FR3036300A1 - METHOD FOR MANUFACTURING A WORKPIECE WITH ADDITIVE FABRICATION ASSEMBLY SURFACE - Google Patents
METHOD FOR MANUFACTURING A WORKPIECE WITH ADDITIVE FABRICATION ASSEMBLY SURFACE Download PDFInfo
- Publication number
- FR3036300A1 FR3036300A1 FR1554553A FR1554553A FR3036300A1 FR 3036300 A1 FR3036300 A1 FR 3036300A1 FR 1554553 A FR1554553 A FR 1554553A FR 1554553 A FR1554553 A FR 1554553A FR 3036300 A1 FR3036300 A1 FR 3036300A1
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- FR
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- Prior art keywords
- layer
- workpiece
- periphery
- assembly
- manufacturing
- Prior art date
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- Granted
Links
- 238000000034 method Methods 0.000 title claims abstract description 35
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 27
- 239000000654 additive Substances 0.000 title claims abstract description 14
- 230000000996 additive effect Effects 0.000 title claims abstract description 14
- 239000000463 material Substances 0.000 claims abstract description 24
- 239000011324 bead Substances 0.000 claims abstract description 15
- 238000005304 joining Methods 0.000 claims abstract description 9
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 8
- 238000010894 electron beam technology Methods 0.000 claims description 9
- 238000002844 melting Methods 0.000 claims description 8
- 230000008018 melting Effects 0.000 claims description 8
- 230000008021 deposition Effects 0.000 claims description 4
- 238000005245 sintering Methods 0.000 claims description 4
- 238000005476 soldering Methods 0.000 claims description 4
- 239000000843 powder Substances 0.000 description 9
- 229910052751 metal Inorganic materials 0.000 description 7
- 239000002184 metal Substances 0.000 description 6
- 239000003292 glue Substances 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 238000005219 brazing Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 238000004026 adhesive bonding Methods 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000000110 selective laser sintering Methods 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 238000010309 melting process Methods 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Classifications
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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
- B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
-
- 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]
-
- 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
-
- 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
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/34—Laser welding for purposes other than joining
- B23K26/342—Build-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/04—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from several pieces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/141—Processes of additive manufacturing using only solid materials
- B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/171—Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects
- B29C64/182—Processes of additive manufacturing specially adapted for manufacturing multiple 3D objects in parallel batches
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/001—Turbines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/22—Manufacture essentially without removing material by sintering
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
- F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
- F05D2230/237—Brazing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/30—Manufacture with deposition of material
- F05D2230/31—Layer deposition
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2250/00—Geometry
- F05D2250/10—Two-dimensional
- F05D2250/18—Two-dimensional patterned
- F05D2250/181—Two-dimensional patterned ridged
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2250/00—Geometry
- F05D2250/10—Two-dimensional
- F05D2250/18—Two-dimensional patterned
- F05D2250/182—Two-dimensional patterned crenellated, notched
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2250/00—Geometry
- F05D2250/60—Structure; Surface texture
- F05D2250/61—Structure; Surface texture corrugated
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2250/00—Geometry
- F05D2250/60—Structure; Surface texture
- F05D2250/61—Structure; Surface texture corrugated
- F05D2250/611—Structure; Surface texture corrugated undulated
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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
L'invention concerne un procédé de fabrication d'une pièce (10, 20) constituée d'un matériau déterminé par fabrication additive, la pièce comprenant au moins une surface d'assemblage (11, 21) et un ensemble de couches (13) solidaires et empilées selon un axe vertical (Z), le procédé comprenant, pour la fabrication d'une couche de pièce, la formation d'une pluralité de lignes adjacentes à partir d'au moins un cordon du matériau (14). Le procédé comprend en outre la formation d'un bord lisse sur la périphérie de la couche à partir d'au moins un cordon du matériau (14), la formation du bord lisse étant interrompue sur au moins une portion de la périphérie de la couche comprenant des extrémités de lignes adjacentes, de manière à laisser subsister sur la périphérie de la couche au moins une portion bosselée (15), la portion bosselée étant destinée à former une surface d'assemblage de la pièce. L'invention vise aussi un procédé d'assemblage de deux pièces.The invention relates to a method for manufacturing a workpiece (10, 20) made of a material determined by additive manufacturing, the workpiece comprising at least one joining surface (11, 21) and a set of layers (13). secured and stacked along a vertical axis (Z), the method comprising, for the production of a workpiece layer, forming a plurality of adjacent lines from at least one bead of the material (14). The method further comprises forming a smooth edge on the periphery of the layer from at least one bead of the material (14), the formation of the smooth edge being interrupted on at least a portion of the periphery of the layer comprising ends of adjacent lines, so as to leave on the periphery of the layer at least one embossed portion (15), the bump portion being intended to form an assembly surface of the workpiece. The invention also relates to a method of assembling two parts.
