DE102018208400A1 - Apparatus for heating a component material, additive manufacturing equipment, and additive manufacturing method - Google Patents

Abstract

The invention relates to a device (300) for selectively heating a component material (P) for the additive, in particular powder-bed-based, production of a component (10). The apparatus comprises a platform (200) with a, in particular inductive, heating head (L), and a suspension (201) which carries the platform (200) and which is designed to control the platform (200) along three perpendicular spatial directions (X , Y, Z) within a construction space (AR) of an additive manufacturing plant (100) to move. Furthermore, an additive manufacturing plant (100) comprising the device (300) and a corresponding method for additive production are specified.

Description

The present invention relates to an apparatus for, in particular selective, heating or preheating a component material in the additive production. The component material is preferably a powder material for the powder-bed-based additive production of the component. Furthermore, an additive manufacturing plant, comprising the device and a method for the additive production of the component is given.

The component is preferably intended for use in a turbomachine, preferably in the hot gas path of a gas turbine. The component is preferably made of a nickel- or cobalt-based superalloy. The alloy may be precipitation hardened or precipitation hardenable.

Modern gas turbines are the subject of continuous improvement to increase their efficiency. However, this leads among other things to ever higher temperatures in the hot gas path. The metallic materials for blades, especially in the first stages, have recently been improved in terms of their strength, creep properties, and resistance to thermomechanical fatigue.

Due to its potentially disruptive potential for the industry, additive or additive manufacturing is becoming increasingly interesting for mass production of the abovementioned turbine components, such as turbine blades or burner components.

Additive manufacturing methods include, for example, as powder bed processes, selective laser melting (SLM) or laser sintering (SLS), or electron beam melting (EBM).

A method for selective laser melting is known, for example EP 2 601 006 B1 ,

Additive manufacturing processes (English: "additive manufacturing") have also proven to be particularly advantageous for complex or filigree designed components, such as labyrinthine structures, cooling and / or lightweight structures. In particular, the additive production is advantageous due to a particularly short chain of process steps, since a manufacturing or production step of a component can take place almost exclusively on the basis of a corresponding CAD file and the selection of corresponding production parameters.

For defect-free or low-defect processing of metals, but in particular of y'-hardened nickel-based superalloys within the powder-bed-based additive manufacturing or "3D printing" is often a preheating of the structure to be built on well above 1000 ° C necessary.

Comparable methods are already known from conventional production (cf the technologies for the catchwords "Hot Box Welding" or "Sweat-Welding"). A preheating of a component material or starting powder on the construction platform, however, for example, not sufficient because of the poor thermal conductivity of the powdery material to achieve over the entire height of a corresponding preheating or adequate heating.

The use of a locally acting "induction heating" is for example in WO 2013/152751 A1 where a system of cross-shaped coils is proposed. However, this system, when integrated into an existing additive manufacturing facility, such as an SLM facility, in the form of a preheat module, requires a lot of space and therefore severely restricts available space and / or surface area. Likewise, when applying a new powder layer, this system must always be moved back into a kind of "parking position" so as not to collide with a coating device.

It is therefore an object of the present invention to provide means which solve the problems described above. In particular, a device is presented which allows a simple and intelligent way of selective or local inductive heating of the component material. The solution also includes the operation of said device, for example, implemented in an additive manufacturing plant.

This object is solved by the subject matter of the independent patent claims. Advantageous embodiments are the subject of the dependent claims.

One aspect of the present invention relates to a device for, in particular selective, heating or preheating a component material for the additive, in particular powder bed-based, production of the component. The device comprises a platform with a, in particular inductive, heating head. By this means, a high preheating temperature can be achieved particularly expediently.

The apparatus further comprises a suspension which supports or holds the platform and which is formed, the platform, for example, controlled or controlled along three vertical spatial directions within a mounting space an additive manufacturing plant to move. In contrast to solutions already described in the prior art, the embodiment of the suspension also makes possible a targeted or controlled movement of the platform along the vertical spatial Z-axis within the mounting space.

The advantages of the proposed solution, in contrast to previously known solutions, for example, the possibility of local and intensive preheating at the place of processing, ie "in situ" of the actual local melting process by a laser or electron beam. Accordingly, the said processing site may designate a (mobile) molten bath in the component material caused by the energy beam.

