DE102014219656A1 - Process for the production of components for gas turbines, and their products - Google Patents
Process for the production of components for gas turbines, and their products Download PDFInfo
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- DE102014219656A1 DE102014219656A1 DE102014219656.6A DE102014219656A DE102014219656A1 DE 102014219656 A1 DE102014219656 A1 DE 102014219656A1 DE 102014219656 A DE102014219656 A DE 102014219656A DE 102014219656 A1 DE102014219656 A1 DE 102014219656A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/90—Means for process control, e.g. cameras or sensors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
- B22F10/364—Process control of energy beam parameters for post-heating, e.g. remelting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/50—Means for feeding of material, e.g. heads
- B22F12/53—Nozzles
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
Die Erfindung betrifft ein Verfahren zur Herstellung von Komponenten mit komplexen inneren Strukturen und/oder vielen Einzelteilen für Turbinen, insbesondere von Gasturbinen wie beispielsweise Laufschaufeln. Die Erfindung bezieht sich insbesondere auf das Verfahren zur Herstellung von Komponenten, die im Heißgaspfad von Gasturbinen angeordnet sind.The invention relates to a method for producing components having complex internal structures and / or many individual parts for turbines, in particular of gas turbines, such as rotor blades. More particularly, the invention relates to the method of manufacturing components disposed in the hot gas path of gas turbines.
Description
Die Erfindung betrifft ein Verfahren zur Herstellung von Komponenten mit komplexen inneren Strukturen und/oder vielen Einzelteilen für Turbinen, insbesondere von Gasturbinen wie beispielsweise Laufschaufeln. Die Erfindung bezieht sich insbesondere auf das Verfahren zur Herstellung von Komponenten, die im Heißgaspfad von Gasturbinen angeordnet sind. The invention relates to a method for producing components having complex internal structures and / or many individual parts for turbines, in particular of gas turbines, such as rotor blades. More particularly, the invention relates to the method of manufacturing components disposed in the hot gas path of gas turbines.
Die Komponenten haben beispielsweise innere Kühlstrukturen, wie Oberflächenrippen, Turbulatoren und/oder besonders feine Strukturen wie dünne Kühlkanäle, dünne Wände und/oder Gitter etc. The components have, for example, internal cooling structures, such as surface ribs, turbulators and / or particularly fine structures, such as thin cooling channels, thin walls and / or mesh, etc.
Bislang sind Gasturbinenkomponenten wie Laufschaufeln bekannt, die insbesondere durch subtraktive Verfahren wie Feinguss mit folgendem Fräsen, Bohren, Erodieren etc. herstellbar sind. Diese aufwändigen Herstellungsmethoden sind insbesondere deshalb Stand der Technik, da bislang keine Herstellungsmethode bekannt ist, mit der diese thermisch und mechanisch höchst beanspruchten Komponenten, die neben extrem hohen Temperaturen auch hohen mechanischen Belastungen, wie z.B. den Fliehkräften, ausgesetzt sind, kostengünstiger herstellbar wären. So far gas turbine components such as blades are known, which can be produced in particular by subtractive methods such as investment casting with subsequent milling, drilling, eroding etc. Therefore, these elaborate production methods are particularly state of the art, since no manufacturing method is known with which these thermally and mechanically highly stressed components, in addition to extremely high temperatures and high mechanical loads, such as. the centrifugal forces are exposed, would be cheaper to produce.
Nachteilig an der Herstellung mittels Feinguss oder Pulverbettschmelzen und nachfolgender subtraktiver Verfahren ist nicht nur der Kostenfaktor, sondern auch die Umständlichkeit der Veränderung, die schnelle Adaption der Komponenten an neue Erkenntnisse und/oder die Herstellung von Prototypen bislang deutlich erschwert. Mit der Verminderung der Anzahl an Prototypen wird aber auch die Effizienzsteigerung beeinträchtigt. A disadvantage of the production by means of investment casting or powder bed melts and subsequent subtractive processes is not only the cost factor, but also the inconvenience of the change, the rapid adaptation of the components to new knowledge and / or the production of prototypes much more difficult. With the reduction in the number of prototypes but also the increase in efficiency is impaired.
Aufgabe der vorliegenden Erfindung ist es deshalb, ein Verfahren zur Herstellung von Gasturbinenkomponenten anzugeben, das die Nachteile des Standes der Technik, insbesondere die kostenträchtigen Prozessschritte und die Umständlichkeit der Prototyperzeugung, zumindest teilweise, durch kostengünstigere Prozesse ersetzt, ohne die Güte und Belastbarkeit der hergestellten Komponenten zu beeinträchtigen. The object of the present invention is therefore to specify a method for the production of gas turbine components which at least partially replaces the disadvantages of the prior art, in particular the costly process steps and the complexity of the prototype production, by less costly processes without the quality and load capacity of the components produced to impair.
