WO2018033405A1 - Method and device for the additive production of a component - Google Patents

Abstract

The invention relates to a method and to a device for the additive production of a component (10), comprising the detection of an edge contour (11) of a layer (12), additively structured or to be structured from a powder bed (1), for the component (10) on a construction platform (2) and the aligning of a coater direction (BR) for a powder layer to be newly applied, relative to the detected edge contour (11), such that an edge (11) of the additively structured layer (12) includes an angle to the coater direction (BR) which is different from 90°.

Description

 METHOD AND DEVICE FOR THE ADDITIVE MANUFACTURE OF A COMPONENT

description

Method for the additive production of a component and device

The present invention relates to a method for the additive production of a component and to a corresponding device. The process may be a coating process as part of an additive manufacturing process.

The component is preferably intended for use in a turbomachine, preferably a gas turbine. The component is preferably made of a superalloy, in particular a nickel- or cobalt-based superalloy.

The superalloy may be precipitation hardened or precipitation hardenable.

Additive manufacturing processes ("additive manufacturing") have proven to be particularly advantageous for complex or complicated or filigree-designed components, for example labyrinth-like structures, cooling structures and / or lightweight structures, In particular, additive manufacturing is characterized by a particularly short chain A manufacturing or manufacturing step of a component can be carried out directly on the basis of design data, such as a corresponding CAD file .Additionally, the additive manufacturing is particularly advantageous for the development or production of prototypes, which, for example, for cost reasons, can not or can not be produced efficiently by conventional subtractive or metal-cutting processes or casting technology.

An additive method of selective laser melting is known, for example, from EP 2 601 006 B1.

In additive manufacturing (in the case of powder bed processes) the powder becomes before melting or solidifying, for example by means of a slider or coater, applied as a thin layer on a preferably flat construction platform. For this purpose, the coater or doctor blade is usually guided linearly over the build platform.

Previously, the component must be placed on the build platform, taking into account a coating direction. Simple components with a simple edge geometry or contour are preferably arranged in the middle of the construction platform and possibly with an edge parallel or perpendicular to the coating direction. Experience has shown that such an arrangement is unfavorable since the coater would approach or cover the said edge for all layers with the full width or extent. This can in particular lead to an uneven layer application and / or increasingly to local tool wear. Since this process or this problem is the same in subsequent layers, so can a fault propagation caused and thus the layer or component quality are particularly affected.

One way to avoid these disadvantages, for example, to arrange the component on the building board so that a coater hits an edge or contour of the component at an oblique or oblique angle, for example 45 °. This can be done, for example, by a rotation or corresponding arrangement of the component or adaptation of a corresponding data model to an orientation of the construction platform. In the case of components to be manufactured, however, this is often difficult, since a simple and / or linear edge geometry or contour of the components is seldom given and in particular the contour changes or varies in the course of the layered structure.

It is therefore an object of the present invention to provide means by which the mentioned disadvantages can be limited or overcome. 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 method for additive manufacturing. The method comprises detecting an edge contour of a layer that is additively constructed or to be constructed from a powder bed on the construction platform. The built-up layer is in particular an already molten and solidified layer for the component.

The detection of the edge contour preferably denotes the detection of a position of the edge contour relative to the build platform or vice versa.

In the present case, the term "edge contour" preferably designates the outer, preferably horizontal, edges of the built-up or built-up layer on the construction platform and / or the contour of the component formed by the edges on the construction platform represent the corresponding built-up layer of the component.

In one embodiment, the edge contour of the layer to be built up additively or to be built up, or the position of the edge contour relative to the build platform, is detected or determined on the basis of a data model, preferably design data, such as CAD data.

In one embodiment, the edge contour or its position relative to the construction platform is detected physically by means of a scanning process, for example with a laser scanner, in which the built-up layer is examined with a corresponding scanner. In one embodiment, the edge contour is screened according to a data model or manufacturing data and - as an alternative or quality assurance measure - by means of a scanner.