Description
1 Arrière-plan de l'invention La présente invention se rapporte au domaine général de la fabrication de pièces par fabrication additive. Plus précisément, l'invention concerne un procédé de fabrication d'une pièce par fabrication additive destinée à être assemblée à une autre pièce. L'invention s'applique particulièrement, mais non exclusivement, à la fabrication de pièces pour l'aéronautique (c'est-à-dire des pièces pouvant être utilisées dans un turboréacteur propulsant un aéronef).BACKGROUND OF THE INVENTION The present invention relates to the general field of additive manufacturing of parts. More specifically, the invention relates to a method of manufacturing a part by additive manufacturing intended to be assembled to another part. The invention applies particularly, but not exclusively, to the manufacture of parts for aeronautics (that is to say, parts that can be used in a jet engine propelling an aircraft).
Il est aujourd'hui courant d'avoir recours à des techniques de fabrication additive pour réaliser facilement et rapidement des pièces tridimensionnelles complexes. Parmi les techniques de fabrication additive, on peut citer par exemple : la fusion sélective par laser (LBM), la fusion sélective par faisceau d'électron (EBM), le frittage sélectif par laser (SLS), le dépôt de fil, etc. Les pièces fabriquées sont souvent destinées à être assemblées, par collage ou brasage. Dans l'un ou l'autre des cas, les surfaces d'assemblage des pièces à assembler qui sont collées ou brasées (le joint entre les deux pièces étant alors constitué par de la colle ou une composition métallique d'apport) doivent présenter un état de surface particulier afin de garantir une bonne tenue mécanique du joint et de favoriser une rupture cohésive du joint (c'est-à-dire que la rupture se produit au sein du joint, à la différence d'une rupture adhésive où le joint se décolle d'une surface d'assemblage).It is now common to use additive manufacturing techniques to easily and quickly produce complex three-dimensional parts. Examples of additive manufacturing techniques include selective laser melting (LBM), selective electron beam melting (EBM), selective laser sintering (SLS), wire deposition, and the like. The manufactured parts are often intended to be assembled, by gluing or brazing. In either case, the assembly surfaces of the parts to be assembled which are glued or brazed (the joint between the two parts then being constituted by glue or a metallic filler composition) must have a special surface condition to ensure a good mechanical strength of the joint and to promote a cohesive rupture of the joint (that is to say that the rupture occurs within the joint, unlike an adhesive rupture where the joint peels off an assembly surface).