Diese Aufgabe wird durch das hier offenbarte Verfahren und die dadurch herstellbaren Komponenten gelöst. This object is achieved by the method disclosed herein and the components that can be produced thereby.
Demgemäß ist Gegenstand der vorliegenden Erfindung ein Verfahren zur Herstellung und/oder Reparatur von Komponenten wie Gasturbinen-Komponenten, beispielsweise von Lauf- oder Leitschaufeln, bei der subtraktive und additive Verfahrensschritte in einem Hybridverfahren kombiniert werden. Accordingly, the subject of the present invention is a method for producing and / or repairing components such as gas turbine components, for example runners or vanes, in which subtractive and additive process steps are combined in a hybrid process.
Dieses kombinierte Verfahren bedient sich ausgewählter additiver und subtraktiver Bearbeitungsschritte zum Aufbau von Gasturbinen-Komponenten mit komplexen und/oder sehr feinen inneren Strukturen. This combined method makes use of selected additive and subtractive processing steps to construct gas turbine components with complex and / or very fine internal structures.
Nach einer vorteilhaften Ausführungsform des Verfahrens werden subtraktive und additive Verfahrensschritte gleichzeitig ausgeführt. According to an advantageous embodiment of the method, subtractive and additive method steps are performed simultaneously.
Nach einer vorteilhaften Ausführungsform werden beispielsweise durch Wechsel der Düsen verschiedene Materialien in einem Arbeitsschritt aufgebracht. So kann man beispielsweise sowohl die mechanische Stärke als auch die Korrosionsfestigkeit einstellen. According to an advantageous embodiment, different materials are applied in one step, for example, by changing the nozzles. For example, you can adjust both the mechanical strength and the corrosion resistance.
Durch die Multi-Material-Möglichkeit des hier genannten Hybrid-Herstellungsverfahrens können Werkstücke in noch ungeahnten Materialkombination herstellbar werden, weil Beschichtungen, Übergänge und in-situ-alloying in ganz neuen Dimensionen realisierbar ist. Due to the multi-material possibility of the hybrid manufacturing process mentioned here, workpieces can be manufactured in yet unimagined material combination, because coatings, transitions and in situ alloying can be realized in completely new dimensions.
Mit den subtraktiven Prozessschritten werden beispielsweise verborgene Oberflächen, z.B. im Hohlfuß während des Prozesses bearbeitet, beispielsweise durch Polieren. For example, with the subtractive process steps, hidden surfaces, e.g. processed in the hollow foot during the process, for example by polishing.
Nach einer vorteilhaften Ausführungsform des Verfahrens werden mehrere Laser und/oder Pulverdüsen-Systeme in Kombination eingesetzt, so dass mehrere „Schriftstärken“ gleichzeitig verbaut werden können. So können in einem Arbeitsschritt sowohl gröbere als auch feinere Strukturen hergestellt werden. According to an advantageous embodiment of the method, a plurality of lasers and / or powder nozzle systems are used in combination, so that a plurality of "font thicknesses" can be installed simultaneously. Thus, both coarser and finer structures can be produced in one step.
Nach einer weiteren vorteilhaften Ausführungsform der Erfindung werden Laserscanner eingesetzt, damit das Werkstück vor- und/oder nachgewärmt werden kann. Dadurch kann auch Verzug minimiert werden. According to a further advantageous embodiment of the invention, laser scanners are used so that the workpiece can be preheated and / or reheated. This can also minimize distortion.
Nach einer bevorzugten Ausführungsform wird der Werkzeugwechsel dadurch erspart, dass durch einen Laser sowohl Laser Metal Deposition, also ein additiver Prozessschritt als auch Laserfräsungen, einen subtraktiven Prozessschritt ausgeführt werden. According to a preferred embodiment, the tool change is avoided in that both laser metal deposition, ie an additive process step and laser milling, are performed by a laser, a subtractive process step.
Durch ein online-Monitoring, durch das ständig die Konturen die Temperatur, der Meltpool kontrolliert werden, können ideale Materialeigenschaften und/oder Detailgetreue Prototypen erzeugt werden. By means of online monitoring, which constantly controls the contours, the temperature and the melt pool, ideal material properties and / or detailed prototypes can be generated.
Nach einer vorteilhaften Ausführungsform der Erfindung sieht das Verfahren vor, dass in einem additiven Verarbeitungsschritt aus der LMD(Laser-Metal-Deposition)-Technologie bekannte Pulverdüsen zum Einsatz kommen. Dabei können metallische Werkstücke, wie beispielsweise solche aus Titanlegierungen, mit nahezu 100%iger Dichtheit hergestellt werden. According to an advantageous embodiment of the invention, the method provides that powder nozzles known from LMD (laser metal deposition) technology are used in an additive processing step. It can metallic workpieces, such as those made of titanium alloys, are produced with almost 100% tightness.