The method further comprises aligning a

Coating direction for a new powder layer to be applied relative to the detected edge contour or vice versa, such that an edge of the layer to be built up or to be built up has an angle which is preferably finite or non-zero and different from 90 °

Coater direction includes.

In one embodiment, the alignment is carried out in such a way that the edge of the additively constructed or to be built up layer forms an angle between 10 ° and 80 ° with the

Coater direction includes. This embodiment is particularly useful to use the advantages of the invention. In particular, said angle is preferably greater than 20 ° relative to the coater direction BR.

Preferably, said angle is between 10 ° and 80 °, more preferably between 20 ° and 70 °, in particular between 30 ° and 60 °, for example 45 °.

If the said edge is not linear or is not straight, preferably according to the invention a plurality of spaced-apart points or all points on the edge or its tangent (s) have an angle different from 90 ° with the coater direction.

The coater direction is preferably a direction along a surface normal of a coater face or perpendicular to the coater face (see below). The

Coater surface is preferably that surface which is in direct contact with the powder and / or the powder bed for the coating process or the distribution of the newly applied layer on a production surface and which the surface which pushes the powder in front of it for a coating process.

The aforementioned newly applied powder layer is expediently designed to build up or solidify a further layer for the component.

Advantageously, it is achieved by the described method that - as described above - edges of layers which are already additively constructed are not run over along their full extent by a coater, and thus coating defects can be avoided.

Furthermore, powder-bed-based processes as a whole can be carried out much more robustly and the quality of the manufactured components can be decisively improved.

In particular, dimensional and form deviations of the component (for example from a model or ideal) can be reduced by improved coating quality. This in turn allows cost or resource savings, as the rejection of faulty components can also be reduced. In one embodiment, the coater direction is aligned relative to the detected edge contour by rotating the build platform, preferably together with a component structure possibly arranged thereon. In one embodiment, the coater direction is aligned relative to the detected edge contour by rotating a coating device and / or the coater direction, for example by a predetermined angle of a few degrees.

In one embodiment, the coater direction relative to the edge contour by rotating the build platform and - like described - aligned by rotating the coater direction.

In one embodiment, the coater direction is aligned relative to the edge contour via a change in the component design. This happens, for example, via a correction of the design data, for example CAD and / or CAM data. In one embodiment, the alignment is carried out in layers or is repeated after each layer constructed.

In one embodiment, the alignment is performed on the basis of a calculation based on CAD and / or CAM data or data derived therefrom for the additive production of the component.

In one embodiment, after each built-up or solidified layer for the component is checked after or by capturing whether the corresponding edge encloses an angle different from 90 ° with the coater direction, the coater direction, if not, reoriented. In one embodiment, the method is a coating method for additive production.

In other words, the method steps of detection and / or alignment can be carried out according to the invention for each powder layer.

A further aspect of the present invention relates to a device for the powder-bed-based additive production of a component, as described above, wherein the device is designed to coat a production surface for the layered additive structure uniformly along a coating direction with a new powder layer (layerwise). layers, wherein a coating direction with the coating direction includes an angle other than 90 °. Accordingly, the device described is preferably likewise designed to solve the abovementioned disadvantages or problems in the coating according to the invention.

The powder is expediently a powdered base material for the component.

In one embodiment, the coater surface (see above), for example at outer edges of the production surface in the direction of the coating direction, is bent. This refinement preferably makes it possible to solve the stated problems according to the invention, without complicated or complicated method steps. In particular, by the curved configuration of the device, in particular of the

Coater surface having part of the device ensures that an edge contour or edge of an already solidified component layer with the coater direction includes an angle different from 90 °.

In one embodiment, the coater surface has at least two planar mutually angled sub-areas, of which at least one with the coating direction expediently encloses an angle different from 90 °. This embodiment is provided as an alternative to the above-described curved configuration of the coater surface and also allows the advantages according to the invention.

