WO2015155745A1 - Process for forming a component by means of additive manufacturing, and powder dispensing device for carrying out such a process - Google Patents

Process for forming a component by means of additive manufacturing, and powder dispensing device for carrying out such a process Download PDF

Info

Publication number
WO2015155745A1
WO2015155745A1 PCT/IB2015/052625 IB2015052625W WO2015155745A1 WO 2015155745 A1 WO2015155745 A1 WO 2015155745A1 IB 2015052625 W IB2015052625 W IB 2015052625W WO 2015155745 A1 WO2015155745 A1 WO 2015155745A1
Authority
WO
WIPO (PCT)
Prior art keywords
powder
powder layer
heating
component
layer
Prior art date
Application number
PCT/IB2015/052625
Other languages
French (fr)
Inventor
Mauro Varetti
Original Assignee
Ge Avio S.R.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ge Avio S.R.L. filed Critical Ge Avio S.R.L.
Priority to US15/302,181 priority Critical patent/US20170021456A1/en
Publication of WO2015155745A1 publication Critical patent/WO2015155745A1/en

Links

Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/10—Induction heating apparatus, other than furnaces, for specific applications
    • H05B6/101—Induction heating apparatus, other than furnaces, for specific applications for local heating of metal pieces
    • 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
    • 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
    • B22F12/10—Auxiliary heating means
    • B22F12/13—Auxiliary heating means to preheat the material
    • 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
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/002—Devices involving relative movement between electronbeam and workpiece
    • 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
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0026—Auxiliary equipment
    • 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
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
    • 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
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/0869—Devices involving movement of the laser head in at least one axial direction
    • 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
    • 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
    • B23K26/60—Preliminary treatment
    • 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
    • B23K26/70—Auxiliary operations or equipment
    • B23K26/702—Auxiliary equipment
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205—Means for applying layers
    • 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
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • 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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/36—Coil arrangements
    • H05B6/44—Coil arrangements having more than one coil or coil segment
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0811—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using induction
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0855—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using microwave
    • 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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • 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