Another advantage relates to the simple possibility of flexible three-dimensional positioning of the platform, preferably at any location within a space and on the build platform. The device advantageously occupies only a small space within the construction field. Since the platform can also be moved along the vertical time axis via the provided device, in particular the space requirement of an additive manufacturing facility in X - and Y - direction not restricted.

Furthermore, a reaction atmosphere can be created at the site of processing or selective solidification of the component material via the device or the platform (in situ), which has an advantageous effect on the structural properties or mechanical properties of the component to be produced (see below).

In one embodiment, the heating head comprises an, in particular water-cooled, induction coil, which, in particular via a high-frequency generator, such as the device, can be operated and / or regulated and is designed locally the component material to a temperature between 800 ° C and 1200 ° C, in particular of 1000 ° C or more, to heat or preheat for the actual additive buildup process, ie to bring to a suitable preheating temperature. By preheating in particular high temperature gradients at the location of the molten bath or in its vicinity, which can exceed 1000 K / s, for example, without a corresponding heating, can be prevented. This further advantageously reduces or reduces the formation of crack centers or hot cracks.

In one embodiment, the suspension includes four actuators, which are individually controlled and evenly, for example, in a quadrangular arrangement, attachable in the mounting space. The actuators are preferably designed to be flexible in each case, in order to allow a mobility of the platform along the three mutually perpendicular spatial directions.

In one embodiment, the actuators are each made flexible.

In one embodiment, the actuators are each controlled via a gear, a cable, a telescopic arm, pneumatic and / or hydraulic means. As a result of this configuration, the actuators can preferably be made particularly flexible.

In one embodiment, the device comprises a temperature measuring device, such as an infrared camera or a pyrometer, which is arranged and designed - for example, viewed in plan view of a construction surface - to measure the temperature of the component material and on the construction area and / or to regulate or control. As a result of this configuration, advantageously the heating head and thus the preheating temperature of the component material can be monitored and regulated.

In one embodiment, the device comprises a protective gas guide, which is coupled to the platform and designed to guide a protective gas, for example an inert gas, laminar or parallel over and / or perpendicular to the component material during the additive production of the component. The vertical guidance of the protective gas onto the component material can be implemented, for example, by means of a showerhead-like arrangement of the protective gas guide or a corresponding gas outlet. By coupling the protective gas guide to the platform, it can be advantageously achieved that the protective gas can be conducted locally to or into the region of the component material which is currently being melted and / or strongly tends to corrode or oxidize.

Another aspect of the present invention relates to an additive manufacturing facility comprising the described apparatus. The manufacturing plant preferably further comprises a coating device and an irradiation device, as in already known additive manufacturing plants. However, the device is arranged in the system, for example, along the construction direction of the corresponding component, above a mounting surface.

A further aspect of the present invention relates to a method for preheating and / or additive production, preferably a powder bed method, of a component comprising the application a layer of a component material on a mounting surface with the coating device.

The method further comprises lowering or approaching a platform in the direction of a region of the construction surface to be irradiated.

The method further comprises heating the area to be irradiated by means of the heating head of the device.

The method further comprises irradiating the area with an energy beam to selectively solidify the component material according to a predetermined geometry of the component.

In one embodiment, after the area has been irradiated, the method comprises lifting or lifting the construction platform out of an area of action of the irradiation device and then repeating the described steps of application, subsidence, heating and / or irradiation.

In one embodiment, the steps of the described heating and irradiation are performed at least partially simultaneously.

In one embodiment, the irradiation of the region is performed synchronously, preferably at the same time and / or location, with the heating, wherein the energy beam is guided during the additive construction of the component, for example through an eye of an induction coil of the device or the heating head.

In one embodiment, the component material is locally heated to a temperature of about 800 ° C, preferably 1000 ° C or more, more preferably 1200 ° C or more.

In one embodiment, the component material is locally heated to a temperature between 800 ° C and 1200 ° C, in particular 1000 ° C or more.

In one embodiment, the component material is a γ and / or γ 'hardened nickel- or cobalt-based superalloy and the component is a component applied or provided in the hot gas path of a gas turbine.

In one embodiment, the component material is merely preheated before the actual additive structure, for example by selective laser melting.

Embodiments, features and / or advantages relating in the present case to the device or the additive manufacturing plant may also relate to the process for additive production or vice versa.

Further features, properties and advantages of the present invention will be explained in more detail below with reference to exemplary embodiments with reference to the attached figures. All features described above and below are advantageous both individually and in combination with one another. It should be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following description is therefore not to be construed in a limiting sense.