In one embodiment, the device comprises a round construction platform. The round shape of the build platform is particularly related to a plan view of the build platform. In contrast to the two aforementioned embodiments, this embodiment of the device allows the object according to the invention to be achieved by rotating the construction platform or the coater direction (see above). In one embodiment, the device is a coating device or coater, in particular a powder slide, a doctor blade or powder roller for the additive construction of complex, high-temperature-resistant components. Accordingly, the device is preferably also high-temperature resistant, preferably resistant or heat-resistant for temperatures above 1000 °, preferably 1200 ° formed.

Embodiments, features and / or advantages relating in the present case to the method may also relate to the device or vice versa.

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

FIG. 1 shows a schematic sectional or side view of a coating device.

FIG. 2 shows a schematic plan view of the device.

FIG. 3 shows a schematic side view of a component on a building platform.

FIG. 4 shows a schematic plan view of the component from FIG. 3.

FIG. 5 shows a schematic side view of a component on a building platform.

FIG. 6 shows a schematic plan view of the component

FIG. 5. FIG. 7 shows a schematic side view of a component. FIG. 8 shows a schematic plan view of the component from FIG. 7.

FIG. 9 shows a schematic side view of another component on a construction platform.

Figure 10 shows a schematic plan view of the component of Figure 9. Figure 11 shows a schematic side view of another component on a construction platform.

FIG. 12 shows a schematic plan view of the component from FIG. 11.

FIG. 13 shows a schematic side view of another component.

FIG. 14 shows a schematic plan view of the component

 13th

FIG. 15 shows a schematic sectional or side view of a device according to the invention. FIG. 16 shows a schematic plan view of the device from FIG. 15.

FIG. 17 shows a schematic flow diagram which indicates method steps of a method according to the invention.

FIG. 18 indicates two different embodiments of a coater according to the invention. FIG. 19 shows a further embodiment of a device according to the invention. 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. FIGS. 1 to 14 describe, in particular, known aspects and relationships in additive production, in particular the corresponding coating methods and devices and methods of the prior art. In particular, Figure 1 shows a device 30 in a schematic sectional or side view. The device 30 comprises a construction platform 2. The construction platform 2 is preferably arranged in a powder bed or powder 1. For the construction of a component by means of a corresponding powder bed process, preferably a production surface HF of the construction platform and / or an already constructed layer (not explicitly shown in FIG. 1) is coated with powder. For this purpose, a coater 32 is provided, which can be guided on a suspension 31 or moved accordingly. The coater 32 may be, for example, machine-controlled. Preferably, the coater for a new powder application along a movement or coating direction BUR (see below), in this case guided from left to right on the manufacturing surface HF and thereby applied a new powder layer. The new powder layer can then be exposed, melted and solidified, for example, by means of a laser or an electron beam according to the desired geometry. FIG. 2 shows the device from FIG. 1 in a schematic plan view. The arrow defining the coating direction BUR and the coater direction BR should be present be valid in particular for the figure 1 as well as for the figure 2.

2, it can be seen that the coater 32 extends along the production surface HF (see FIG.

Axis). The coater 32 may have a roller, a blade, a squeegee, a brush, or another convenient embodiment. FIG. 3 shows a component 10 which is arranged on an, for example, conventional construction platform 2. According to the powder bed-based method, the build platform 2 is usually lowered in layers during the additive construction of the component 10. This is preferably done via a lowering device 20.

The component further comprises an edge or edge contour 11. FIG. 4 shows a schematic plan view of the component or the corresponding build platform from FIG. 3. It can be seen in particular that the component is arranged or oriented relative to the build platform 2 such that the edges 11 parallel to edges of the building platform 2 are oriented. If, according to this arrangement, a coater 32 (cf. FIG. 2), for example, traveled horizontally in accordance with the coating direction BUR over the production area HF, wherein the production area HF can also be defined by a layer already built up in order to apply a new powder layer At some point, coaters meet with their full width (compare coater surface BF in FIG. 2) an edge 11 of the component 10 (see dashed line, which indicates the coater surface or the coater). This can lead to uneven coating results or coating defects to a considerable extent, as this process is repeated layer by layer during the construction of the component and can thus propagate or add coating defects. To solve this problem, for example, the component 10 can be arranged or aligned on the construction platform 2 according to the representations of FIGS. 5 and 6. FIG. 6 shows, for example, that a contour or edges 11 of the component 10 are not oriented parallel to the side edges of the construction platform and accordingly not parallel to a coating direction BUR. Therefore, one would

Coater (see again dashed line in Figure 6) initially meet only a corner 13 or vertical edge of the component 10, whereby, however, the described coating error hardly occur.