Definitions

  • the present invention relates to a process for forming a component by means of additive manufacturing.
  • additive manufacturing techniques consist in repeating cycles during which successive horizontal sections of the component to be formed are created.
  • a powder layer is deposited at the beginning of each cycle, where such a layer has a substantially constant thickness, and the powders have the same composition as the component that must be formed; then specific areas of the powder layer are melted by scanning a focused energy beam, generally a laser beam or an electron beam, where such areas are selected according to a mathematical model, which represents the geometry and the size of the component that must be formed.
  • a focused energy beam generally a laser beam or an electron beam
  • the part of the component that was already formed is lowered by a quantity equal to the thickness of the powder layer which is deposited each time, so as to move to the next cycle. Finally, once all cycles are completed, the residual powders are removed.
  • the melting step must be preceded by a pre-heating step of the powder layer (to increase the temperature thereof to a level which is in any case lower than the melting temperature) , in order to reduce the thermal shock and therefore avoid the formation of residual tensions and imperfections in the component being formed.
  • the pre-heating step is carried out by means of a defocused electron beam but this solution is poorly satisfactory.
  • the operating times are relatively long, especially for relatively large components, because the pre-heating step is carried out after the powder layer has been completely deposited.
  • the electron beam is not suitable for being used for all materials, because it must operate under partial vacuum where the residual gas is very low pressure helium gas. Indeed, these ambient conditions are not suitable for those materials (for example aluminium alloys) which suffer from evaporation in the case of vacuum ambient.
  • a process is provided for forming a component by means of additive manufacturing, as defined in claim 1.
  • the present invention further relates to a powder dispensing device for carrying out a process of additive manufacturing, as defined in claim 6.
  • FIG. 5 is a simplified cross section of a powder dispensing device, diagrammatically shown in figures 1 to 4.
  • FIG. 6 is a bottom view, of a back portion of the powder dispensing device in figure 5.
  • Numeral 1 in figures 1 to 4 indicates a component that is formed starting from metallic powders, by means of an additive manufacturing technique, that is a "layer by layer” type of manufacturing technique.
  • the composition of the metallic powders is close to the one of component 1 that must be formed.
  • titanium alloys are commonly used in the aeronautics field, for example a known alloy with the abbreviation Ti6-4 or Ti6AI-4V (having 6% aluminium and 4% vanadium) .
  • the temperatures required to obtain the melting of the powders may reach 1800 °C, according to the particular alloy used.
  • the process is carried out by means of a machine 11 (diagrammatically and partly shown) comprising a work chamber 12, which houses a base plate 13, also called “starting platform”, on which the first powder layer is deposited .
  • the base plate 13 is actuated (in a manner not shown) to translate progressively downwards along the vertical direction (arrow V) , in response to a control unit 16 commands.
  • the base plate 13 must be made of a material which is capable of resisting the high temperatures for melting the powders.
  • the metallic powders are deposited by a distributor device 14, which will be described in greater detail below, so as to form overlapping successive layers 22.
  • Machine 11 also comprises an emitter or gun 15 for emitting an energy beam downwards, for example a focused electron beam or a focused laser light beam, so as to obtain the melting or the sintering of the powders: emitter 15 is actuated and controlled by the control unit 16 so as to melt each powder layer locally, at the areas to be actually formed.
  • emitter 15 for emitting an energy beam downwards, for example a focused electron beam or a focused laser light beam, so as to obtain the melting or the sintering of the powders: emitter 15 is actuated and controlled by the control unit 16 so as to melt each powder layer locally, at the areas to be actually formed.
  • the laser is generally used for powder layers 22 having thickness up to 40 ⁇ , while the electron beam for a thickness up to 180 ⁇ .
  • Emitter 15 and the base plate 13 are preferably movable with respect to one another to carry out the scanning of the top surface of each powder layer 22 by means of the energy beam.
  • a system of driven deflectors for deflecting the energy beam towards the desired areas may be provided.
  • machine 11 may comprise a system (not shown) for generating the vacuum in chamber 12, and/or a system (not shown) for emitting an inert gas jet (for example argon and helium) into chamber 12 towards the melting area, for example to protect the material that is being melted from oxidization.
  • an inert gas jet for example argon and helium
  • the selection of the areas to be melted is based on a three-dimensional mathematical model generated beforehand and corresponding to the shape and to the size desired for component 1.
  • the three- dimensional model may be generated by means of computer assisted design (CAD) and transferred to the control unit 16 in the form of "files".
  • CAD computer assisted design
  • the three-dimensional model is stored in the control unit 16 and is divided into overlapping horizontal levels, each associated to a relative horizontal section of component 1, which is formed by locally melting corresponding areas of the powder layer 22.
  • Figure 1 depicts an intermediate step of the formation of component 1.
  • a lower portion 17 and a series of pedestals 18 have already been formed.
  • the pedestals 18 are also defined in the three-dimensional model together with component 1, are formed in chamber 12 to keep component 11 fixed to plate 13 during forming and, at the same time, to space portion 17 apart from plate 13.
  • the pedestals 18 are removed at the end of the manufacturing process .
  • a top portion 19 still to be formed is indicated in figures 1 to 4 with a dotted line.
  • the portions 17, 18, already formed, are surrounded by a mass of residual powders 20, which were deposited in layers beforehand but which were not subjected to melting.
  • the powders have a grain size included in the range from 20 to 150 ⁇ .
  • the choice of the powder grain size is a compromise between various needs: having increased manufacturing speed (which would favor powders with larger grain size) ; having good shape and homogeneity accuracy in the structure of component 1 which must be formed; being able to easily empty any cavities and/or pores of component 1 from residual powders 20 at the end of the forming.
  • powders are used which are obtained by means of gas atomization processes, that is processes capable of forming granules that are substantially spherical in shape .
  • device 14 With regard to device 14, the latter is actuated (in a manner not shown) to translate along a horizontal direction HR above a surface 21 which defines portion 17 at the top and the surrounding residual powders 20. At the same time, device 14 is controlled so as to distribute a powder layer 22 on surface 21.
  • surface 21 is arranged at a fixed reference height (line Q) with respect to the height position of device 14, by means of adjusting the base plate 13 in height.
  • device 14 comprises a dispenser 24, for example an auger dispenser, which is fed with powder from a tank 25 and is controlled so as to cause a quantity of powder to drop onto surface 21 through a horizontal slit 26 which is made on a bottom wall 27 of device 14 and is elongated orthogonally to direction HR.
  • dispenser 24 is of the adjustable type for varying the quantity of powder caused to drop.
  • at least a part of tank 25 constitutes part of device 14.
  • device 14 comprises at least one leveling element, for example a blade 28, which extends parallel to slit 26 and protrudes downwards with respect to the bottom wall 27 so as to pass on the powder which is dropped through slit 26 in order to distribute and level such a powder.
  • a leveling element for example a blade 28, which extends parallel to slit 26 and protrudes downwards with respect to the bottom wall 27 so as to pass on the powder which is dropped through slit 26 in order to distribute and level such a powder.
  • layer 22 takes on a substantially even thickness (which was intentionally exaggerated in figures from 1 to 4 for reasons of clarity) .
  • blade 28 and dispenser 24 constitute part of two members which are separate and which are actuated separately from one another to move above surface 21.
