WO2023046539A1 - Sensoranordnung für eine vorrichtung zur additiven fertigung, vorrichtung zur additiven fertigung und messverfahren - Google Patents
Sensoranordnung für eine vorrichtung zur additiven fertigung, vorrichtung zur additiven fertigung und messverfahren Download PDFInfo
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- WO2023046539A1 WO2023046539A1 PCT/EP2022/075442 EP2022075442W WO2023046539A1 WO 2023046539 A1 WO2023046539 A1 WO 2023046539A1 EP 2022075442 W EP2022075442 W EP 2022075442W WO 2023046539 A1 WO2023046539 A1 WO 2023046539A1
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- sensor
- gas
- sensor module
- filter element
- sensor arrangement
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Classifications
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/26—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating electrochemical variables; by using electrolysis or electrophoresis
- G01N27/403—Cells and electrode assemblies
- G01N27/406—Cells and probes with solid electrolytes
- G01N27/407—Cells and probes with solid electrolytes for investigating or analysing gases
- G01N27/4071—Cells and probes with solid electrolytes for investigating or analysing gases using sensor elements of laminated structure
-
- 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
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/90—Means for process control, e.g. cameras or sensors
-
- 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
- B29C64/30—Auxiliary operations or equipment
- B29C64/364—Conditioning of environment
- B29C64/371—Conditioning of environment using an environment other than air, e.g. inert gas
-
- 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
- B29C64/30—Auxiliary operations or equipment
- B29C64/386—Data acquisition or data processing for additive manufacturing
- B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
-
- 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
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
-
- 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
- B22F12/40—Radiation means
- B22F12/44—Radiation means characterised by the configuration of the radiation means
-
- 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
- B22F12/40—Radiation means
- B22F12/44—Radiation means characterised by the configuration of the radiation means
- B22F12/45—Two or more
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/26—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating electrochemical variables; by using electrolysis or electrophoresis
- G01N27/403—Cells and electrode assemblies
- G01N27/406—Cells and probes with solid electrolytes
- G01N27/407—Cells and probes with solid electrolytes for investigating or analysing gases
- G01N27/4077—Means for protecting the electrolyte or the electrodes
Definitions
- the invention relates to a sensor arrangement for a device for the additive manufacturing of a component in a manufacturing process in which building material, preferably comprising a metal powder, is solidified in layers on a building site in a process space by means of irradiating the building material with at least one energy beam, and such a device and a Measuring method with such a sensor arrangement.
- additive manufacturing processes are becoming increasingly relevant in the manufacture of prototypes and now also in series production.
- “additive manufacturing processes” are understood to mean those manufacturing processes in which a manufacturing product (hereinafter also referred to as “component”) is usually built up by depositing material (the “construction material”) on the basis of digital 3D design data.
- the structure is usually, but not necessarily, layered.
- 3D printing is often used as a synonym for additive manufacturing, the production of models, samples and prototypes with additive manufacturing processes is often referred to as “rapid prototyping", the manufacture of tools as “rapid tooling” and the flexible Production of series components is referred to as “rapid manufacturing”.
- a key point is the selective hardening of the construction material, with this hardening being achieved in many manufacturing processes with the aid of irradiation with radiant energy, e.g. B. electromagnetic radiation, in particular light and / or heat radiation, but possibly also with particle radiation such. B. electron beams can be done.
- radiant energy e.g. B. electromagnetic radiation, in particular light and / or heat radiation, but possibly also with particle radiation such.
- B. electron beams can be done.
- processes that work with irradiation are "selective laser sintering" or “selective laser melting”. In this process, thin layers of a mostly powdered construction material are repeatedly applied one on top of the other.
- the construction material is selectively hardened in a "welding process" by spatially limited irradiation of the areas that are to belong to the component to be manufactured after production, in which the powder grains of the construction material are partially or partially melted with the help of the energy introduced locally at this point by the radiation be completely melted. After cooling, these powder grains are then solidified together to form a solid.
- the energy beam is usually guided along hardening tracks over the construction area and the remelting or hardening of the material in the respective layer takes place accordingly in the form of "weld tracks” or “weld beads", so that ultimately there are a large number of such layers formed from weld tracks in the component . In this way, components with very high quality and breaking strength can now be produced.