La surface d'assemblage des pièces ne doit être ni trop lisse, ni trop rugueuse, mais présenter une rugosité moyenne favorisant l'accroche du joint dans le cas du collage, et la diffusion des éléments métalliques dans le cas du brasage. Si la surface d'assemblage est trop rugueuse, des défauts peuvent être générés dans le joint à cause d'un manque de mouillage de la colle sur la surface d'assemblage, et certaines zones peuvent ne pas être remplies par le joint. A l'inverse, une surface d'assemblage trop lisse présente une surface d'accroche trop faible, l'adhésion de la colle n'est alors pas suffisante, ou les éléments d'une composition métallique d'apport pour le brasage ne diffusent pas suffisamment entre les deux surfaces d'assemblage. Les problèmes de 3036300 2 rugosité précités favorisent une rupture adhésive du joint, ce qui n'est pas souhaitable. Lorsque l'on désire assembler deux pièces réalisées par fabrication additive, on doit généralement effectuer un traitement sur la 5 surface d'assemblage des pièces. Par exemple, on peut sabler ou polir grossièrement a posteriori la surface à assembler jusqu'à obtenir un état de surface qui soit acceptable pour réaliser le collage ou le brasage. Cependant, lorsque les pièces à assembler sont complexes et nombreuses, les étapes de préparation de la surface d'assemblage 10 peuvent s'avérer longues et coûteuses, et l'état de surface obtenu est difficilement reproductible. Objet et résumé de l'invention La présente invention a donc pour but principal de pallier de 15 tels inconvénients en proposant un procédé de fabrication d'une pièce constituée d'un matériau déterminé par fabrication additive, la pièce comprenant au moins une surface d'assemblage et un ensemble de couches solidaires et empilées selon un axe vertical, le procédé comprenant, pour la fabrication d'une couche de pièce, la formation d'une 20 pluralité de lignes adjacentes à partir d'au moins un cordon du matériau, caractérisé en ce que le procédé comprend en outre la formation d'un bord lisse sur la périphérie de la couche à partir d'au moins un cordon du matériau, la formation du bord lisse étant interrompue sur au moins une portion de la périphérie de la couche comprenant des extrémités de lignes 25 adjacentes, de manière à laisser subsister sur la périphérie de la couche au moins une portion bosselée, la portion bosselée étant destinée à former une surface d'assemblage de la pièce. Dans les procédés de fabrication du type fabrication additive, la pièce est constituée d'un empilement vertical de couches qui sont 30 solidaires les unes des autres. La fabrication additive s'applique à tout type de matériaux, qu'ils soient métalliques, céramiques, plastiques, etc. Chaque couche est réalisée à l'aide d'au moins un cordon de matériau qui forme des lignes adjacentes. Dans le cas d'un procédé de fusion sélective sur lit de poudre, un cordon de matériau est créé par le 35 passage d'un laser ou d'un faisceau d'électrons qui fait fusionner des grains de poudre sur son passage. Dans le cas d'un frittage sélectif sur lit 3036300 3 de poudre, un cordon de matériau est créé par le passage d'un laser ou d'un faisceau d'électrons qui fritte un ensemble de grains de poudre sur son passage. Dans le cas d'un dépôt de fil, le cordon est constitué par le fil fondu qui est déposé sur chaque couche.The assembly surface of the parts must not be too smooth or too rough, but have a medium roughness favoring the attachment of the seal in the case of bonding, and the diffusion of the metal elements in the case of brazing. If the joint surface is too rough, defects may be generated in the joint due to a lack of wetting of the glue on the joint surface, and some areas may not be filled by the joint. Conversely, an assembly surface which is too smooth has a gripping surface that is too low, the adhesion of the adhesive is then not sufficient, or the elements of a solder metal composition for soldering do not diffuse not enough between the two joining surfaces. The above-mentioned roughness problems promote adhesive breakage of the seal, which is undesirable. When it is desired to assemble two pieces made by additive manufacturing, it is generally necessary to perform a treatment on the assembly surface of the pieces. For example, the surface to be joined can be sandblasted or coarsely polished a posteriori to obtain a surface condition that is acceptable for bonding or soldering. However, when the parts to be assembled are complex and numerous, the steps of preparation of the assembly surface 10 can be long and expensive, and the surface condition obtained is difficult to reproduce. OBJECT AND SUMMARY OF THE INVENTION The main object of the present invention is therefore to overcome such drawbacks by proposing a method of manufacturing a part made of a material determined by additive manufacturing, the part comprising at least one surface of assembly and a set of layers integral and stacked along a vertical axis, the method comprising, for the manufacture of a workpiece layer, forming a plurality of adjacent lines from at least one bead of the material, characterized in that the method further comprises forming a smooth edge on the periphery of the layer from at least one bead of the material, the formation of the smooth edge being interrupted on at least a portion of the periphery of the layer comprising ends of adjacent lines, so as to leave on the periphery of the layer at least one bumpy portion, the bumpy portion being intended to form a e assembly surface of the part. In manufacturing processes of the additive manufacturing type, the part consists of a vertical stack of layers which are integral with each other. Additive manufacturing applies to all types of materials, be they metal, ceramics, plastics, etc. Each layer is made using at least one cord of material that forms adjacent lines. In the case of a powder bed selective melting process, a bead of material is created by the passage of a laser or electron beam which fuses grains of powder in its path. In the case of selective sintering on a powder bed 3036300, a bead of material is created by the passage of a laser or an electron beam which sinter a set of grains of powder in its path. In the case of a wire deposit, the cord is constituted by the melted wire which is deposited on each layer.
