Method and device for the additive manufacture of at least one component region of a component

Patent metadata

Field	Value
Publication number	US-10507526-B2
Application number	US-201715470439-A
Country	US
Kind code	B2
Filing date	Mar 27, 2017
Priority date	Apr 1, 2016
Publication date	Dec 17, 2019
Grant date	Dec 17, 2019

Abstract

The invention relates to a method for the additive manufacture of at least one region of a component. Here, at least the following steps are carried out: a) layer-wise application of at least one powder-form component material onto a component platform in the region of a build-up and joining zone; b) layer-wise and local solidifying of the component material by selective exposure of the component material by at least one high-energy beam in the region of the build-up and joining zone, with the formation of a component layer; c) layer- wise lowering of the component platform by a pre-defined layer thickness; and d) repeating steps a) to c) until the component region or the component has been completely fabricated.

First claim

What is claimed is:

1. A method for the additive manufacture of at least one region of a component, comprising the following steps:
a) layer-wise application of at least one powder-form component material onto a component platform in the region of a build-up and joining zone;
b) layer-wise and local solidifying of the component material by selective exposure of the component material by at least one high-energy beam in the region of the build-up and joining zone, with the formation of a component layer;
c) layer-wise lowering of the component platform by a pre-defined layer thickness; and
d) repeating steps a) to c) until the component region or the component has been completely fabricated;
wherein during at least one step b), at least one exposure parameter of the high-energy beam from the group: power, velocity, and focal position, is adjusted as a function of at least one construction parameter from the group: component thickness, hatch distance to an adjacent exposure trace, angle of incidence of the high-energy beam relative to the surface of the component layer, angle of deflection of the high-energy beam with respect to a vertical axis of the component layer, overhang angle of the component layer, layer thickness of the component layer, and distance from a complete volume element of the component layer, and
wherein during at least one step b), the method further comprises determining, with a controller, at least the overhang angle of the component layer, and adjusting
at least the exposure parameter, power, of the high-energy beam to reduce the power, when compared to the power in an inskin region, if the construction parameter, overhang angle, of the component layer in the exposed region corresponds to a downskin region, and
at least the exposure parameter, power, of the high-energy beam to increase the power, when compared to the power in an inskin region, if the construction parameter, overhang angle, of the component layer in the exposed region corresponds to an upskin region.

2. The method according to claim 1 , wherein
a laser sintering method and/or a laser melting method is used as the additive manufacturing method, and/or a laser beam is used as the high-energy beam.

3. The method according to claim 1 , wherein
the at least one exposure parameter of the high-energy beam from the group: power, velocity, and focal position, is determined in advance, prior to the manufacture of the component layer in step b) as a function of at least one construction parameter from the group: component thickness, hatch distance to an adjacent exposure trace, angle of incidence of the high-energy beam relative to the surface of the component layer, angle of deflection of the high-energy beam with respect to a vertical axis of the component layer, overhang angle of the component layer, layer thickness of the component layer, and distance from a complete volume element of the component layer, and is provided as a data set for control and/or regulation of the high-energy beam.

4. The method according to claim 3 , wherein
the at least one exposure parameter of the high-energy beam is pre-determined in the scope of a determination of a hatch geometry of the component layer.

5. The method according to claim 1 , wherein
during at least one step b) and/or after at least one step b), at least one measurement parameter characterizing a quality of the manufactured component layer is determined, and the at least one exposure parameter of the high-energy beam from the group: power, velocity and focal position, is determined and/or modified as a function of the measurement parameter and of the at least one construction parameter.

6. The method according to claim 1 , wherein
a radiation source, which generates the high-energy beam, is not moved, at least during one step b).

7. The method according to claim 1 , wherein during at least one step b), each of the exposure parameters is determined as a function of at least a plurality of the construction parameters from the group: component thickness, hatch distance to an adjacent exposure trace, angle of incidence of the high-energy beam relative to the surface of the component layer, angle of deflection of the high-energy beam with respect to a vertical axis of the component layer, overhang angle of the component layer, layer thickness of the component layer, and distance from a complete volume element of the component layer.

8. A device for the additive manufacture of at least one region of a component of a turbine or of a compressor, comprising:
at least one powder supply for applying at least one powder layer from a component material onto a build-up and joining zone of a component platform that can be lowered; and
at least one radiation source for generating at least one high-energy beam, by which the powder layer can be solidified locally into a component layer in the region of the build-up and joining zone;
a control device for controlling and/or regulating the radiation source, wherein the control device is designed for the purpose of pre-determining at least one exposure parameter of the high-energy beam from the group: power, velocity, and focal position, as a function of a data set, the data set comprises at least one construction parameter from the group: component thickness, hatch distance to an adjacent exposure trace, angle of incidence of the high-energy beam relative to the surface of the component layer, angle of deflection of the high-energy beam with respect to a vertical axis of the component layer, overhang angle of the component layer, layer thickness of the component layer, and distance from a complete volume element of the component layer,
wherein the control device is configured and arranged to determine at least the overhang angle of the component layer, and configured and arranged to adjust
at least the exposure parameter, power, of the high-energy beam to reduce the power, when compared to the power in an inskin region, if the construction parameter, overhang angle, of the component layer in the exposed region corresponds to a downskin region, and
at least the exposure parameter, power, of the high-energy beam to increase the power, when compared to the power in an inskin region, if the construction parameter, overhang angle, of the component layer in the exposed region corresponds to an upskin region.

9. The device according to claim 8 wherein
further comprising a measuring instrument, by which at least one measurement parameter characterizing a quality of the manufactured component layer can be determined.

10. The device according to claim 9 , wherein
the control device is coupled to the measuring instrument for exchanging data, and is designed to determine in advance the at least one exposure parameter of the high-energy beam from the group: power, velocity, and focal position, as a function of the data set and of the measurement parameter, and/or to modify at least one already pre-determined exposure parameter.

11. The device of claim 8 wherein the controller is configured and arranged to determine each of the exposure parameters as a function of at least a plurality of the construction parameters from the group: component thickness, hatch distance to an adjacent exposure trace, angle of incidence of the high-energy beam relative to the surface of the component layer, angle of deflection of the high-energy beam with respect to a vertical axis of the component layer, overhang angle of the component layer, layer thickness of the component layer, and distance from a complete volume element of the component layer.

Assignees

• MTU Aero Engines AG

Inventors

• Liebl Christian
• Ladewig Alexander
• Buerger Laura
• Schlick Georg
• Schlothauer Steffen
• Dusel Karl-Heinz

Classifications

• B23K26/083 Primary

  Devices involving movement of the workpiece in at least one axial direction · CPC title

• B22F5/009

  of turbine components other than turbine blades (of turbine blades B22F5/04) · CPC title

• B22F2999/00

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

• B23K26/342

  Build-up welding · CPC title

• B23K2101/001

  Turbines · CPC title