Method and device for manufacturing at least a portion of a component

Patent metadata

Field	Value
Publication number	US-10507525-B2
Application number	US-201715486853-A
Country	US
Kind code	B2
Filing date	Apr 13, 2017
Priority date	Apr 19, 2016
Publication date	Dec 17, 2019
Grant date	Dec 17, 2019

Abstract

A method for manufacturing at least a metallic portion of a component: a) depositing metallic material layer by layer onto at least one building platform; b) locally fusing and/or sintering the material layer by layer by supplying energy by at least one high-energy beam in the region of a buildup and joining zone to form at least a portion of at least one component layer of the component portion and/or of the component; c) lowering the building platform layer by layer by a predefined layer thickness; and d) repeating the steps a) through c) until completion of the component portion and/or of the component. Before, during and/or after process step b), at least one further portion of the component layer is formed by locally fusing and/or sintering the material by inductive heating at a temperature or in a temperature range above the solidus temperature of the metallic material used. A system for manufacturing at least a portion of a component is also provided.

First claim

What is claimed is:

1. A method for manufacturing at least a portion of a component, the method comprising at least the following steps:
a) depositing at least one metallic material layer by layer onto at least one building platform;
b) locally fusing or sintering the material layer by layer by supplying energy by at least one high-energy beam in a region of a buildup and joining zone to form at least a portion of at least one component layer of the component portion or of the component;
c) lowering the building platform layer by layer by a predefined layer thickness; and
d) repeating the steps a) through c) until completion of the component portion or of the component,
wherein before, during or after local layer-by-layer fusion or sintering according to process step b), at least one further portion of the component layer is formed by locally fusing or sintering the material by inductive heating at a temperature or in a temperature range above the solidus temperature of the metallic material used.

2. The method as recited in claim 1 wherein the inductive heating is used to fuse or sinter a contour region of the component portion or of the component at least within the at least one material layer.

3. The method as recited in claim 1 wherein during the additive manufacture of the at least one component layer of the component portion or of the component according to process step b), the material, prior to being locally fused or sintered layer by layer by the at least one high-energy beam, is at least partially heated by inductively heating the material to a temperature below the solidus temperature of the material.

4. The method as recited in claim 1 wherein the additive manufacturing method is a selective laser melting or sintering process or an electron beam melting or sintering process or a combination of these processes.

5. The method as recited in claim 1 wherein the formation of the further portion of the component layer by locally fusing or sintering the material by inductive heating occurs in all material layers.

6. The method as recited in claim 1 wherein the formation of the further portion of the component layer by locally fusing or sintering the material by inductive heating does not occur in all material layers.

7. The method as recited in claim 1 wherein the component is a turbomachine component.

8. A device for additive manufacturing of at least a portion of a component, the device comprising:
a powder feeder for depositing at least one powder layer of a metallic material onto a buildup and joining zone of a building platform;
at least one radiation source for generating at least one high-energy beam, the at least one powder layer locally fusable or sinterable in the region of the buildup and joining zone by the high energy beam to form at least a portion of a component layer;
at least one induction device adapted to form a further portion of the component layer by locally fusing or sintering the material of the powder layer by inductive heating at a temperature or in a temperature range above the solidus temperature of the metallic material used; and
a controller controlling the induction device to inductively heat at the temperature or in the temperature range above the solidus temperature of the metallic material used.

9. The device as recited in claim 8 wherein the induction device has at least one induction coil.

10. The device as recited in claim 9 wherein the at least one induction coil includes two induction coils forming an intersection region.

11. The device as recited in claim 9 wherein the at least one induction device includes at least one further induction coil designed to cause a contour region of the component portion or of the component within the powder layer to be fused or sintered by inductive heating.

12. The device as recited in claim 8 wherein the induction device is controllable such that different temperatures or temperature ranges achievable by inductive heating can be set and controlled before, during or after the additive manufacture of the component portion or of the component.

13. The device as recited in claim 12 wherein at least one temperature or a temperature range is below the solidus temperature of the material during the additive manufacture of the component portion or of the component.

14. The device as recited in claim 8 wherein the further portion of the at least one component layer, the further portion being produced by inductive heating, is a contour region of the component portion or of the component.

15. The device as recited in claim 8 wherein the device includes at least one selective laser melting apparatus or at least one electron beam melting apparatus.

16. The device as recited in claim 8 wherein the device is a turbomachine component manufacturing device.

17. A component for a turbomachine obtained by the method as recited in claim 1 .

18. A component for an aircraft engine turbomachine obtained by the method as recited in claim 1 .

19. The device as recited in claim 8 wherein the controller is an open- and closed-loop controller controlling power of induction coils of the induction device as well as a position of the induction coils above the building platform.

20. The method as recited in claim 1 wherein before the local layer-by-layer fusion or sintering according to process step b), the at least one further portion of the component layer is formed by locally fusing or sintering the material by the inductive heating at the temperature or in the temperature range above the solidus temperature of the metallic material used.

21. The method as recited in claim 1 wherein during the local layer-by-layer fusion or sintering according to process step b), the at least one further portion of the component layer is formed by locally fusing or sintering the material by the inductive heating at the temperature or in the temperature range above the solidus temperature of the metallic material used.

22. The method as recited in claim 1 wherein after the local layer-by-layer fusion or sintering according to process step b), the at least one further portion of the component layer is formed by locally fusing or sintering the material by the inductive heating at the temperature or in the temperature range above the solidus temperature of the metallic material used.

Assignees

• MTU Aero Engines AG

Inventors

• Casper Johannes
• Schlick Georg
• Ladewig Alexander

Classifications

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B23K13/01

  by induction heating · CPC title

• B23K26/346

  in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding · CPC title

• B23K26/342

  Build-up welding · CPC title