5 Les lignes adjacentes formées par un cordon de matériau présentent des extrémités intrinsèquement arrondies et de largeur déterminée. Le procédé selon l'invention permet d'utiliser les extrémités des lignes formées par un cordon de matériau pour créer une surface d'assemblage qui présente une rugosité optimale pour l'utilisation 10 ultérieure d'un joint collé ou brasé. Une étape du procédé consiste à former un bord lisse sur la périphérie de la couche (il s'agit en d'autres termes d'une étape de lissage de la surface), ce bord lisse consistant généralement en un cordon de matériau qui vient « effacer » en les recouvrant, les extrémités des lignes 15 adjacentes. Ainsi, une surface lisse est obtenue sur la pièce finale, là où le bord lisse a été formé sur la périphérie des couches. Conformément à l'invention, la formation du bord lisse est interrompue sur une portion de la périphérie de la couche (correspondant à la surface d'assemblage souhaitée) pour ne pas effacer les extrémités des lignes adjacentes. Par 20 conséquent, au niveau de la portion où la formation du bord lisse est interrompue, les extrémités arrondies des lignes adjacentes sont toujours présentes et laissent subsister une portion bosselée, destinée à former la surface d'assemblage de la pièce. La surface d'assemblage présente ainsi une rugosité régulière et 25 contrôlée grâce aux portions bosselées de chaque couche. Cette rugosité dépend principalement des caractéristiques du cordon de matériau (c'est-à-dire des caractéristiques de la poudre, du matériau de la poudre, du faisceau laser ou du faisceau d'électrons, ou du fil le cas échéant, etc.), et de la stratégie d'élaboration de chaque couche.The adjacent lines formed by a bead of material have intrinsically rounded ends and a determined width. The method according to the invention makes it possible to use the ends of the lines formed by a bead of material to create an assembly surface which has an optimum roughness for the subsequent use of a bonded or brazed joint. One step of the method consists in forming a smooth edge on the periphery of the layer (it is in other words a step of smoothing the surface), this smooth edge generally consisting of a bead of material which comes " erase by covering them, the ends of the adjacent lines. Thus, a smooth surface is obtained on the final piece, where the smooth edge has been formed on the periphery of the layers. According to the invention, the formation of the smooth edge is interrupted on a portion of the periphery of the layer (corresponding to the desired assembly surface) so as not to erase the ends of the adjacent lines. Therefore, at the portion where the formation of the smooth edge is interrupted, the rounded ends of the adjacent lines are still present and leave a bumpy portion to form the assembly surface of the workpiece. The assembly surface thus has a regular and controlled roughness through the bumpy portions of each layer. This roughness depends mainly on the characteristics of the bead of material (ie characteristics of the powder, the material of the powder, the laser beam or the electron beam, or the wire if necessary, etc.) , and the development strategy of each layer.