Darüber hinaus sind beim LMD-Verfahren viele Prozessparameter veränderbar und einstellbar, beispielsweise können die Energie des Laserstrahls beim Aufschmelzen, die Energieverteilung, die Zufuhrgeschwindigkeit des Pulvers, die Abscheidungsgeschwindigkeit, also die Geschwindigkeit mit der der Laser über das Werkstück gefahren wird, die Legierungszusammensetzung, der Abscheide-Bereich, Abscheide-Raten, Schutzgasatmosphäre, und viele andere Prozessparameter von Komponente zu Komponente, aber auch von Bereich zu Bereich geändert werden. In addition, in the LMD method, many process parameters are variable and adjustable, for example, the energy of the laser beam during melting, the energy distribution, the feed rate of the powder, the deposition rate, ie the speed with which the laser is moved over the workpiece, the alloy composition, the Separation range, deposition rates, inert gas atmosphere, and many other process parameters are changed from component to component, but also from region to region.
Durch Kombination mehrerer Laserquellen und Pulverdüsen mit unterschiedlicher Leistung sowie Strahldurchmesser, Modulation und weiteres kann bei hohen Aufbauraten eine hohe Detailgenauigkeit erreicht werden. Der additive Aufbau kann durch integrierte Regelprozesse an veränderliche Prozessbedingungen sowie Komponenten-Geometrie und -Materialien angepasst werden. By combining several laser sources and powder nozzles with different power as well as beam diameter, modulation and more, a high level of detail accuracy can be achieved at high build-up rates. The additive structure can be adapted to changing process conditions as well as component geometry and materials through integrated control processes.
Verschiedene Sensorsysteme wie z.B. Pyrometer, IR-Kamera, mechanischer Taster, berührungslose optische Wegmess-Systeme ermöglichen ein Prozess-Monitoring verbunden mit einer online-Prozess-Steuerung, um durch gezielte Veränderung der Prozessgrößen die Materialeigenschaften und die Teilequalität zu beeinflussen. Insbesondere kann auch die Laserenergie in Verbindung mit verschiedenen Optiken, wie beispielsweise Laser-Scanner-Systemen dazu dienen, Bereiche am Bauteil vor oder nach dem Pulverauftrag gezielt zu erwärmen. Durch das Vorhandensein mehrerer Pulverdüsen und/oder mehrerer Pulverfördereinrichtungen an einer Düse besteht zudem die Möglichkeit, unterschiedliche Materialien im Bauteil zu verbauen und diese auch gradiert zu vermischen. Various sensor systems such as e.g. Pyrometer, IR camera, mechanical probe, non-contact optical distance measuring systems enable process monitoring combined with online process control to influence material properties and part quality through targeted changes in process variables. In particular, the laser energy in conjunction with various optics, such as laser scanner systems can serve to specifically heat areas on the component before or after the powder application. Due to the presence of several powder nozzles and / or several powder conveying devices on a nozzle, it is also possible to obstruct different materials in the component and also to mix them in a graded manner.
Die subtraktiven Bearbeitungsschritte erfolgen bevorzugt entweder jeweils nach oder während der additiven Bearbeitungsschritte. Dadurch können in Verbindung mit einer Konturerfassung, beispielsweise mittels Kamera, Abweichungen der Ist- von der Soll-Gestalt des Bauteils beim Herstellungsprozess korrigiert werden. The subtractive processing steps are preferably carried out either after or during the additive processing steps. As a result, deviations of the actual shape from the desired shape of the component during the manufacturing process can be corrected in conjunction with a contour detection, for example by means of a camera.
Eine derartige adaptive subtraktive Bearbeitung kann je nach Anforderung an die Konturgenauigkeit z.B. mittels Fräser oder durch Laserablation erfolgen. Durch subtraktive Bearbeitungsschritte während des Aufbaus der Komponente können feine, innenliegende Strukturen realisiert werden, was insbesondere bei luftgekühlten Komponenten wie Lauf- und/oder Leitschaufeln relevant ist. Such adaptive subtractive processing can be performed according to the contour accuracy requirement e.g. by means of milling cutters or by laser ablation. By subtractive processing steps during the construction of the component fine, internal structures can be realized, which is particularly relevant for air-cooled components such as running and / or vanes.
Insbesondere für die Bearbeitung von Nickel-Basis Superlegierungen in GT-Komponenten konnte in Versuchen gezeigt, werden, dass vor allem die Anwendung von ultraschallunterstützten Fräskopfen zu effektiven Abtragsraten mit sehr guter Oberflächenqualität führen. In particular, for the processing of nickel-based superalloys in GT components could be shown in experiments, that especially the use of ultrasonically assisted milling heads lead to effective removal rates with very good surface quality.