  • blade 28 and dispenser 24 are fixed with respect to one another.
  • device 14 comprises two blades 28, which are arranged on opposite sides of slit 26, considering direction HR.
  • the powders of each layer 22 are subjected to a pre-heating step to avoid, or at least reduce, the occurrence of deformations and/or residual tensions of component 1.
  • the temperature of the powders obtained by means of the pre-heating step is in any case less than the melting temperature of the material (in the case of titanium alloy, the pre-heating temperature is for example around 800 °C) .
  • the pre-heating is carried out by means of a heat source 30 which is movable so as to carry out a scanning on the powder layer 22.
  • the heat source 30 advances horizontally and progressively on the powder layer 22 by following the path of device 14 along direction HR.
  • the present invention at least for the initial part of the path carried out by the heat source 30, the latter is moved on the powder layer 22 at the same time as device 14, so as to reduce the times of all cycles of the process.
  • the heat source 30 is fixed with respect to dispenser 24 and/or with respect to blade 28, so as to be part of device 14.
  • the heat source 30 has an elongated shape in direction parallel to slit 26 and to blade 28 and is arranged downstream of blade 28, considering the advancement direction of device 14 along direction HR.
  • the heat source 30 is of the inductive type, but generally the tracking of device 14 may also be carried out with different heat sources (energy beam, electric resistors, etc.) .
  • device 14 With the configuration shown, where a single heat source 30 is provided, the latter defines a back portion of device 14. In this case, device 14 must be rotated by 180° before depositing a new powder layer 22, so as to have the heat source 30 always arranged at the tail, considering the advancement direction of device 14 along direction HR. To avoid this rotation about the vertical axis, as an alternative (not shown) device 14 may comprise two heat sources 30, arranged at the front and at the back end, respectively, that is arranged outside with respect to the two blades 28 shown in the embodiment in figure 5. Or, device 14 may carry out the depositing step while travelling the horizontal direction HR in a single direction and then be quickly retracted to the beginning of the path to carry out the next depositing step.
  • the heat source 30 may be separate from and be moved separately from dispenser 24 and from blade 28 above surface 21.
  • the heat source 30 comprises a plurality of induction coils 31, which are wound about respective vertical axes 32 and are arranged in positions distributed, for example along at least one row, so as to cover a dimension which is at least equal to the length of slit 26 and/or of blade 28 (that is at least equal to the width of the powder layer 22), orthogonally to direction HR.
  • the heat source 30 preferably comprises two rows 31a, 31b of coils, where each coil of row 31a is coupled and ad acent to a coil of row 31b, so as to close the magnetic field lines in such a pair of coils .
  • the heat source 30 preferably comprises an adjustment device 35 (diagrammatically shown) , which transfers the electric energy to the coils 31 starting from a power supply (not shown) and is controlled so as to adjust the electrical power fed to the different coils 31, to vary the average pre-heating temperature of the powder layer 22 and/or to differentiate the power between the various coils 31 and therefore vary the temperature between the various areas of layer 22.
  • an adjustment device 35 (diagrammatically shown) , which transfers the electric energy to the coils 31 starting from a power supply (not shown) and is controlled so as to adjust the electrical power fed to the different coils 31, to vary the average pre-heating temperature of the powder layer 22 and/or to differentiate the power between the various coils 31 and therefore vary the temperature between the various areas of layer 22.
  • the temperature of the powders during the pre ⁇ heating is preferably kept under control, for example by using a suitably calibrated infrared sensor. According to the temperature detected, it is possible to adjust the power of the coils in closed loop, for example similarly to what provided in common electromagnetic induction ovens or microwave ovens.
  • Machine 11 also preferably comprises an adjustment device (not shown) for varying the frequency of the electric current fed to the coils 31.
  • the physical features of the materials treated such as the magnetic permeability
  • the depth of the powder layer 22 that must be heated determine the most suitable choice for the frequency value.
  • device 14 comprises a shield 37, for example of type similar to the ones used in common cathode ray tubes, so as to avoid any interferences generated by the magnetic field of the coils 31 on the other equipment of device 14 and of machine 11.
  • Shield 37 surrounds the coils 31 and preferably also device 35, on all sides except for the bottom one, which must be crossed by the magnetic field lines so as to heat the powder layer 22 by induction.
  • the melting is also carried out for at least part of each cycle at the same time as the distribution of the powders and as pre-heating.
  • the energy beam of emitter 15 is moved on the powder layer 22 at the same time as device 14, so as to track the movement of the heat source 30 along direction HR and therefore further reduce the times of all cycles.
  • the melting is carried out in localized areas selected by the control unit 16 on the basis of the three- dimensional model stored so as to form a new section 170 above portion 17.
  • the cross section 170 is "amalgamated" with portion 17 below so as to form a new portion 170' (shown in figure 4) .
  • the thickness of section 170 that was just formed is essentially a function of the thickness of the powder layer that was deposited by device 14.
  • plate 13 is lowered by a predetermined height (arrow V) corresponding substantially to the thickness of section 170 that was just formed, so as to bring the top surface of portion 170' and of the surrounding powders back to the fixed reference height (line Q) .
  • device 14 starts again in the opposite direction, if necessary after having been rotated by 180° about a vertical axis, to bring the heat source 30 behind blade 28, so as to then deposit a new layer of powders (indicated by numeral 23) which are pre-heated and subjected to localized melting in rapid succession.
  • the process continues this way with the repetition of the steps of depositing, pre-heating, melting and lowering the base plate 13, until the three- dimensional model stored in the control unit 16 is completed, that is until missing portion 19 is completed .
  • component 1 is advantageously cooled by means of a flow of inert gas (for example helium or argon) introduced into chamber 12, before being detached from the base plate 13.
  • inert gas for example helium or argon
  • Other processing steps may be possibly carried out, for example for completely removing the remaining residual powders in the cavities of component 1 or for eliminating any traces of the supports 18.
  • the fact of moving the heat source 30 above surface 21 together with dispenser 24 and/or with blade 28 allows a significant reduction of the manufacturing times to be guaranteed with respect to known solutions in which the pre-heating step is carried out after having completed the depositing step.
  • the fact of integrating the heat source 30 in device 14 allows the volumes to be reduced to the maximum extent possible and the times between the depositing and pre-heating steps to be reduced. Furthermore, this way a single movement system (not shown) is used for moving dispenser 24, blade 28 and the heat source 30 together above surface 21 along direction HR.
  • induction heat source which may operate in controlled and inert atmosphere for the pre ⁇ heating step, it is possible to avoid the use of electron beams and therefore it is also possible to process alloys suffering from vacuum evaporation.
  • device 14 allows the heating efficiency to be optimized and the volumes to be limited with respect to known solutions in which induction coils are arranged in fixed positions.
  • the process is extremely flexible, because by adjusting the power supplied to the various coils 31, it is possible to fine tune the pre-heating temperature between the various areas of the powder layer 22 and therefore to optimize the heating efficiency.
  • direction HR might not be rectilinear, and/or the shape and configuration of device 14 could be different from the ones shown diagrammatically in the accompanying figures; and/or tank 25 could be arranged in remote position and connected to dispenser 24 by means of a conveying tube.