30 En outre, le procédé selon l'invention présente l'avantage de ne pas nécessiter d'étape supplémentaire pour préparer la surface d'assemblage une fois la fabrication de la pièce terminée. Aussi, le procédé selon l'invention est répétable, c'est-à-dire que l'état de la surface d'assemblage peut être reproduit sur une série de 35 pièces très facilement, à la différence des procédés d'assemblage de l'art 3036300 4 antérieur pour lesquels la rugosité de la surface peut varier d'une pièce à l'autre. Enfin, comme les machines utilisées en fabrication additive sont généralement programmables avec un ordinateur, il devient alors aisé de 5 créer des surfaces d'assemblage complexes en modifiant la portion bosselée d'une couche à l'autre. Lorsque l'on souhaite disposer d'une surface d'assemblage sur toute une face de la pièce fabriquée, la portion de la périphérie de la couche sur laquelle la formation du bord lisse est interrompue peut être 10 sensiblement la même sur toutes les couches formant la pièce. Le procédé décrit précédemment peut être de l'un des types suivants : fusion sélective par laser ou par faisceau d'électrons, frittage sélectif par laser ou par faisceau d'électrons, ou dépôt de fil. L'invention vise également un procédé tel que celui décrit 15 précédemment dans lequel la pièce à fabriquer est une pièce pour l'aéronautique. Par « pièce pour l'aéronautique » on entend une pièce pouvant être utilisée dans un turboréacteur destiné à propulser un aéronef, par exemple : une aube de turbomachine aéronautique, un anneau de turbine, un distributeur basse pression, un système d'injection 20 de chambre à combustion aéronautique, un composant de système d'injection aéronautique, une bride, un système de bridage, un support d'équipements moteur, un capot, etc. L'invention vise encore un procédé d'assemblage d'au moins deux pièces fabriquées par un procédé tel que celui décrit plus haut, 25 caractérisé en ce qu'il comprend l'assemblage des pièces au niveau de leur surface d'assemblage, l'assemblage pouvant être un collage, ou, en variante, un brasage. Brève description des dessins 30 D'autres caractéristiques et avantages de la présente invention ressortiront de la description faite ci-dessous, en référence aux dessins annexés qui en illustrent des exemples de réalisation dépourvus de tout caractère limitatif. Sur les figures : - la figure 1 est une vue schématique de deux pièces fabriquées 35 par un procédé selon un mode de réalisation de l'invention, 3036300 5 - la figure 2 est une vue schématique d'une couche composant une pièce de la figure 1, et - la figure 3 est une vue schématique d'une autre pièce fabriquée par un procédé selon l'invention.In addition, the method according to the invention has the advantage of not requiring an additional step to prepare the assembly surface once the manufacture of the part is complete. Also, the method according to the invention is repeatable, that is to say that the state of the assembly surface can be reproduced on a series of pieces very easily, unlike the assembly methods of the invention. prior art 3036300 4 for which the roughness of the surface can vary from one room to another. Finally, since the machines used in additive manufacturing are generally programmable with a computer, it then becomes easy to create complex assembly surfaces by modifying the bumpy portion from one layer to another. When it is desired to have an assembly surface on an entire face of the fabricated part, the portion of the periphery of the layer on which the formation of the smooth edge is interrupted can be substantially the same on all the layers forming the room. The method described above may be of one of the following types: selective laser or electron beam melting, selective laser or electron beam sintering, or wire deposition. The invention also relates to a method such as that described above in which the part to be manufactured is a piece for aeronautics. By "piece for aeronautics" is meant a part that can be used in a turbojet engine for propelling an aircraft, for example: an aeronautical turbine engine blade, a turbine ring, a low pressure distributor, a fuel injection system 20. aeronautical combustion chamber, an aeronautical injection system component, a flange, a clamping system, an engine equipment support, a hood, etc. The invention also relates to a method of assembling at least two parts manufactured by a method such as that described above, characterized in that it comprises assembling the parts at their assembly surface, assembly may be a bonding, or, alternatively, soldering. BRIEF DESCRIPTION OF THE DRAWINGS Other features and advantages of the present invention will emerge from the description given below, with reference to the accompanying drawings which illustrate embodiments having no limiting character. In the figures: FIG. 1 is a diagrammatic view of two parts manufactured by a method according to one embodiment of the invention, FIG. 2 is a diagrammatic view of a layer constituting a part of FIG. 1, and - Figure 3 is a schematic view of another part manufactured by a method according to the invention.
5 Description détaillée de l'invention La figure 1 illustre très schématiquement deux pièces 10 et 20 réalisées par fusion sélective sur lit de poudre par faisceau laser (LBM ou « Laser Beam Melting ») conformément à un procédé selon l'invention.DETAILED DESCRIPTION OF THE INVENTION FIG. 1 very schematically illustrates two pieces 10 and 20 made by selective laser beam melting (LBM) according to a method according to the invention.