- the oxygen content in the process chamber has an impact on the quality of the components.
- the porosity of metallic components there is a correlation between the porosity of metallic components and the concentration of oxygen in the process chamber. For this reason, for components of the highest quality and strength, the oxygen concentration should be measured in the process chamber during the construction process and should not exceed 1000 ppm, for example.
- the oxygen concentration (from molecular oxygen) in the process space is measured with an oxygen sensor.
- an oxygen sensor There are different functional principles. In particular, amperometric sensors and potentiometric sensors should be mentioned here. With potentiometric sensors, a voltage or resistance reflects the oxygen concentration. In amperometric sensors, oxygen molecules are ionized at a cathode and recombine at an anode, producing a current that is proportional to the oxygen concentration. Under certain circumstances, however, the measurement of oxygen can be incorrect, which is mainly due to the cross-sensitivity of the sensor to hydrogen and water molecules. At low oxygen concentrations, these substances can produce erroneous signals in the sensor.
- sensors based on the amperometric principle exhibit unstable signal behavior due to cross-sensitivity when the oxygen concentration drops to low values of approx. ⁇ 400ppm, e.g. due to moisture or hydrogen accumulation on the sensor.
- the specified value of 400 ppm is not the desired oxygen concentration in the process room (which is around 0.1%), but the limit below which the measurement signal on the sensor typically becomes unstable.
- water and hydrogen/oxygen can be generated alternately and this can lead to strongly fluctuating signal characteristics.
- This object is achieved by a sensor arrangement according to patent claim 1, a device according to patent claim 8, and a measuring method according to patent claim 11.
- a sensor arrangement according to the invention is used in a device for the additive manufacturing of a component in a manufacturing process (“manufacturing device”), in which building material, preferably comprising a metal powder, is solidified on a building site in a process space by means of irradiating the building material with at least one energy beam.
- the sensor assembly includes the following components:
- a sensor module designed to detect oxygen molecules in a gas sample entering the sensor module and to generate an electrical sensor signal based on the amount of oxygen molecules
- a selective filter element designed to filter the gas sample such that at least hydrogen molecules and/or hydrogen ions and/or water molecules and/or hydroxide ions are filtered out of the gas sample.
- the two components mentioned can be housed on or in a housing, acting together, or separately from one another, in which case the filter element must be attached in such a way that it can filter the gas sample.
- the sensor module can be arranged in a gas line and the filter element can be attached in such a way that it filters the gas flow through the gas line.
- the sensor arrangement can also include other components, e.g. elements for holding or attaching the sensor, electronics for processing the measurement signals (e.g. an ADC) or a control device for controlling the measurement operation.
- a suitable sensor module is known in the prior art.
- the invention can be used particularly advantageously for sensors that measure amperometrically or potentiometrically, but is also advantageous for other sensors.
- the sensor modules can be equipped with a reference sensor and/or a reference component capable of carrying out a reference measurement.
- a reference chamber or the reference volume is integrated in the sensor, with the reference volume being in direct contact with an electrode.
- the term “reference sensor” also means the "reference component" of a sensor.
- the reference sensor and/or the reference component comprises an electrochemical reference cell, for example a solid cell (for example, solid cells made of palladium, rhodium, rubidium and the corresponding oxides used) and a reference gas volume for potentiometric sensors.
- a reference sensor and/or a reference component can also be arranged or designed in such a way that its gas sample is not filtered by the filter element or is filtered by another filter element.
- a sensor generates its sensor signal depending on the oxygen molecules present in the measuring area.
- the sensor signal is therefore initially dependent on the quantity of oxygen molecules.
- the measurement parameters are usually known (e.g. the volume of the gas sample and its pressure)
- the oxygen concentration can usually be directly inferred from the sensor signal, or the sensor signal is a direct measure of the oxygen concentration.
- the sensor signal is preferably proportional to the oxygen concentration.
- the sensor signal can be an analog signal, in particular a voltage or a current, or a digital signal, e.g. a digital numerical value.