Landscapes

  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Optics & Photonics (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Plasma & Fusion (AREA)
  • Electromagnetism (AREA)
  • Health & Medical Sciences (AREA)
  • Thermal Sciences (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Toxicology (AREA)
  • Powder Metallurgy (AREA)

Abstract

A component (1) is formed by means of additive manufacturing by repeating a series of cycles, where each cycle has a depositing step for forming a powder layer (22) of substantially constant thickness; a pre¬ heating step, for pre-heating the powder layer (22); and a melting step, for melting some areas of said powder layer (22) by means of an energy beam so as to form a horizontal section (170) of the component (1) that must be obtained; at the end of all cycles, the top surface (21) of the horizontal section that has been formed is lowered until it reaches a predetermined height (Q); the pre-heating step is performed by moving a heat source (30) above the powder layer (22) at the same time as the depositing step, at least for an initial part of the pre-heating step.

Description

PROCESS FOR FORMING A COMPONENT BY MEANS OF ADDITIVE MANUFACTURING, AND POWDER DISPENSING DEVICE FOR CARRYING OUT SUCH A PROCESS TECHNICAL FIELD
The present invention relates to a process for forming a component by means of additive manufacturing.
BACKGROUND ART
As is known, additive manufacturing techniques consist in repeating cycles during which successive horizontal sections of the component to be formed are created. In particular, a powder layer is deposited at the beginning of each cycle, where such a layer has a substantially constant thickness, and the powders have the same composition as the component that must be formed; then specific areas of the powder layer are melted by scanning a focused energy beam, generally a laser beam or an electron beam, where such areas are selected according to a mathematical model, which represents the geometry and the size of the component that must be formed. In other words, in the areas where the powders are melted, a continuous structure is formed which defines a corresponding horizontal section of the component .
Once the melting is complete, the part of the component that was already formed is lowered by a quantity equal to the thickness of the powder layer which is deposited each time, so as to move to the next cycle. Finally, once all cycles are completed, the residual powders are removed.
For materials with high contraction coefficients during their solidification, the melting step must be preceded by a pre-heating step of the powder layer (to increase the temperature thereof to a level which is in any case lower than the melting temperature) , in order to reduce the thermal shock and therefore avoid the formation of residual tensions and imperfections in the component being formed.
Normally, the pre-heating step is carried out by means of a defocused electron beam but this solution is poorly satisfactory.
On the one hand, the operating times are relatively long, especially for relatively large components, because the pre-heating step is carried out after the powder layer has been completely deposited. Secondly, the electron beam is not suitable for being used for all materials, because it must operate under partial vacuum where the residual gas is very low pressure helium gas. Indeed, these ambient conditions are not suitable for those materials (for example aluminium alloys) which suffer from evaporation in the case of vacuum ambient.
To obviate this last disadvantage, other techniques are generally used for the pre-heating step. For example, International Patent Application WO2013152750A1 describes a system provided with an induction coil, which is embedded in an insulator material surrounding a cylindrical cavity housing the component being formed. Nevertheless, a system of this type is relatively cumbersome and does not allow the pre-heating temperature to be varied between the various areas of the powder layer.
DISCLOSURE OF INVENTION
It is the object of the present invention to provide a process for forming a component by means of additive manufacturing, which allows the above-described problems to be resolved in a simple and cost-effective manner.
According to the present invention, a process is provided for forming a component by means of additive manufacturing, as defined in claim 1.
The present invention further relates to a powder dispensing device for carrying out a process of additive manufacturing, as defined in claim 6.
BRIEF DECRIPTION OF THE DRAWINGS
For a better understanding of the present invention, a preferred embodiment thereof is now described, by way of a mere non-limiting example, with reference to the accompanying drawings, in which: - figures 1 to 4 are diagrams showing some steps of a preferred embodiment of the process for forming a component by means of additive manufacturing according to the present invention;
- figure 5 is a simplified cross section of a powder dispensing device, diagrammatically shown in figures 1 to 4; and
- figure 6 is a bottom view, of a back portion of the powder dispensing device in figure 5.
BEST MODE FOR CARRYING OUT THE INVENTION
Numeral 1 in figures 1 to 4 indicates a component that is formed starting from metallic powders, by means of an additive manufacturing technique, that is a "layer by layer" type of manufacturing technique.
These layer by layer manufacturing techniques are referenced to in literature by different acronyms, for example acronyms such as "Direct Laser Forming" (DLF) , "Direct Metal Laser Sintering" (DMLS), "Selective Laser Melting" (SLM) or "Electron Beam Melting" (EBM) .
The composition of the metallic powders is close to the one of component 1 that must be formed. In particular, titanium alloys are commonly used in the aeronautics field, for example a known alloy with the abbreviation Ti6-4 or Ti6AI-4V (having 6% aluminium and 4% vanadium) . With regard to titanium alloys, the temperatures required to obtain the melting of the powders may reach 1800 °C, according to the particular alloy used.
The process is carried out by means of a machine 11 (diagrammatically and partly shown) comprising a work chamber 12, which houses a base plate 13, also called "starting platform", on which the first powder layer is deposited .
The base plate 13 is actuated (in a manner not shown) to translate progressively downwards along the vertical direction (arrow V) , in response to a control unit 16 commands. Obviously the base plate 13 must be made of a material which is capable of resisting the high temperatures for melting the powders.
The metallic powders are deposited by a distributor device 14, which will be described in greater detail below, so as to form overlapping successive layers 22.
Machine 11 also comprises an emitter or gun 15 for emitting an energy beam downwards, for example a focused electron beam or a focused laser light beam, so as to obtain the melting or the sintering of the powders: emitter 15 is actuated and controlled by the control unit 16 so as to melt each powder layer locally, at the areas to be actually formed.
The laser is generally used for powder layers 22 having thickness up to 40 μπι, while the electron beam for a thickness up to 180 μπι. Emitter 15 and the base plate 13 are preferably movable with respect to one another to carry out the scanning of the top surface of each powder layer 22 by means of the energy beam. Alternatively to or in combination with this relative movement, a system of driven deflectors for deflecting the energy beam towards the desired areas may be provided.
Furthermore, machine 11 may comprise a system (not shown) for generating the vacuum in chamber 12, and/or a system (not shown) for emitting an inert gas jet (for example argon and helium) into chamber 12 towards the melting area, for example to protect the material that is being melted from oxidization.
The selection of the areas to be melted is based on a three-dimensional mathematical model generated beforehand and corresponding to the shape and to the size desired for component 1. For example, the three- dimensional model may be generated by means of computer assisted design (CAD) and transferred to the control unit 16 in the form of "files". The three-dimensional model is stored in the control unit 16 and is divided into overlapping horizontal levels, each associated to a relative horizontal section of component 1, which is formed by locally melting corresponding areas of the powder layer 22.
Figure 1 depicts an intermediate step of the formation of component 1. In this step, it is assumed that a lower portion 17 and a series of pedestals 18 have already been formed. The pedestals 18 are also defined in the three-dimensional model together with component 1, are formed in chamber 12 to keep component 11 fixed to plate 13 during forming and, at the same time, to space portion 17 apart from plate 13. The pedestals 18 are removed at the end of the manufacturing process .
A top portion 19 still to be formed is indicated in figures 1 to 4 with a dotted line. The portions 17, 18, already formed, are surrounded by a mass of residual powders 20, which were deposited in layers beforehand but which were not subjected to melting.
Preferably, the powders have a grain size included in the range from 20 to 150 μπι. The choice of the powder grain size is a compromise between various needs: having increased manufacturing speed (which would favor powders with larger grain size) ; having good shape and homogeneity accuracy in the structure of component 1 which must be formed; being able to easily empty any cavities and/or pores of component 1 from residual powders 20 at the end of the forming. In particular, powders are used which are obtained by means of gas atomization processes, that is processes capable of forming granules that are substantially spherical in shape .
With regard to device 14, the latter is actuated (in a manner not shown) to translate along a horizontal direction HR above a surface 21 which defines portion 17 at the top and the surrounding residual powders 20. At the same time, device 14 is controlled so as to distribute a powder layer 22 on surface 21.
Before the passage of device 14 and therefore the depositing of the powder, surface 21 is arranged at a fixed reference height (line Q) with respect to the height position of device 14, by means of adjusting the base plate 13 in height.
