto the initially created anchors or anchor structures 4A to 4D (exemplarily T-shaped in cross section in FIG. 3) using the second laser LM.
  • the metal structure 4E can, for example, form a conductor track in the finished component B.
  • the different lasers LM and LP can generate laser radiation at different times for the selective further processing of the metal and plastic components in the printing material containing the metal-plastic particles 1 and thus in different process phases and in particular a connection of the respective plastic jackets 11 or metal cores 10 each other in layers.
  • a corresponding connection can also be provided across several layers.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Plasma & Fusion (AREA)
  • Physics & Mathematics (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Composite Materials (AREA)
  • Structural Engineering (AREA)

Abstract

La solution proposée concerne en particulier un procédé de fabrication additive d'un composant (B) dans lequel un matériau d'impression sous forme de poudre est appliqué couche par couche. Un mélange de poudre métallique/polymère comprenant un composant métallique (10) et un composant polymère (11) est utilisé en tant que matériau d'impression. Après l'application du mélange de poudre métallique/polymère, un composant polymère du mélange de poudre métallique/polymère est vaporisé au moins localement par l'introduction de chaleur, avant qu'un composant métallique (10) au moins localement restant du mélange de poudre métallique/polymère appliqué soit connecté – pour former une portion avec une structure métallique solide (4, 4A-4E) pour le composant (B) à produire – par l'introduction de chaleur.
PCT/EP2023/069097 2022-07-12 2023-07-11 Procédé de fabrication additive d'un composant à l'aide d'un mélange de poudres métallique/polymère WO2024013123A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102022207112.3A DE102022207112A1 (de) 2022-07-12 2022-07-12 Verfahren zur additiven Fertigung eines Bauteils unter Nutzung eines Metall-Kunststoff-Pulvergemischs
DE102022207112.3 2022-07-12

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WO2024013123A1 true WO2024013123A1 (fr) 2024-01-18

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