- ADC analog-to-digital converter
- the filter element is selective, which means that it does not filter all molecules, but selectively individual molecule types or a group of molecule types.
- These types of molecules are at least hydrogen molecules and/or hydrogen ions and/or water molecules and/or hydroxide ions. These can cause interference signals in the sensor, which can have a particularly disadvantageous effect at low oxygen concentrations. If these types of molecules are now filtered out of the gas sample, the oxygen concentration only changes insignificantly, since the largest part of the gas sample is formed by the protective gas or inert gas, e.g. argon or nitrogen. In this way, interference components in the sensor signal can be reduced without significantly distorting the meaningfulness of the sensor signal.
- the protective gas or inert gas e.g. argon or nitrogen.
- oxygen comes into the process space primarily from leaks in the process space itself.
- water which escapes from the powder
- the energy beam e.g. laser radiation
- hydrogen and oxygen atoms which recombine to generate molecular oxygen and molecular hydrogen.
- Hydrogen and oxygen can diffuse in the process chamber up to the sensor, bearing in mind that oxygen is more easily picked up by metal condensates. It can therefore be assumed that the ratio of oxygen and hydrogen in the process chamber or on the sensor is not 1:2.
- the oxygen present in the gas sample in the sensor comes mainly from the leaks in the process chamber and has no chemical relationship to the hydrogen, which mainly arises from the splitting of water or escapes directly from the metal powder.
- water can also be formed from the reaction between oxygen and hydrogen at the sensor.
- This reaction is caused by the high temperature at the sensor (the operating temperature should be between 300-700°C to allow the diffusion of the oxygen ions through the ZrC>2 plate).
- This reaction leads to a reduction in the measured current at the sensor, because oxygen is consumed by this reaction and consequently no longer reaches the cathode.
- hydrogen can be split into hydrogen ions at the sensor and lead to a current between the electrodes. If the oxygen concentration is significantly greater than the hydrogen concentration, the sensor can reliably measure oxygen. In the opposite case (excess H2), the hydrogen causes instability on the sensor. Hydrogen can be adsorbed by platinum in two different states. In one of these states, the absorption of hydrogen causes an increase in the electrical resistance of platinum, in the other a decrease in electrical resistance. In what condition is the adsorbed hydrogen is primarily dependent on temperature. Due to the high operating temperature of the sensor, hydrogen can switch from one state to another and cause signal instability.
- water (H2O) can be split into hydrogen anions (H + ) and hydroxide ions (OH-) in the sensor. If at least a minimal concentration of water is present at the sensor (from the material of construction or from the reaction between hydrogen and oxygen), the water will be adsorbed by platinum. The resulting ions behave in the same way as oxygen at the sensor: hydrogen anions (H + ) are reduced at the cathode and hydrogen diffuses into the process chamber, while hydroxide ions (OH') are oxidized at the anode in a similar way to oxygen ions. Due to the oxidation of hydroxide ions, a current is measured on the amperometer as if oxygen were present in the process chamber. This course of reaction is equivalent to the electrolysis of water.
- the concentration of oxygen is overestimated.
- water is consumed, moreover, hydrogen is produced in the process chamber, which again leads to an unstable signal due to hydrogen absorption on platinum, or again to consumption of oxygen (due to the reaction between oxygen and hydrogen) and therefore to a reduction in the signal at the sensor or an underestimation of the oxygen concentration.
- the hydroxide ions can also lead to a current between the electrodes, which is also normally well below the oxygen signal but can also become dominant at low oxygen concentrations and high water concentrations.
- a device according to the invention (“manufacturing device”) is used for the additive manufacturing of a component in a manufacturing process in which building material, preferably comprising a metal powder, is solidified on a building site in a process room by means of irradiating the building material with at least one energy beam.
- the device includes the following components: - a feed device for applying material layers of construction material to the construction field,
- an irradiation device in order to selectively solidify building material between the application of two layers of material by irradiation with at least one energy beam
- the feeding device e.g. an arrangement for layering a metal powder
- the irradiation device e.g. a laser
- the special feature lies in the sensor arrangement according to the invention, which allows better measurement of the oxygen concentration.
- the production device can also have further components such as are usually present for production.