10 Les pièces 10, 20 sont destinées à être assemblées entre elles. Chaque pièce 10, 20 dispose d'une surface d'assemblage 11, 21, et de surfaces lisses 12, 22. Les surfaces d'assemblage 11, 21 de chaque pièce sont destinées à être collées ou brasées l'une avec l'autre, et présentent une rugosité contrôlée et optimale pour l'assemblage avec un 15 joint par collage ou brasage. Les pièces 10, 20 représentées peuvent être avantageusement fabriquées simultanément par un procédé selon l'invention. De façon connue en soi, pour réaliser une pièce par un procédé de fabrication additive du type fusion sélective sur lit de poudre par faisceau laser, une pièce 10, 20 est réalisée couche par couche, 20 chaque couche étant formées par le passage du faisceau laser sur une poudre qui est sélectivement fusionnée. Les couches sont empilées selon un axe vertical Z et solidaires entre elles. Une couche 13 de la pièce 10 a été représentée très schématiquement sur la figure 2 dans un plan horizontal XY.Parts 10, 20 are intended to be assembled together. Each piece 10, 20 has an assembly surface 11, 21, and smooth surfaces 12, 22. The assembly surfaces 11, 21 of each piece are intended to be glued or brazed with each other and have a controlled and optimum roughness for joining with a joint by gluing or brazing. The parts 10, 20 shown can be advantageously manufactured simultaneously by a method according to the invention. In a manner known per se, to produce a part by an additive manufacturing process of the selective melting type on a powder bed by laser beam, a part 10, 20 is produced layer by layer, each layer being formed by the passage of the laser beam. on a powder that is selectively fused. The layers are stacked along a vertical axis Z and integral with each other. A layer 13 of the part 10 has been shown very schematically in FIG. 2 in a horizontal plane XY.
25 Pour réaliser la couche 13, le laser forme successivement des cordons de matériau en faisant fusionner de la poudre solide (par exemple en métal ou en plastique). Les cordons représentés sur les figures ont été volontairement grossis pour une meilleure lisibilité. Les cordons présentent généralement une largeur comprise entre 50 pm et 500 dam dans le cas de 30 la fusion sélective par laser. Des lignes adjacentes 14 sont tout d'abord formées par des cordons de matériau. Elles sont réparties le long de l'axe X et s'étendent dans la direction Y. Ces lignes 14 présentent des extrémités 14a, 14b, arrondies à cause de la taille et de la forme du faisceau laser.To produce the layer 13, the laser successively forms cords of material by fusing solid powder (for example metal or plastic). The cords shown in the figures have been voluntarily enlarged for better readability. The cords generally have a width of between 50 μm and 500 μm in the case of selective laser melting. Adjacent lines 14 are first formed by cords of material. They are distributed along the X axis and extend in the Y direction. These lines 14 have ends 14a, 14b, rounded because of the size and shape of the laser beam.
35 On notera que les lignes adjacentes 14 se recouvrent partiellement selon l'axe X. Ces lignes 14 constituent le « coeur » de la 3036300 6 pièce fabriquée. On notera également que les lignes adjacentes 14 ne sont pas nécessairement des lignes droites mais peuvent être courbes, et éventuellement formées par un unique cordon de matériau. Lors de la fabrication d'une couche 13 de la pièce 10, un bord 5 lisse 15 est formé sur la périphérie de la couche 13 à partir d'un cordon de matériau (on peut éventuellement utiliser plusieurs cordons pour former le bord lisse). Ce bord lisse 15 est destiné à former les surfaces lisses 12 de la pièce 13 en recouvrant des extrémités 14a des lignes adjacentes 14. La formation de ce bord lisse 15 est interrompue sur une portion 10 16 de la périphérie de la couche comprenant des extrémités 14b de lignes adjacentes 14. La portion 16 est alors une portion bosselée destinée à former la surface d'assemblage 11 de la pièce 10. La portion bosselée 16 présente une rugosité régulière, contrôlée et répétable entre deux couches. L'opérateur peut en outre agir sur cette rugosité en réglant des 15 paramètres tels que la taille du faisceau laser ou le taux de recouvrement entre deux lignes adjacentes 14. Une fois les pièces 10, 20 réalisées par un procédé selon l'invention, on peut alors les assembler l'une avec l'autre. Il est notamment possible de les coller en appliquant une colle adéquate sur 20 l'une et/ou l'autre des surfaces d'assemblage 11, 21, puis en les mettant en contact l'une avec l'autre. En variante, on peut aussi braser les deux surfaces d'assemblage 