Sehr gute Oberflächenqualitäten, jedoch mit geringeren Abtragsraten als beim Fräsen, können auch mit der subtraktiven Bearbeitung von Ultrakurzpulslaser (Femto (fs) oder Pico-(ps) Laser) erreicht werden. Die subtraktive Bearbeitung mittels Lasertechnologie ist vor allem für hochpräzise Oberflächen und Mikrostrukturen kleiner 80µm geeignet. Very good surface qualities, but with lower removal rates than milling, can also be achieved with the subtractive processing of ultrashort pulse lasers (femto (fs) or pico (ps) lasers). The subtractive processing by means of laser technology is particularly suitable for high-precision surfaces and microstructures smaller than 80 μm.
Eine integrierte Konturerfassung empfiehlt sich insbesondere auch bei der Nutzung des Prozesses für Reparaturanwendungen. An integrated contour detection is especially recommended when using the process for repair applications.
Im Prozess kann zusätzlich auch die Möglichkeit bestehen, das Bauteil thermisch zu behandeln, um die Materialeigenschaften positiv zu beeinflussen, z.B. durch induktive, resistive, oder radiative Heizung oder Kühlung mittels geeigneter Medien. In addition, there may be the possibility in the process of thermally treating the component in order to positively influence the material properties, e.g. by inductive, resistive or radiative heating or cooling by means of suitable media.
Dadurch können die Anzahl der benötigten Verfahrensschritte reduziert und die Anzahl der Prototypen erhöht werden. As a result, the number of required process steps can be reduced and the number of prototypes can be increased.
Die Nutzung des LMD-Verfahrens als additiven Prozess eröffnet eine große geometrische Flexibilität, erlaubt insbesondere die Realisierung von Komponenten aus mehreren Materialien (Materialgradienten), gestattet Reduzierung von Stützstrukturen und auch höhere Aufbauraten alternativ oder in Ergänzung zu Metall-aufbauenden additiven-manufacturing-Pulverbettverfahrensschritten wie Selective Laser Melting, SLM. The use of the LMD process as an additive process opens up a great deal of geometric flexibility, in particular allows the realization of components of multiple materials (material gradients), allows reduction of support structures and also higher build-up rates as an alternative or in addition to metal-building additive-manufacturing powder bed process steps such Selective Laser Melting, SLM.
Insbesondere werden mehrere aus LMD und SLM bekannte additive Werkzeuge (Laser, Optiken, Scanner, Pulverdüsen) mit bekannten subtraktiven Methoden (Fräsen, gepulster Laser) kombiniert und mittels fortgeschrittenem Monitoring und Prozessregelung derart miteinander verknüpft, dass ein guter Kompromiss hinsichtlich Genauigkeit, Qualität und Baugeschwindigkeit erzielt werden kann. Schon bei der Definition der Prozessführung (CAD/CAM-Software) wird eine Optimierung vorgenommen, um generative und subtraktive Bearbeitungsschritte miteinander zu kombinieren und so eine hohe Qualität mit maximaler Produktivität zu erreichen. In particular, several additive tools known from LMD and SLM (lasers, optics, scanners, powder nozzles) are combined with known subtractive methods (milling, pulsed lasers) and linked together by means of advanced monitoring and process control in such a way that a good compromise with regard to accuracy, quality and construction speed can be achieved. As early as the definition of process control (CAD / CAM software), an optimization is carried out in order to combine generative and subtractive processing steps in order to achieve high quality with maximum productivity.
Weitere Vorteile des Verfahrens sind die aus dem LMD-Prozess bekannten hohen Aufbauraten, z.B. 10–20 mal höher als für typische SLM-Prozesse, und die Fähigkeit, große Bauteile, z.B. Abmessungen > 50cm, zu verarbeiten. Die vom LMD-Prozess bekannte geringere Konturgenauigkeit wird durch die subtraktiven Verfahren eliminiert, so dass hier bzgl. SLM kein signifikanter Nachteil besteht. Zudem ist zu erwarten, dass sich aufgrund des subtraktiven Verfahrens aufwendige Stützstrukturen vermeiden lassen können. Further advantages of the method are the high build-up rates known from the LMD process, e.g. 10-20 times higher than typical SLM processes, and the ability to handle large components, e.g. Dimensions> 50cm, to process. The lower contour accuracy known from the LMD process is eliminated by the subtractive methods, with the result that there is no significant disadvantage with respect to SLM. In addition, it can be expected that complex support structures can be avoided due to the subtractive method.
Claims (12)
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CN112338209A (en) * | 2020-10-30 | 2021-02-09 | 广东工业大学 | Laser material-increasing and material-reducing composite five-axis machining forming equipment and machining method |
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