As shown in figure 5, device 14 comprises a dispenser 24, for example an auger dispenser, which is fed with powder from a tank 25 and is controlled so as to cause a quantity of powder to drop onto surface 21 through a horizontal slit 26 which is made on a bottom wall 27 of device 14 and is elongated orthogonally to direction HR. Preferably, dispenser 24 is of the adjustable type for varying the quantity of powder caused to drop. Furthermore, in the particular example shown, at least a part of tank 25 constitutes part of device 14.
Preferably, device 14 comprises at least one leveling element, for example a blade 28, which extends parallel to slit 26 and protrudes downwards with respect to the bottom wall 27 so as to pass on the powder which is dropped through slit 26 in order to distribute and level such a powder. In other words, with the passage of blade 28, layer 22 takes on a substantially even thickness (which was intentionally exaggerated in figures from 1 to 4 for reasons of clarity) .
According to a variant not shown, blade 28 and dispenser 24 constitute part of two members which are separate and which are actuated separately from one another to move above surface 21.
On the other hand, in the example shown, blade 28 and dispenser 24 are fixed with respect to one another. In particular, device 14 comprises two blades 28, which are arranged on opposite sides of slit 26, considering direction HR.
The powders of each layer 22 are subjected to a pre-heating step to avoid, or at least reduce, the occurrence of deformations and/or residual tensions of component 1. The temperature of the powders obtained by means of the pre-heating step is in any case less than the melting temperature of the material (in the case of titanium alloy, the pre-heating temperature is for example around 800 °C) .
The pre-heating is carried out by means of a heat source 30 which is movable so as to carry out a scanning on the powder layer 22. In other words, the heat source 30 advances horizontally and progressively on the powder layer 22 by following the path of device 14 along direction HR. According to the present invention, at least for the initial part of the path carried out by the heat source 30, the latter is moved on the powder layer 22 at the same time as device 14, so as to reduce the times of all cycles of the process.
In the preferred embodiment shown in figure 5, the heat source 30 is fixed with respect to dispenser 24 and/or with respect to blade 28, so as to be part of device 14. In particular, the heat source 30 has an elongated shape in direction parallel to slit 26 and to blade 28 and is arranged downstream of blade 28, considering the advancement direction of device 14 along direction HR.
Preferably, the heat source 30 is of the inductive type, but generally the tracking of device 14 may also be carried out with different heat sources (energy beam, electric resistors, etc.) .
With the configuration shown, where a single heat source 30 is provided, the latter defines a back portion of device 14. In this case, device 14 must be rotated by 180° before depositing a new powder layer 22, so as to have the heat source 30 always arranged at the tail, considering the advancement direction of device 14 along direction HR. To avoid this rotation about the vertical axis, as an alternative (not shown) device 14 may comprise two heat sources 30, arranged at the front and at the back end, respectively, that is arranged outside with respect to the two blades 28 shown in the embodiment in figure 5. Or, device 14 may carry out the depositing step while travelling the horizontal direction HR in a single direction and then be quickly retracted to the beginning of the path to carry out the next depositing step.
As a further, albeit less advantageous, alternative, the heat source 30 may be separate from and be moved separately from dispenser 24 and from blade 28 above surface 21.
According to an advantageous aspect of the present invention, the heat source 30 comprises a plurality of induction coils 31, which are wound about respective vertical axes 32 and are arranged in positions distributed, for example along at least one row, so as to cover a dimension which is at least equal to the length of slit 26 and/or of blade 28 (that is at least equal to the width of the powder layer 22), orthogonally to direction HR.
As shown in figure 6, the heat source 30 preferably comprises two rows 31a, 31b of coils, where each coil of row 31a is coupled and ad acent to a coil of row 31b, so as to close the magnetic field lines in such a pair of coils .
Again, with reference to figure 5, the heat source 30 preferably comprises an adjustment device 35 (diagrammatically shown) , which transfers the electric energy to the coils 31 starting from a power supply (not shown) and is controlled so as to adjust the electrical power fed to the different coils 31, to vary the average pre-heating temperature of the powder layer 22 and/or to differentiate the power between the various coils 31 and therefore vary the temperature between the various areas of layer 22.
The temperature of the powders during the pre¬ heating is preferably kept under control, for example by using a suitably calibrated infrared sensor. According to the temperature detected, it is possible to adjust the power of the coils in closed loop, for example similarly to what provided in common electromagnetic induction ovens or microwave ovens.
Machine 11 also preferably comprises an adjustment device (not shown) for varying the frequency of the electric current fed to the coils 31. The physical features of the materials treated (such as the magnetic permeability) and the depth of the powder layer 22 that must be heated, determine the most suitable choice for the frequency value.
Advantageously, device 14 comprises a shield 37, for example of type similar to the ones used in common cathode ray tubes, so as to avoid any interferences generated by the magnetic field of the coils 31 on the other equipment of device 14 and of machine 11. Shield 37 surrounds the coils 31 and preferably also device 35, on all sides except for the bottom one, which must be crossed by the magnetic field lines so as to heat the powder layer 22 by induction.
Advantageously, the melting is also carried out for at least part of each cycle at the same time as the distribution of the powders and as pre-heating. In other words, the energy beam of emitter 15 is moved on the powder layer 22 at the same time as device 14, so as to track the movement of the heat source 30 along direction HR and therefore further reduce the times of all cycles.
As disclosed above, considering figure 3, the melting is carried out in localized areas selected by the control unit 16 on the basis of the three- dimensional model stored so as to form a new section 170 above portion 17. During the melting of the powders, the cross section 170 is "amalgamated" with portion 17 below so as to form a new portion 170' (shown in figure 4) . The thickness of section 170 that was just formed is essentially a function of the thickness of the powder layer that was deposited by device 14.
After the melting step, plate 13 is lowered by a predetermined height (arrow V) corresponding substantially to the thickness of section 170 that was just formed, so as to bring the top surface of portion 170' and of the surrounding powders back to the fixed reference height (line Q) .
At this point, device 14 starts again in the opposite direction, if necessary after having been rotated by 180° about a vertical axis, to bring the heat source 30 behind blade 28, so as to then deposit a new layer of powders (indicated by numeral 23) which are pre-heated and subjected to localized melting in rapid succession. The process continues this way with the repetition of the steps of depositing, pre-heating, melting and lowering the base plate 13, until the three- dimensional model stored in the control unit 16 is completed, that is until missing portion 19 is completed .
At the end of the forming, component 1 is advantageously cooled by means of a flow of inert gas (for example helium or argon) introduced into chamber 12, before being detached from the base plate 13. Other processing steps may be possibly carried out, for example for completely removing the remaining residual powders in the cavities of component 1 or for eliminating any traces of the supports 18.
The advantages of the above-described manufacturing process are apparent from what mentioned above.
Firstly, the fact of moving the heat source 30 above surface 21 together with dispenser 24 and/or with blade 28 allows a significant reduction of the manufacturing times to be guaranteed with respect to known solutions in which the pre-heating step is carried out after having completed the depositing step.
Moreover, the fact of integrating the heat source 30 in device 14 allows the volumes to be reduced to the maximum extent possible and the times between the depositing and pre-heating steps to be reduced. Furthermore, this way a single movement system (not shown) is used for moving dispenser 24, blade 28 and the heat source 30 together above surface 21 along direction HR.
By using one induction heat source which may operate in controlled and inert atmosphere for the pre¬ heating step, it is possible to avoid the use of electron beams and therefore it is also possible to process alloys suffering from vacuum evaporation.
In particular, device 14 allows the heating efficiency to be optimized and the volumes to be limited with respect to known solutions in which induction coils are arranged in fixed positions.
Furthermore, the process is extremely flexible, because by adjusting the power supplied to the various coils 31, it is possible to fine tune the pre-heating temperature between the various areas of the powder layer 22 and therefore to optimize the heating efficiency.
Finally, it is clear that modifications and variants may be made to the above-described process and device 14 which are disclosed with reference to the accompanying figures, without departing from the scope of the present invention.
In particular, direction HR might not be rectilinear, and/or the shape and configuration of device 14 could be different from the ones shown diagrammatically in the accompanying figures; and/or tank 25 could be arranged in remote position and connected to dispenser 24 by means of a conveying tube.