11, 21 l'une avec l'autre (dans le cas où les pièces sont métalliques par exemple), en ajoutant éventuellement une composition métallique d'apport entre les deux pièces.It will be noted that the adjacent lines 14 overlap partially along the X axis. These lines 14 constitute the "core" of the fabricated part. It will also be noted that the adjacent lines 14 are not necessarily straight lines but may be curved, and possibly formed by a single bead of material. During the manufacture of a layer 13 of the part 10, a smooth edge 15 is formed on the periphery of the layer 13 from a bead of material (it is possible to use several cords to form the smooth edge). This smooth edge 15 is intended to form the smooth surfaces 12 of the part 13 by covering ends 14a of adjacent lines 14. The formation of this smooth edge 15 is interrupted on a portion 16 of the periphery of the layer comprising ends 14b Adjacent lines 14. The portion 16 is then a bumpy portion intended to form the assembly surface 11 of the part 10. The bumped portion 16 has a regular roughness, controlled and repeatable between two layers. The operator can furthermore act on this roughness by adjusting parameters such as the size of the laser beam or the overlap ratio between two adjacent lines 14. Once the parts 10, 20 made by a method according to the invention are can then assemble them with each other. It is in particular possible to glue them by applying a suitable glue on one and / or the other of the joining surfaces 11, 21, then putting them in contact with each other. Alternatively, one can also braze the two assembly surfaces 11, 21 with each other (in the case where the parts are metal for example), possibly adding a metal filler composition between the two parts.
25 Dans l'exemple des figures 1, 2 et 3, et pour des raisons de simplification, toutes les couches formant chaque pièce 10, 20, 30 sont identiques. La pièce 30 parallélépipédique de la figure 3 comprend des surfaces lisses 32 et une surface d'assemblage 31 qui représente la totalité d'une de ses faces.In the example of FIGS. 1, 2 and 3, and for reasons of simplification, all the layers forming each part 10, 20, 30 are identical. The parallelepipedal part 30 of FIG. 3 comprises smooth surfaces 32 and an assembly surface 31 which represents all of one of its faces.
30 Il est bien entendu envisageable de faire varier la taille et la position de la portion bosselée 16 entre les différentes couches 13 afin de réaliser des surfaces d'assemblage 11 plus complexes et adaptées aux différents besoins. Dans ce dernier cas, il faut généralement que les portions bosselées de deux couches consécutives au niveau de la surface 35 d'assemblage conservent une partie commune entre deux couches consécutives.It is of course conceivable to vary the size and the position of the bumped portion 16 between the different layers 13 in order to achieve more complex joining surfaces 11 and adapted to different needs. In the latter case, it is generally necessary that the bumpy portions of two consecutive layers at the joining surface maintain a common portion between two consecutive layers.
3036300 7 Dans d'autres variantes, une pièce peut présenter plusieurs surfaces d'assemblage et être assemblée à plusieurs pièces. Aussi, la géométrie des pièces que l'on peut fabriquer par un procédé selon l'invention n'est pas limitée aux exemples illustrés.In other embodiments, a part may have a plurality of joining surfaces and be assembled to a plurality of parts. Also, the geometry of the parts that can be manufactured by a method according to the invention is not limited to the examples illustrated.
5 L'invention s'applique à tout procédé du type fabrication additive, notamment la fusion sélective par laser ou par faisceau d'électrons, le frittage sélectif par laser ou par faisceau d'électrons, ou encore le dépôt de fil, tant que ces procédés comprennent la création de couches successives à partir de cordons de matériau déposés, fusionnés 10 ou frittés. Enfin, l'invention s'applique à tout type de matériau convenant aux procédés précités, par exemple : métal, alliage métallique, céramique, plastique, etc.The invention applies to any process of the additive manufacturing type, in particular selective laser or electron beam melting, selective sintering by laser or electron beam, or wire deposition, as long as these Methods include creating successive layers from deposited, fused or sintered material beads. Finally, the invention applies to any type of material suitable for the aforementioned methods, for example: metal, metal alloy, ceramic, plastic, etc.
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