As used herein, the term "and / or" when used in a series of two or more elements means that each of the listed elements may be used alone, or any combination of two or more of the listed elements may be used.

• 1 deutet anhand einer schematischen Schnittansicht einen pulverbett-basierten additiven Herstellungsprozess eines Bauteils an.
• 2 zeigt eine vereinfachte und schematische perspektivische Ansicht einer erfindungsgemäßen Vorrichtung.
• 3 deutet anhand eines schematischen Flussdiagramms erfindungsgemäße Verfahrensschritte an.

Further details of the invention are described below with reference to the figures.

• 1 indicates by means of a schematic sectional view of a powder bed-based additive manufacturing process of a component.
• 2 shows a simplified and schematic perspective view of a device according to the invention.
• 3 indicates method steps according to the invention on the basis of a schematic flow chart.

In the exemplary embodiments and figures, identical or identically acting elements can each be provided with the same reference numerals. The illustrated elements and their proportions with each other are basically not to be regarded as true to scale, but individual elements, for better representation and / or better understanding exaggerated be shown thick or large.

1 shows an additive manufacturing plant 100 , The attachment 100 is preferably a device for the additive production of a component (see reference numeral 10 ) from a powder bed, for example by selective laser melting or electron beam melting. The attachment 100 has a substrate plate 11 on. On the substrate plate or the substrate 11 becomes part of its additive manufacturing process 10 constructed, ie preferably also directly cohesively connected or "welded".

The component is preferably a component which is used in the hot gas path of a turbomachine, for example a gas turbine. In particular, the component may designate a rotor or vane, a segment or ring segment, a burner part or a burner tip, a frame, a shield, a nozzle, a seal, a filter, a mouth or lance, a resonator, a stamp or a swirly, or a corresponding transition, use, or a corresponding retrofit part.

The component 10 is preferably in a body space AR of the plant 100 built up.

The component 10 is in 1 preferably shown only partially constructed, for example, only two layers S a component material P ,

In the component material P it may be a powder of a γ- and / or γ'-hardened, nickel- or cobalt-based superalloy.

Individual layers of the material P for the layers S of the component are preferably via a coating device 30 applied and then by means of an energy beam 21 for the construction of the component 10 selectively melted and solidified. The energy beam is preferably from an irradiation device 20 For example, comprising or comprising an electron beam or a laser source emitted.

After a shift S has been built, the substrate plate 11 preferably one of the layer thickness S corresponding amount lowered. Subsequently, a new powder layer for the construction of the component 10 applied, for example, starting from a powder supply, which on the left in 1 is shown.

The additive buildup process is preferably carried out under an inert or inert gas atmosphere or at least in an atmosphere with reduced oxygen content in order to prevent corrosion, oxidation or other influences which affect the quality of the component material, ie the powder P , or the final manufactured component 10 influence, avoid.

An appropriate inert gas or inert gas guide is in 1 not explicitly marked; However, it may be provided and designed, an inert gas, for example laminar, over a construction area AF respectively.

Furthermore, in 1 a camera, for example an infrared camera 50 , which is preferably arranged and formed, the temperature of the component material P on the mounting surface AF to measure and / or to regulate.

Furthermore, in 1 already a platform according to the invention 200 , For example, a device 300 (see 2 below), via which a targeted or selective heating of the component material P can be done. The platform 200 Can have a suspension 201 (You too 2 stored and / or moved below).

A mounting direction (not explicitly marked) for the component 10 corresponds to 1 a vertically upward direction.

2 shows details of a device 300 or a partial view of the plant 100 which the device 300 contains or in which the device 300 is installed, for example, as a retrofit kit. In 2 is the device 300 above the construction area AF arranged.

The device 300 is preferably for selectively heating or preheating the component material P for the additive, in particular powder bed-based, production of a component 10 intended.

As already on the basis of 1 indicated, includes the device 300 a platform 200 with a, in particular inductive, heating head L , and a suspension 201 which the platform 200 wears and which is formed, the platform 200 along three vertical spatial directions X . Y . Z within a construction space AR to move. In addition to a lateral movement in X -, or Y Direction allows the device according to the invention 300 So also a vertical movement of the platform 200 along the Z -Axis.

The platform 200 For example, may be configured annular, so that, for example, during the additive production of the component 10 , the energy beam 21 can be passed through them.