Claims

1. - A process for forming a component (1) by means of additive manufacturing, the process comprising the steps of:
a) depositing powders having the same composition as said component (1) so as to define a powder layer (22) having a substantially constant thickness;
b) pre-heating said powder layer (22);
c) carrying out a melting of some areas of said powder layer (22) by means of an energy beam so as to form a horizontal section (170) of said component (1);
d) lowering the top surface (21) of the horizontal section formed until it reaches a predetermined height (Q) ;
e) repeating the previous steps until all horizontal sections of said component (1) are formed;
characterized by performing the pre-heating step by moving a heat source (30) above said powder layer (22) at the same time as the depositing step, at least for an initial part of the pre-heating step.
2. - A process according to claim 1, characterized in that the pre-heating step is carried out by induction.
3. - A process according to claim 1 or 2, characterized by carrying out the melting step by moving said energy beam on said powder layer (22) simultaneously to the depositing and pre-heating steps, at least for an initial part of the melting step.
4. - A process according to any one of the preceding claims, characterized in that the depositing and pre¬ heating steps are carried out by moving a single device (14) along an advancement direction (HR) .
5. - A process according to any one of the preceding claims, characterized by varying the pre-heating power between various areas of the powder layer that are pre¬ heated .
6.- A powder dispensing device (14) for carrying out the process according to claim 4, the device being movable along an advancement direction (HR) and comprising at least one of:
a powder dispenser (24) for dropping a layer of powder from the device (14);
a leveling element (28) adapted to pass on powder dropped during the advancement of the device (14) for making the thickness of said layer of powder (22) even;
characterized by further comprising at least one heat source (30) for pre-heating said layer of powder (22) .
7.- A device (14) according to claim 6, characterized in that said heat source (30) and said powder dispenser (24) and/or leveling element (28) are elongated along directions that are parallel to each other and orthogonal to said advancement direction (HR) .
8. - A device (14) according to claim 6 or 7, characterized in that said heat source (30) comprises a plurality of induction coils (31) with respective vertical axes (32) .
9. - A device according to claims 7 and 8, characterized in that said heat source (30) comprises a first and a second row of induction coils; each induction coil of said first row (31a) being associated with, and adjacent to, a corresponding induction coil of said second row (31b) so as to close the magnetic field lines .
10. - A device according to any one of claims 6 to 9, characterized by comprising a shield (37) arranged around said induction coils (31), except for a bottom side which faces, in use, said powder layer (22) .
11. - A device according to any one of claims 6 to 10, characterized by comprising adjustment means for varying the pre-heating power between various areas of the powder layer that are pre-heated.
PCT/IB2015/052625 2014-04-10 2015-04-10 Process for forming a component by means of additive manufacturing, and powder dispensing device for carrying out such a process WO2015155745A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US15/302,181 US20170021456A1 (en) 2014-04-10 2015-04-10 Process for forming a component by means of additive manufacturing, and powder dispensing device for carrying out such a process

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITTO20140309 2014-04-10
ITTO2014A000309 2014-04-10

Publications (1)

Publication Number Publication Date
WO2015155745A1 true WO2015155745A1 (en) 2015-10-15

Family

ID=50943488

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2015/052625 WO2015155745A1 (en) 2014-04-10 2015-04-10 Process for forming a component by means of additive manufacturing, and powder dispensing device for carrying out such a process

Country Status (2)

Country Link
US (1) US20170021456A1 (en)
WO (1) WO2015155745A1 (en)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017065796A1 (en) * 2015-10-16 2017-04-20 Hewlett-Packard Development Company, L.P. Build material supply for additive manufacturing
WO2017202520A1 (en) 2016-05-24 2017-11-30 Messer Group Gmbh Method for manufacturing metallic components by means of generative production
DE102016225616A1 (en) 2016-12-20 2018-06-21 Robert Bosch Gmbh Device and method for the generative production of components
EP3342583A1 (en) * 2016-12-29 2018-07-04 EOS GmbH Electro Optical Systems Method and device for generative production of a three-dimensional object
CN109420766A (en) * 2017-08-28 2019-03-05 通用电气公司 Powder bed recoats device equipment and its application method
EP3390012A4 (en) * 2016-05-12 2019-08-28 Hewlett-Packard Development Company, L.P. Fuse lamp calibration
CN110573322A (en) * 2017-04-26 2019-12-13 株式会社Lg化学 Nozzle assembly and 3D printer including same
US10507525B2 (en) 2016-04-19 2019-12-17 MTU Aero Engines AG Method and device for manufacturing at least a portion of a component
WO2020126684A1 (en) 2018-12-20 2020-06-25 Messer Group Gmbh Method for finishing a workpiece made by additive manufacturing
US11685079B2 (en) 2017-07-03 2023-06-27 Rampf Holding Gmbh & Co. Kg Apparatus and method for dispensing and curing of liquid media

