Surfacing of additively manufactured components and corresponding manufactured components of a turbomachine

Patent metadata

Field	Value
Publication number	US-9862059-B2
Application number	US-201514842343-A
Country	US
Kind code	B2
Filing date	Sep 1, 2015
Priority date	Sep 8, 2014
Publication date	Jan 9, 2018
Grant date	Jan 9, 2018

Abstract

The present invention relates to a method for manufacturing components, in particular components of turbomachines, such as aircraft engines, wherein an additive method is used at least partially for the manufacture of the component ( 1 ), wherein at least one surface region ( 3 ) of the additively manufactured portion of the component ( 1 ) is provided with a smoothing layer ( 2 ), which is deposited by vapor deposition. In addition, the invention relates to a correspondingly manufactured component of a turbomachine.

First claim

What is claimed is:

1. A method for manufacturing a component, wherein an additive method is used at least partially for the manufacture of a component from a plurality of layers each having edges, the plurality of layers defining a first surface region having a rough surface defined by the edges of the plurality of layers of the layerwise construction of the plurality of layers, wherein the first surface region of the additively manufactured part of the component is provided with a smoothing layer, which is deposited by vapor deposition, the smoothing layer including a diffusion layer that at least partially diffuses into the plurality of layers of the first surface region adhering thereto, whereby the smoothing layer forms a part of and remains on the component, and whereby the smoothing layer provides a protective coating to the first surface region during use of the component.

2. The method according to claim 1 , wherein the additive manufacturing method comprises a layerwise construction of the component from powder material that is joined to form a solid component, wherein the method is selected from a group that comprises selective laser melting, selective electron-beam melting, selective laser sintering, selective electron-beam sintering, and powder hardfacing.

3. The method according to claim 1 , wherein a second surface region on a portion of the component is provided with a smoothing layer.

4. The method according to claim 1 , wherein the vapor deposition is selected from the group that comprises physical vapor deposition, chemical vapor deposition, thermal deposition, electron-beam deposition, pulsed laser deposition, plasma-enhanced vapor deposition, and plasma-enhanced chemical vapor deposition.

5. The method according to claim 1 , wherein the smoothing layer has a thickness of 5 μm to 200 μm.

6. The method according to claim 1 , wherein the smoothing layer is formed from a material having one or more chemical elements of the base material of the component being coated.

7. The method according to claim 1 , wherein the smoothing layer is formed from a pure metal or an alloy or a chemical compound.

8. The method according to claim 1 , wherein the component with the smoothing layer is subjected to a heat treatment.

9. The method according to claim 1 , further comprising the step of:
depositing another functional layer on the smoothing layer.

10. The method according to claim 1 , wherein the component is selected from the group that comprises flow duct limiting walls, rotating blades and guide vanes, and/or the component has as a base material an alloy from the group that comprises nickel-based alloys, nickel-based superalloys, iron alloys, titanium alloys, and cobalt alloys.

11. The method according to claim 1 , wherein the component is formed from a nickel-based alloy and the smoothing layer is formed from aluminum or nickel.

12. The method according to claim 1 , wherein the smoothing layer has an average roughness R a that is less than or equal to 10 μm.

13. The method according to claim 1 , wherein the component has at least one flow surface, and the at least one flow surface is provided with the smoothing layer.

14. The method according to claim 5 , wherein the smoothing layer has a thickness of 10 μm to 100 μm.

15. The method according to claim 8 , wherein the heat treatment is diffusion annealing.

16. The method according to claim 12 , wherein the smoothing layer has an average roughness R a that is less than or equal to 5 μm.

17. The method according to claim 9 , wherein the functional layer is a layer for corrosion protection.

18. The method according to claim 9 , wherein the functional layer is a thermal barrier coating.

Assignees

• MTU Aero Engines AG

Inventors

• Liebl Christian
• Blumenschein Karl
• Schlothauer Steffen
• Hess Thomas

Classifications

• C23C10/28 Primary

  using solids, e.g. powders, pastes · CPC title

• B22F10/64

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

• B23K26/342 Primary

  Build-up welding · CPC title