Manufacturing of components of a vehicle using additive layer manufacturing

Patent metadata

Field	Value
Publication number	US-10442002-B2
Application number	US-201514942466-A
Country	US
Kind code	B2
Filing date	Nov 16, 2015
Priority date	Nov 19, 2014
Publication date	Oct 15, 2019
Grant date	Oct 15, 2019

Abstract

This relates to a method for manufacturing a shell-like structural component for a vehicle using additive layer manufacturing. In a step of the method, a first material is applied to a region of the shell-like structural component. In another step of the method, the region of the shell-like structural component is heated by a laser beam such that the first material is added to the shell-like structural component. The shell-like structural component comprising the first material is cooled in another step such that an internal stress is generated within the shell-like structural component resulting in a bending of the shell-like structural component. This further relates to a shell-like structural component which is manufactured by a method using additive layer manufacturing.

First claim

What is claimed is:

1. A method for manufacturing a shell-like structural component for a vehicle using additive layer manufacturing, comprising:
applying a first material to a region of the shell-like structural component;
heating the region of the shell-like structural component by a laser beam such that the first material is added to the shell-like structural component; and
cooling the shell-like structural component comprising the first material, such that an internal stress is generated within the shell-like structural component resulting in a bending of the shell-like structural component;
wherein internal stresses are induced within the shell-like structural component such that a predetermined bending occurs when a certain force or load is applied to the shell-like structural component in a loaded condition; and
wherein the internal stress is induced using different temperatures when heating the region of the shell-like structural component.

2. The method according to claim 1 , further comprising:
applying the first material to a plurality of regions of the shell-like structural component from different directions.

3. The method according to claim 1 , wherein a bending direction is opposite to a direction of a force which acts on the shell-like structural component when it is installed in the vehicle, wherein the force is generated by a cargo unit standing on the shell-like structural component or by cabin air pressure.

4. The method according to claim 1 , further comprising:
generating a layered structure of the shell-like structural component by applying the first material to the surface of the shell-like structural component, wherein the layered structure comprises a layer of the first material.

5. The method according to claim 1 , wherein the internal stress is induced using different materials.

6. The method according to claim 1 , wherein the shell-like structural component is a floor panel.

7. The method according to claim 6 , wherein a thickness of the floor panel is between 2 millimeters and 100 millimeters, preferably between 2 millimeters and 4 millimeters.

8. The method according to claim 1 , wherein the first material has a coefficient of thermal expansion which differs from a coefficient of thermal expansion of the region of the shell-like structural component to which the first material is applied.

9. The method according to claim 1 , wherein the shell-like structural component is selected from the group comprising an aircraft cargo floor panel, a part of an aircraft outer skin, a part of an aircraft wing and a part of an aircraft door.

10. The method according to claim 1 , wherein the first material is selected from the group comprising silicone, iron, copper, manganese, chromium, tin, vanadium, titanium, bismuth, gallium, lead, aluminum and zirconium.

11. A method for manufacturing a shell-like structural component for a vehicle using additive layer manufacturing, comprising:
applying a first material to a region of the shell-like structural component;
heating the region of the shell-like structural component by a laser beam such that the first material is added to the shell-like structural component; and
cooling the shell-like structural component comprising the first material, such that an internal stress is generated within the shell-like structural component resulting in a bending of the shell-like structural component;
wherein internal stresses are induced within the shell-like structural component such that a predetermined bending occurs when a certain force or load is applied to the shell-like structural component in a loaded condition; and
wherein additional internal stress is generated within the shell-like structural component by shot-peening and flare-fitting.

12. A method for manufacturing a shell-like structural component for a vehicle using additive layer manufacturing, the method comprising the steps of:
performing a multi-direction additive manufacturing process to print a first material on a first surface of the shell-like structural component and to simultaneously print the first material on a second surface of the shell-like structural component, resulting in a layered structure;
heating regions of the shell-like structural component by a laser beam such that the first material is added to the shell-like structural component; and
cooling the shell-like structural component comprising the first material to generate an internal stress within the shell-like structural component, resulting in a bending of the shell-like structural component in an unloaded condition;
wherein internal stresses are induced within the shell-like structural component such that a predetermined bending occurs when a certain force or load is applied to the shell-like structural component in a loaded condition.

Assignees

• Airbus Operations Gmbh

Inventors

• Benthien Hermann
• Hegenbart Matthias

Classifications

• B22F7/08 Primary

  with one or more parts not made from powder {(B22F7/062 takes precedence)} · CPC title

• B22F10/66

  by mechanical means · CPC title

• B22F10/64

  by thermal means (control of energy beam parameters for post heating B22F10/364) · CPC title

• B22F10/47

  characterised by structural features · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title