Families Citing this family (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10130993B2 (en) * 2013-12-18 2018-11-20 Arcam Ab Additive manufacturing of three-dimensional articles
KR20180042305A (en) * 2015-09-16 2018-04-25 어플라이드 머티어리얼스, 인코포레이티드 Adjustable Z-axis Printhead Module for Multilayer Manufacturing Systems
EP3349967B1 (en) * 2015-09-16 2022-10-26 Applied Materials, Inc. Printhead module for additive manufacturing system
JP2018530672A (en) 2015-09-16 2018-10-18 アプライド マテリアルズ インコーポレイテッドＡｐｐｌｉｅｄ Ｍａｔｅｒｉａｌｓ，Ｉｎｃｏｒｐｏｒａｔｅｄ Array of printhead modules for additive manufacturing systems
DE102016216859A1 (en) * 2016-09-06 2018-03-08 Siemens Aktiengesellschaft A method of producing a component having a powder bed based additive manufacturing method and powder for use in such a method
EP3630394A4 (en) * 2017-05-23 2021-03-31 Huntington Ingalls Incorporated System and method for in-situ processing of additive manufacturing materials and builds
WO2019125406A1 (en) * 2017-12-19 2019-06-27 Hewlett-Packard Development Company, L.P. Variable heating in additive manufacturing
WO2019217515A1 (en) * 2018-05-08 2019-11-14 Applied Materials, Inc. Inductive heating of powder for additive manufacturing
US11426818B2 (en) 2018-08-10 2022-08-30 The Research Foundation for the State University Additive manufacturing processes and additively manufactured products
CN108857031A (en) * 2018-09-05 2018-11-23 南京中科煜宸激光技术有限公司 The autonomous induction heating increasing material manufacturing device and method of continuous wire feed
CN108941562B (en) * 2018-10-16 2023-07-28 南京尚吉增材制造研究院有限公司 Method and device for manufacturing metal additive by continuous powder feeding induction heating
US20220184889A1 (en) * 2019-10-24 2022-06-16 Hewlett-Packard Development Company, L.P. Additive manufacturing machines comprising focused and unfocused energy sources
US11518097B2 (en) 2019-11-25 2022-12-06 Applied Materials, Inc. Selective powder dispenser configurations for additive manufacturing
US11524455B2 (en) 2019-11-25 2022-12-13 Applied Materials, Inc. Removable unit for selective powder delivery for additive manufacturing
SE544890C2 (en) * 2020-04-17 2022-12-20 Freemelt Ab Preheating of powder bed
US11724314B2 (en) 2020-07-15 2023-08-15 Applied Materials, Inc. Large area recoating for additive manufacturing

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006121797A2 (en) * 2005-05-06 2006-11-16 The Ex One Company Solid free-form fabrication apparatuses and methods
DE102006053121B3 (en) * 2006-11-10 2007-12-27 Eos Gmbh Electro Optical Systems Coating device for applying powdered layers to a device for producing a three-dimensional object comprises longitudinal walls joined together, a unit for fluidizing powdered material and a controlling and/or regulating unit
CN201168782Y (en) * 2008-02-03 2008-12-24 何德生 Laser powder sintering rapid forming machine having preheat function
US20100155985A1 (en) * 2008-12-18 2010-06-24 3D Systems, Incorporated Apparatus and Method for Cooling Part Cake in Laser Sintering
DE102010026084A1 (en) * 2010-07-05 2012-01-05 Mtu Aero Engines Gmbh Applying material layer on workpiece made of material containing titanium aluminide, comprises heating workpiece by induction at preheating temperature and applying powdery additive on heated surface of workpiece by deposition welding
CN103100713A (en) * 2013-01-23 2013-05-15 西安铂力特激光成形技术有限公司 Preheat device and preheat method of selective laser selection area melting subscriber loop multiplex (SLM) equipment powder feeding barrel
WO2013152750A1 (en) 2012-04-13 2013-10-17 Mtu Aero Engines Gmbh Method for producing low-pressure turbine blades from tial
WO2014131444A1 (en) * 2013-02-27 2014-09-04 Slm Solutions Gmbh Apparatus and method for producing work pieces having a tailored microstructure
WO2014202415A2 (en) * 2013-06-20 2014-12-24 MTU Aero Engines AG Device and method for additively producing at least one component region of a component
WO2014202413A2 (en) * 2013-06-20 2014-12-24 MTU Aero Engines AG Device and method for additively producing at least one component region of a component

Family Cites Families (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5071678A (en) * 1990-10-09 1991-12-10 United Technologies Corporation Process for applying gas phase diffusion aluminide coatings
DE4119967C1 (en) * 1991-06-18 1992-09-17 Mtu Muenchen Gmbh
EP1396556A1 (en) * 2002-09-06 2004-03-10 ALSTOM (Switzerland) Ltd Method for controlling the microstructure of a laser metal formed hard layer
WO2008013483A1 (en) * 2006-07-27 2008-01-31 Arcam Ab Method and device for producing three-dimensional objects
CN101835554B (en) * 2007-10-26 2012-08-22 松下电器产业株式会社 Production device and production method of metal powder sintered component
DE102010018686B4 (en) * 2010-04-22 2017-08-17 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Apparatus and method for laser cladding with powdered filler material
US9457403B2 (en) * 2011-06-23 2016-10-04 Grid Logic Incorporated Sintering method and apparatus
JP2013075308A (en) * 2011-09-30 2013-04-25 Hitachi Ltd Powder-supplying nozzle and build-up-welding method
US9527162B2 (en) * 2011-11-07 2016-12-27 Siemens Energy, Inc. Laser additive repairing of nickel base superalloy components
US9688032B2 (en) * 2013-07-01 2017-06-27 GM Global Technology Operations LLC Thermoplastic component repair
EP3017085A4 (en) * 2013-07-02 2016-12-28 Eaton Corp Laser cladding with carbide hard particles
DE102013217598A1 (en) * 2013-09-04 2015-03-05 MTU Aero Engines AG Device for laser material processing
CN105705295B (en) * 2013-09-17 2017-12-08 斯蒂沃控股有限公司 Include the welding equipment of the heater to work for heated partses
US10328685B2 (en) * 2013-12-16 2019-06-25 General Electric Company Diode laser fiber array for powder bed fabrication or repair
US10532556B2 (en) * 2013-12-16 2020-01-14 General Electric Company Control of solidification in laser powder bed fusion additive manufacturing using a diode laser fiber array
US20150367418A1 (en) * 2014-06-20 2015-12-24 Velo3D, Inc. Apparatuses, systems and methods for three-dimensional printing
US20160271732A1 (en) * 2015-03-19 2016-09-22 Dm3D Technology, Llc Method of high rate direct material deposition
US20170252817A1 (en) * 2016-03-03 2017-09-07 Desktop Metal, Inc. Nozzle cleaning for semi-solid deposition nozzles