FIG. 7 shows another component 10 in a schematic side view. A schematic plan view of this component is shown in FIG.

This component 10 has in particular a first area Bl. The first region Bl may be a main body or base region for the component 10. On the first area Bl, a second area B2 is still constructed and displayed. The second area B2 may be, for example, a functional area.

The first area Bl and the second area B2 are both cuboid-shaped. However, the edge contours (see reference numeral 11) of the first area Bl and the second area B2 are arranged rotated against each other according to the individual geometry of the component 10 so that side edges 11 of the first area Bl and side edges 11 of the second area B2 are not parallel.

To give a concrete example, the component 10 may be a turbine blade, the first region Bl a

Shovel foot and the second area B2, for example, the actual blade designated. In such complex, in particular not parallelepiped-shaped components, the edge contour along a construction direction (from bottom to top) of the component varies, so that, to the present mentioned disadvantages To avoid the coating, a compromise for the alignment of the component 10 on the build platform 2 must be found (see Figures 13 and 14 below). If the component 10 from FIG. 7 is arranged on the build platform 2, for example, according to FIGS. 9 and 10, a coater 32, for example, which coats the manufacturing surface HF from the left along a coating direction BUR (see FIG meet first portion Bl of the component 10 (see dashed line in Figure 10). At a later stage of the construction, namely when the construction has already progressed to the second area B2, an edge 11 of the second area would again coincide with the full width of the coater 32.

If the component were aligned in accordance with FIGS. 11 and 12, the process would be reversed, and an edge 11 of the first region Bl of the component 10 would be approached by the coater 32 and cause the corresponding coating defects, although the coating errors would be for the construction of the second region B2 would be eliminated.

FIG. 13 indicates the arrangement of the described component 10 on the building platform 2, according to which the coating defects described are at least largely prevented during the additive construction. This is the case in particular, since neither the edges of the first region nor the edges of the second region are aligned parallel to the coater surface BF or the coater 32 when the coater moves across the production surface in the coating direction BUR (see dashed line in FIG. 14) ).

The extent or height of the regions B1, B2 indicated in FIG. 13 preferably corresponds to a multiple of a single solidified layer (cf. reference numeral 12 in FIG. 13), which is likewise indicated by a dashed line. However, such a compromise as shown in Figure 14, according to the shape complexity additively manufactured components is often difficult or even impossible, regardless of the relevant technical field in which these components are used, since the alignment of the components relative to the build platform, once a single

Layer was solidified on this, can hardly be subsequently changed. FIGS. 15 to 18 describe solutions according to the invention which make it possible, for example, to solve the problem of coating defects a priori and independently of the initial orientation of the respective component. FIG. 15 shows a device 50 according to the invention in a schematic side view or sectional view. The device 50 according to the invention likewise comprises a construction platform 2. The device 50 furthermore comprises a suspension 61 to which a coater 60 is expediently coupled in a movable or movable manner. According to the presentation of the

1, the device 50 is preferably designed to apply powder layers or powder layers for additive production to a production surface HF by means of the coater 60. This is preferably done as shown from left to right according to the coating direction BUR.

The construction platform 2 is preferably round, as shown in FIG. 16 in the corresponding schematic plan view of the device 50.

According to the invention, the construction platform 2 and / or the remaining parts of the device, comprising the coating device of suspension 61 and coater 60, are movable about a rotation axis DA. In particular, the construction platform 2 and the other components are preferably movable or rotatable about the axis of rotation DA independently of each other. These embodiments make it possible to adapt the orientation of the component or of individual layers constructed for it (not explicitly 16) during additive production, such that a coater surface BF of the coater 60 preferably does not meet along its full width (compare Y-axis in FIG. 16) edges of a corresponding component, and preferably not always at the same locations along the edge.