The heating head L For example, an induction coil, such as a high-frequency coil, which can be operated and / or regulated, in particular via a high-frequency generator, and is designed, the component material P locally to a temperature of about 800 ° C, preferably 1000 ° C, more preferably 1200 ° C. or to heat more, for example, to heat (before) the actual additive construction.

In one embodiment, the component material is locally heated to a temperature in a range between 800 ° C and 1200 ° C, in particular 1000 ° C or more.

The frequency at which the described coil or the corresponding generator can be operated, for example, can be up to 2000 kHz for high-frequency generators, and for example up to 200 kHz for medium-frequency generators.

Alternatively, the heating head L other means for heating, such as a radiant heater or other known from the prior art means for locally selective heating of a metallic powder have.

The suspension 201 preferably comprises three or four actuators 201 , An embodiment with four in the corners of the body space AR arranged actuators 201 is in 2 exemplified explicitly. The actuators 201 can, preferably individually driven, and evenly in the construction space AR be attached or attached, and / or driven accordingly or activated.

The actuators 201 may preferably continue to be flexible, ie that the platform 200 via a corresponding activation of the actuators 201 for example, according to any in the body space AR lying (Cartesian) coordinates X . Y . Z can be arranged or moved. This can be done for example via a transmission, a cable, telescopic arm or pneumatic and / or hydraulic means. For example, it is possible to coordinate the actuators via compressed air or electrically controlled telescopic arms and / or to activate them in a coordinated and controlled manner.

The device 300 also has a protective gas or inert gas supply 220 on. The protective gas guide 220 is, preferably formed, a protective gas, for example an inert gas, such as argon or helium or other inert gases, during the additive production of the component 10 laminar over and / or perpendicular to the component material P to guide (see arrows in the area of the molten bath SB in 2 ).

A vertical guidance of the protective gas on the component material P can be made possible for example via a shower head or showerhead-like gas guide.

The protective gas guide 220 In particular, it may comprise or constitute a miniaturized and / or endoscopic protective gas nozzle, thereby providing, in particular locally, a reduction in the oxygen content in the selectively preheated or heated zone during the additive production of the component 10 ,

This protective gas nozzle (not explicitly identified) can be provided, in particular, in addition to a global or laminar protective gas guide, which reduces the oxygen content or partial pressure in additive manufacturing processes or in construction spaces of conventional plants.

The device 300 or the plant 100 may also have a corresponding protective gas outlet (not explicitly marked).

In the present invention and in the presented device 300 Advantageously, a preheating by means of a radio frequency coil, which from the platform 200 is worn, suspended in particular four actuators. Thus, the coil, similar to a spider or a spider body, on the construction field or the construction area AF be suspended and by a corresponding activation of the actuators 201 In each XYZ Position within the installation space AR to be moved.

The four actuators 201 For example, each in the corners of the body space AR attached and grab all in the platform 200 ,

The protective gas guide 220 and, for example, also a power supply 210 and a control of the heating head or the coils L and supply lines or supplies of inert gas guide 220 or the power supply 210 can also on the, in particular annular, platform 200 to be appropriate. The said leads are preferably also made flexible, so no limitation of movement of the platform 200 or the heating head L arises.

3 shows, with reference to a schematic flowchart, method steps of a method according to the invention, in particular a method for operating said device 300 or an additive manufacturing process.

The method comprises a ), applying a coat S of the component material P on the construction area AF by means of the coating device 30 ,

The method further comprises b ), lowering or placing the platform 200 in the direction of an area to be irradiated B the construction area AF ,

At the mentioned movement of the platform 200 this is preferably at least proportionally along the vertical axis ( Z -Axis) down to the platform or, preferably, the heating head L to move in the direction of area B.

Region B preferably describes the region which stratified for the additive construction of the component 10 is provided for irradiation. Accordingly, the region B can be lateral (in plan view of the mounting surface AF considered) a molten bath SB include or include. The area B preferably describes a dynamic or - during the construction of the component 10 - Movable area or a corresponding irradiation trajectory.

The method further comprises c ) heating or preheating the area to be irradiated B , preferably a larger area, which covers the area B contains, by means of the heating head L the device 300 ,

The method further comprises d ), irradiating the area B with an energy ray 21 according to a predetermined geometry of the component 10 ,

According to one embodiment, the method further comprises, preferably after the irradiation of the area B (compare process steps d ) and e ), lifting or lifting the platform 200 from an area of effect of the irradiation device 30 ,

The area of action preferably describes an area just above the construction area AF within which the irradiation device, in particular a squeegee or a blade, is laterally moved, that is to say preferably a region which only has a small vertical region in the construction space (height in Z Direction).