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006121797A2 (en) * 2005-05-06 2006-11-16 The Ex One Company Solid free-form fabrication apparatuses and methods
DE102006053121B3 (en) * 2006-11-10 2007-12-27 Eos Gmbh Electro Optical Systems Coating device for applying powdered layers to a device for producing a three-dimensional object comprises longitudinal walls joined together, a unit for fluidizing powdered material and a controlling and/or regulating unit
CN201168782Y (en) * 2008-02-03 2008-12-24 何德生 Laser powder sintering rapid forming machine having preheat function
US20100155985A1 (en) * 2008-12-18 2010-06-24 3D Systems, Incorporated Apparatus and Method for Cooling Part Cake in Laser Sintering
DE102010026084A1 (en) * 2010-07-05 2012-01-05 Mtu Aero Engines Gmbh Applying material layer on workpiece made of material containing titanium aluminide, comprises heating workpiece by induction at preheating temperature and applying powdery additive on heated surface of workpiece by deposition welding
WO2013152750A1 (en) 2012-04-13 2013-10-17 Mtu Aero Engines Gmbh Method for producing low-pressure turbine blades from tial
CN103100713A (en) * 2013-01-23 2013-05-15 西安铂力特激光成形技术有限公司 Preheat device and preheat method of selective laser selection area melting subscriber loop multiplex (SLM) equipment powder feeding barrel
WO2014131444A1 (en) * 2013-02-27 2014-09-04 Slm Solutions Gmbh Apparatus and method for producing work pieces having a tailored microstructure
WO2014202415A2 (en) * 2013-06-20 2014-12-24 MTU Aero Engines AG Device and method for additively producing at least one component region of a component
WO2014202413A2 (en) * 2013-06-20 2014-12-24 MTU Aero Engines AG Device and method for additively producing at least one component region of a component

Cited By (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107848220A (en) * 2015-10-16 2018-03-27 惠普发展公司有限责任合伙企业 Building material feeding mechanism for increasing material manufacturing
WO2017065796A1 (en) * 2015-10-16 2017-04-20 Hewlett-Packard Development Company, L.P. Build material supply for additive manufacturing
US10507525B2 (en) 2016-04-19 2019-12-17 MTU Aero Engines AG Method and device for manufacturing at least a portion of a component
EP3390012A4 (en) * 2016-05-12 2019-08-28 Hewlett-Packard Development Company, L.P. Fuse lamp calibration
WO2017202520A1 (en) 2016-05-24 2017-11-30 Messer Group Gmbh Method for manufacturing metallic components by means of generative production
DE102016006383A1 (en) 2016-05-24 2017-11-30 Messer Group Gmbh Method for producing metallic components by means of generative production
DE102016225616A1 (en) 2016-12-20 2018-06-21 Robert Bosch Gmbh Device and method for the generative production of components
EP3345697A1 (en) 2016-12-20 2018-07-11 Robert Bosch GmbH Device and method for the generative production of components
EP3342583A1 (en) * 2016-12-29 2018-07-04 EOS GmbH Electro Optical Systems Method and device for generative production of a three-dimensional object
US10967575B2 (en) 2016-12-29 2021-04-06 Eos Gmbh Electro Optical Systems Method and device for the generative manufacturing of a three-dimensional object
CN108248024B (en) * 2016-12-29 2022-06-07 德国易欧司光电技术有限公司 Method and device for the productive manufacture of three-dimensional objects
CN108248024A (en) * 2016-12-29 2018-07-06 德国易欧司光电技术有限公司 The method and apparatus manufactured for the productivity of three-dimension object
CN110573322A (en) * 2017-04-26 2019-12-13 株式会社Lg化学 Nozzle assembly and 3D printer including same
CN110573322B (en) * 2017-04-26 2021-10-22 株式会社Lg化学 Nozzle assembly and 3D printer including same
US11203152B2 (en) 2017-04-26 2021-12-21 Lg Chem, Ltd. Nozzle assembly and 3D printer comprising the same
US11685079B2 (en) 2017-07-03 2023-06-27 Rampf Holding Gmbh & Co. Kg Apparatus and method for dispensing and curing of liquid media
EP3450058A1 (en) * 2017-08-28 2019-03-06 General Electric Company Powder bed re-coater apparatus and methods of use thereof
CN109420766B (en) * 2017-08-28 2022-05-06 通用电气公司 Powder bed recoater apparatus and method of use
CN109420766A (en) * 2017-08-28 2019-03-05 通用电气公司 Powder bed recoats device equipment and its application method
WO2020126684A1 (en) 2018-12-20 2020-06-25 Messer Group Gmbh Method for finishing a workpiece made by additive manufacturing
DE102018010079A1 (en) 2018-12-20 2020-06-25 Messer Group Gmbh Process for the aftertreatment of a workpiece produced by means of additive manufacturing
US11938542B2 (en) 2018-12-20 2024-03-26 Messer Se & Co. Kgaa Method for finishing a workpiece made by additive manufacturing

Also Published As

Publication number Publication date
US20170021456A1 (en) 2017-01-26

Similar Documents

Publication Publication Date Title
US20170021456A1 (en) Process for forming a component by means of additive manufacturing, and powder dispensing device for carrying out such a process
CN106536165B (en) Layered heating, wire heating, plasma heating, and multi-feed materials in additive manufacturing
CN104781022B (en) The powder pre-treating manufactured for addition
EP2847782B1 (en) Use of a plasma electron source for additive manufacturing
US9950366B2 (en) Apparatus for additive manufacturing
EP2155421B1 (en) Method and device for producing three-dimensional objects
US8187521B2 (en) Method and device for producing three-dimensional objects
CN104010749B (en) Method and apparatus for preparing three-dimensional body
EP3708280A1 (en) Multi-materials and print parameters for additive manufacturing
CN107921707A (en) Increasing material manufacturing with coolant system
US20150054191A1 (en) Powder distribution in additive manufacturing
EP3200942A1 (en) Additive manufacturing apparatus and method
KR20200009120A (en) Method and apparatus for increasing the resolution in additively manufactured three-dimensional articles
KR20130139247A (en) 3 method for production of a three-dimensional body
JP6919714B2 (en) 3D modeling device and 3D modeling method
EP3646967B1 (en) Enhanced cooling during additive manufacturing
EP3434396A1 (en) Pre-fusion laser sintering for metal powder stabilization during additive manufacturing

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 15724043

Country of ref document: EP

Kind code of ref document: A1

WWE Wipo information: entry into national phase

Ref document number: 15302181

Country of ref document: US

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 15724043

Country of ref document: EP

Kind code of ref document: A1