Unlike in Figure 16, the coating device, i. The suspension 61 and the coater 60 can preferably be moved down and back up completely from the platform 2 by suitable means, so that, for example, the platform 2 is rotated relative to the coater, when the base material to be newly applied (see reference numeral 1) in Figure 16) is preferably not in contact with a manufacturing surface HF. This could otherwise lead to unwanted powder movements (vortex movement) and also affect the manufacturing quality.

With reference to FIGS. 15, 16 and 17, a method according to the invention is presented and described which solves the coating problems addressed in the present case.

In particular, Figure 17 shows a schematic flow diagram. The method step a) describes the detection of the edge contour 11 or edge geometry of a powder bed 1 additively constructed or to be built layer 12 for the component 10 on a build platform 2 (see Figure 13 and dashed line in Figure 16, which the edge contour 11 of a corresponding Layer indicates).

By way of example, the edge contour or its position relative to the construction platform is detected on the basis of a data model, preferably based on design data and / or CAD data.

Alternatively or additionally, the edge contour 11 or its position or course relative to the build platform 2 physically by means of a scan, for example with a Laser scanner detected in which the built-up layer is examined with a corresponding scanner.

The method step b) describes the alignment of a coater direction BR for a newly applied powder layer relative to the detected edge contour 11 such that an edge 11 of the additively constructed or to be built layer 12 has an angle different from 90 ° with the

Coater direction BR. Accordingly, an angle is shown in Figure 16, which is preferably different from 0 and 90 °, in particular, for example, greater than 20 ° and a relative rotation between the edge contour 11 of the layer 12 and the coating direction BUR indicates. The coater direction BR can correspond to the described coating direction BUR (compare FIGS. 1 to 16).

Said orientation can be effected such that in particular the coater direction BR is changed by rotating the coater and / or the coating device relative to the edge contour 11 or the component 10.

Alternatively or additionally, for the change of an unfavorable orientation of the component and the coating direction for the coating result, the construction platform can preferably be rotated with a component structure optionally arranged thereon relative to the coating direction.

A corresponding alignment can likewise be effected by making a change in the component design, in particular for a layer to be newly applied and subsequently to be consolidated.

The alignment is carried out according to the invention preferably in layers and on the basis of a calculation based on CAD and / or CAM data or derived data for the additive production of the component. According to the invention, it is preferably checked after each built-up layer 12 for the component 10 after or by detecting whether the edge 11 encloses an angle other than 90 ° (see FIG. 1) with the coater direction BR, and, where the coater direction BR, or is realigned.

Under certain circumstances, it is not always possible or for all edge regions or edge points, in particular in the case of round contours, that all points of an edge or its tangent (s) enclose an angle other than 90 ° with the coater direction BR.

However, the problem according to the invention can also be solved if many of the points or the corresponding edge enclose a (finite) angle different from 90 ° with the coater direction BR to the greatest possible extent. In the case of round or oval edge contours, the

Coater BR preferably such layer by layer, ie changed per layer, during the additive building of the component or "further rotated" that along the edge contour always different or successively different points on the contour or the edge "unfavorable" are arranged, ie, that At the latter points or positions on the edge nor the problems to be solved according to the invention occur. FIGS. 18 and 19 show, in particular, alternative solutions to the described methods, which are achieved by the device according to the invention and the coaters shown in FIG. In the illustrations of FIGS. 18 and 19, the coater direction BR deviates from the described coating direction BUR as indicated by the design of the coater or coater. In the left-hand view of FIG. 18, a coater 60 according to the invention is shown. The coater may in particular be a squeegee, a slider, a brush or a roller, suitable for coating an arbitrary production surface for the additive construction of a component. The coater 60 shown on the left in FIG. 18 has or defines a coater surface BF (see above). It is further shown that this

Coater is angled or its coating surface BF is divided into two mutually angled sub-surfaces 70. The named coater is in particular designed such that both a coater direction BR 1 and a

Coater direction BR 2 of the corresponding faces in a coating direction BUR from left to right, an edge contour of a component (not explicitly shown in Figures 18 to 19) meet at a different angle of 90 ° and thus provide the advantages of the invention.