Of course, the method steps mentioned can be achieved by way of the layer-by-layer additive production of the component 10 be repeated according to the number of layers still to be built up and required.

In one embodiment of the method, the described steps of heating ( c )) and irradiation ( d )) performed at least partially simultaneously. This is indicated by the dashed circle in the 3 indicated.

The irradiation of the area B can continue to be performed synchronously with the heating, wherein the energy beam 21 for example, during the additive construction of the component 10 by an eye (not explicitly indicated) of the induction coil or the heating head and / or the device 300 to be led. This can advantageously be a synchronous movement with a working laser (cf. 21 in 1 ) for the construction of the component 10 enable.

In other words, an energy ray 21 during the manufacture of the component 10 always in operation by the "eye" of the induction coil L to the predetermined position in the area B on the construction area AF aim. This area B is preferably the area which at least through the heating head L is heated.

The invention is not limited by the description based on the embodiments of these, but includes each new feature and any combination of features. This includes in particular any combination of features in the patent claims, even if this feature or combination itself is not explicitly stated in the patent claims or exemplary embodiments.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 2601006 B1 [0006]
• WO 2013/152751 A1 [0010]

Claims (13)

Device (300) for selectively heating a component material (P) for the additive, in particular powder-bed-based, production of a component (10), comprising: - A platform (200) with a, in particular inductive, heating head (L), and - A suspension (201) which carries the platform (200) and which is adapted to move the platform (200) along three vertical spatial directions (X, Y, Z) within a mounting space (AR) of an additive manufacturing plant (100). Device (300) according to Claim 1 wherein the heating head (L) comprises an induction coil, which can be operated and regulated in particular via a high-frequency generator, and is designed locally to a component temperature between 800 ° C and 1200 ° C, in particular 1000 ° C or more, to warm. Device (300) according to Claim 1 or 2 , Wherein the suspension comprises four actuators (201), which are individually controlled and evenly, for example in a quadrangular arrangement, in the mounting space (AR) can be attached. Device (300) according to Claim 3 , wherein the actuators (201) can each be controlled pneumatically and / or hydraulically via a gear, a cable, a telescopic arm. Device (300) according to one of the preceding claims, comprising a temperature measuring device, for example an infrared camera or a pyrometer, which is arranged and designed to measure and / or regulate the temperature of the component material (P) on a mounting surface (AF). Device (300) according to one of the preceding claims, comprising a protective gas guide (220), which is coupled to the platform (200) and formed, a protective gas, for example an inert gas during the additive production of the component (10) laminar over and / or perpendicular to the component material (P) to lead. An additive manufacturing plant (100), comprising the device (300) according to one of the preceding claims, further comprising a coating device (30) and an irradiation device (20) and wherein the device (300) is arranged above a mounting surface (AF). Method for the additive production of a component (10), comprising the following steps: a) application of a layer (S) of a component material (P) on a mounting surface (AF) with a coating device (30), b) lowering of a platform (200) according to one of Claims 1 to 6 c) heating the area to be irradiated (B) by means of a heating head (L) of the device (300), and - d) irradiating the area (B) with a Energy beam (21) according to a predetermined geometry of the component (10). Method according to Claim 8 comprising, after irradiating the region (B), e) lifting the platform (200) out of an area of action of the irradiation device (30) and then repeating steps a) to d). Method according to Claim 8 or 9 , wherein steps c) and d) are carried out at least partially simultaneously. Method according to one of Claims 8 to 10 wherein the irradiation of the region (B) is performed in synchronism with the heating, wherein the energy beam (21) is guided during the additive construction of the device (10), for example, through an eye of an induction coil of the device (300). Method according to one of Claims 8 to 11 , wherein the component material (P) is locally heated to a temperature between 800 ° C and 1200 ° C, in particular 1000 ° C or more. Method according to one of Claims 8 to 12 , wherein the component material (P) is a γ and / or γ ', hardened nickel or cobalt-based superalloy and the component (10) is a component used in the hot gas path of a gas turbine and the component material (P) before the actual additive structure, for example by selective Laser melting is merely preheated.

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