Micro-forging by a generative manufacturing process

Patent metadata

Field	Value
Publication number	US-10456867-B2
Application number	US-201715449431-A
Country	US
Kind code	B2
Filing date	Mar 3, 2017
Priority date	Mar 7, 2016
Publication date	Oct 29, 2019
Grant date	Oct 29, 2019

Abstract

The present invention relates to a device as well as a method for the additive manufacture of components by deposition of material layers by layer-by-layer joining of powder particles to one another and/or to an already produced pre-product or substrate, via selective interaction of the powder particles with a high-energy beam, wherein, for smoothing a surface of the component being produced running crosswise to the deposited material layers in between the deposition of two layers of the component, the complete edge region of the last layer that is applied and that runs along a surface of the component being produced is compacted in a direction of action that has a directional component parallel to the build-up direction of the layers, and/or at least one edge region of a surface of the component is also compacted.

First claim

What is claimed is:

1. A method for the additive manufacture of components by depositing material layers by layer-by-layer joining of powder particles to one another and/or to an already produced pre-product or substrate, via selective interaction of the powder particles with a high-energy beam, comprising the steps of:
for smoothing a surface of the component being produced running crosswise to the deposited material layers in between the deposition of two layers of the component, the complete edge region of the last layer introduced, which runs along a surface of the component being produced, is compacted by laser shock peening or ultrasonic impact treatment in a direction of action that has a directional component parallel to the build-up direction of the layers, and/or at least one edge region of a surface of the component is compacted by laser shock peening or ultrasonic impact treatment in a direction of action that has a directional component parallel to the normal line of the surface,
wherein the laser shock peening or the ultrasonic impact treatment in between the deposition of two layers of the component takes place exclusively in the edge region of a surface of the component.

2. The method according to claim 1 , wherein
the compacting is conducted from the side of the surface of the component in a direction of action with a directional component parallel to the normal line of the surface.

3. The method according to claim 1 , wherein
a layer is deposited after each laser shock peening or ultrasonic impact treatment.

4. The method according to claim 1 , wherein
after the deposition of each layer or every second, third or fourth layer, or after the deposition of a multiple number of layers, a laser shock peening or an ultrasonic impact treatment of the one or more edge regions of a surface of the component takes place.

5. The method according to claim 1 , wherein
after applying one layer and prior to compacting the edge region of a surface, post-welding the edge region of the applied layer.

6. The method according to claim 1 , wherein
the high-energy beam is a laser beam or an electron beam.

7. The method according to claim 1 , wherein
the powder in a powder bed is applied onto the already produced pre-product or substrate.

8. The method according to claim 7 , wherein
during the compacting, the component already produced, except for a region on which the next layer shall be applied, is arranged in the powder bed, or is raised out from the powder bed around the layers to be compacted in the edge region.

9. The method according to claim 1 , wherein
in the case of the ultrasonic impact treatment, a tool acting on the surface of the component is moved linearly back and forth, so that a directional component of the linear movement runs parallel to the surface normal line.

10. The method according to claim 1 , wherein
in the case of the ultrasonic impact treatment, a tool that acts on the surface of the component and that is formed from one of a material which is identical to the material from which the component is built up, a material that belongs to the same class of materials from which the component is built up, a material that corresponds to the same type of alloy as the materials from which the component is built up, or a material that agrees quantitatively and/or qualitatively by more than 50% in their chemical composition as the materials from which the component is built up.

11. The method according claim 1 , wherein
the produced component is subjected to a heat treatment.

12. A device for the additive manufacture of components by layer-by-layer joining of powder particles to one another and/or to an already produced pre-product or substrate, via selective interaction of the powder particles with a high-energy beam, particularly according to a method according to one of the preceding claims, with an irradiation device for providing a high-energy beam and a processing region, in which a powder layer can be arranged, wherein the high-energy beam and the processing region can be moved relative to one another, so that the high-energy beam can interact selectively with the powder in the processing region, comprising:
at least one ultrasonic impact device for conducting an ultrasonic impact treatment, which has a tool for acting on a component being produced, and is configured and arranged so that the tool can move in the processing region, so that any desired component shape can be processed on its surface in the processing region,
wherein a controller is configured and arranged to control a laser shock peening or the ultrasonic impact treatment in between the deposition of two layers of the component exclusively in an edge region of a surface of the component.

13. The device according to claim 12 , wherein
a powder bed is provided in the processing region, wherein the tool is configured and arranged and can be driven in the powder bed.

Assignees

• MTU Aero Engines AG

Inventors

• Bamberg Joachim
• Hessert Roland
• Schlick Georg

Classifications

• B22F12/41

  characterised by the type, e.g. laser or electron beam · CPC title

• B22F10/50

  Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up · CPC title

• B22F10/38

  to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures · CPC title

• B22F10/28

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

• B29C64/153 Primary

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title