This applies in particular also to the coater shown in the right-hand view of FIG

Coater BF has. By this configuration, an edge contour of a component, if it is linear or rectilinear edges automatically approached or "hit" at a certain angle, if the

Coater, for example, by a suspension or removal device 61 (see Figure 15) in the direction of the coating direction BUR (see Figure 18) is moved.

The described coater 60 with the curved

Coater surface BF describes a particularly preferred embodiment, which almost always allows the advantages according to the invention; namely, whenever, for example, an edge contour of a component deviates in shape and orientation from the geometry of the curved coater surface BF.

FIG. 19 shows a further embodiment of a device 50 according to the invention, which likewise has a coater 60. The coater 60 has, analogously to the illustrations 1 to 16 preferably a flat and linear coater surface BF on. 19, a coater direction BR (see dashed line in FIG. 19 is "set" at an angle to a coating direction BUR.) According to this embodiment, a component, for example as shown in FIGS. are aligned with its edges parallel to the edges of the build platform 2 without the coating defects described above will occur.

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.

Claims

claims 1. Method for the additive production of a component (10) comprising the following steps: Detecting an edge contour (11) of a powder bed (1) additively constructed or to be built layer (12) for the component (10) on a construction platform (2), aligning a coater direction (BR) for a newly applied powder layer relative to the detected Edge contour (11) such that an edge (11) of the additively constructed or to be built up layer (12) includes an angle different from 90 ° with the coater direction (BR). 2. The method according to claim 1, wherein the edge contour (11) of the additively constructed or to be built layer (12) or the position of the edge contour (11) relative to the build platform (2) on the basis of a data model, preferably construction onsdaten, such as CAD data, is detected. 3. The method according to claim 1 or 2, wherein the alignment is carried out such that the edge (11) of the additively constructed or to be built up layer (12) an angle between see see 10 ° and 80 ° with the coater direction (BR) includes. 4. The method according to any one of the preceding claims, wherein the coater direction (BR) relative to the edge contour (11) by rotation of the building platform (2) is aligned. 5. The method according to any one of the preceding claims, wherein the coater direction (BR) relative to the edge contour (11) is aligned by rotating the coater direction (BR). 6. The method according to any one of the preceding claims, wherein the coater direction (BR) relative to the edge contour (11) by turning the build platform (2) and turning the coater direction (BR). 7. The method according to any one of the preceding claims, wherein the coater direction (BR) relative to the detected Edge contour (11) is aligned over a change in the component design. 8. Method according to one of the preceding claims, wherein the alignment takes place in layers and is carried out on the basis of a calculation based on CAD and / or CAM data for the additive production of the component. 9. Method according to one of the preceding claims, wherein, after each built-up layer (12) for the component (10), it is checked after or after the detection whether the edge (11) has an angle different from 90 ° with the coater direction (FIG. BR) and, wherein the coater direction (BR) is, if appropriate, realigned. 10. Device (50) for the powder bed-based additive production of a component (10), which is designed to coat a production area (HF) for the layered additive structure uniformly along a coating direction (BUR) with a powder layer, wherein a  Coater direction (BR) with the coating direction (BUR) includes an angle different from 90 °. 11. Device (50) according to claim 10, wherein the Coater surface (BF), for example, at outer edges of the manufacturing surface (HF), in the direction of the coating direction (BUR) is bent. 12. Device (50) according to claim 10 or 11, wherein the coater surface (BF), at least two planar mutually angled partial surfaces (70). 13. Device (50) according to one of claims 10 to 12, comprising a round building platform (2). 14. Device (50) according to one of claims 10 to 13, which has a coating device, in particular a powder slide, for the additive construction of complex high-temperature-resistant components.