- the device according to the invention can also have a number of irradiation devices which can be controlled in a correspondingly coordinated manner using control data.
- the energy beam can be either particle radiation or electromagnetic radiation, such as light or preferably laser radiation.
- a measuring method according to the invention with a sensor arrangement according to the invention in a device according to the invention comprises the following steps:
- the gas flow can be generated, for example, by a circulating pump or a pump for blowing in a protective or inert gas. It does not necessarily have to be blown directly onto the sensor module. It is sufficient if gas moves past the sensor, which can be caused by circulation in the process room or by means of an air flow through a line in which the sensor is located.
- a control or regulation can be easily achieved in that the sensor signal is compared with a limit value, which is the boundary between a represents a desired and an undesired area. As soon as the sensor signal leaves the desired range, an action is taken, eg the gas flow is changed so that the sensor signal moves back into the desired range.
- the filter element comprises a molecular sieve and/or an adsorbent through which the gas sample is passed before entering the sensor module.
- Preferred molecular sieves or adsorbents include a zeolite or activated carbon.
- zeolite with the right pore size (3A) is able to advantageously adsorb hydrogen and water.
- Catalytic adsorption on suitable other adsorber materials is also possible in particular for the selective purification of working gases from hydrogen.
- a platinum layer can be used, which the gas sample is guided past before it penetrates into the sensor module. This platinum layer can be in the form of an extended surface or in the form of a surface of granules.
- the sensor module has (at least) one anode and (at least) one cathode and is in particular an amperometric or potentiometric sensor.
- the sensor arrangement between the anode and cathode includes a solid electrolyte, in particular zirconium dioxide (ZrÜ2) and that the filter element is arranged in or on the solid electrolyte.
- the filter element is located in the sensor module between the electrodes and it is preferred that it adsorbs hydroxide ions or converts them to water.
- a filter element is arranged to filter the gas sample before it enters the sensor module. This can be an additional filter element to the previously mentioned filter element in the sensor module or an alternative filter element. It is preferred that the filter element at least partially surrounds the sensor module or at least its electrodes, or that it is arranged in such a way is that it filters the gas sample in a gas feed line to the sensor module (i.e. filters the feed line to the sensor module).
- the filter element is formed by an electrode of the sensor module, the electrode material of the electrode being selected such that the conversion of gaseous water into hydrogen ions and hydroxide ions and/or the conversion of molecular hydrogen into hydrogen ions and/or the adsorption of gaseous Water and/or hydrogen is inhibited.
- the electrode material is preferably selected such that, due to its chemical properties and/or surface properties, it is able to adsorb water and/or hydrogen and thereby prevent water and/or hydrogen from causing an erroneous measurement signal of the oxygen concentration.
- the inhibition of the conversion of water and/or hydrogen into ions can be given by the chemical and/or the surface properties of the electrode material.
- the adsorption of water and hydrogen and/or the inhibition of an erroneous measurement signal and/or the inhibition of the conversion of water and/or hydrogen into ions can be prevented by changing the voltage applied to the electrodes during measurement and/or by changing the operating temperature of the sensor module can be achieved and/or amplified.
- a preferred sensor arrangement includes a control device which is designed to control the operating voltage and/or the operating temperature of the sensor module and/or the operating temperature of the filter element.
- voltage or temperature are kept in a predetermined range in which ionization, accumulation or storage of gaseous water and/or hydrogen is avoided.
- a voltage is preferably lowered below a predetermined limit value. It is preferred that the operating voltage of the sensor is reduced by ⁇ 0.8/0.9V down to ⁇ 0.3/0.4V. It is generally preferred to operate the sensor at a temperature between 300-700°C.
- the filter element preferably includes a temperature controller with which the filter element can be heated and/or cooled. Heating can take place in particular when no manufacturing process is carried out in order to release adsorbed substances and thus clean the filter element. Refrigeration can be used to adjust an adsorption rate.
- the control device is preferably designed to control or regulate this temperature control of the filter element depending on the sensor signal.
- a preferred sensor arrangement includes a reference sensor module (whereby this term, as stated above, can also mean a sensor with a reference component), which is preferably operated with a different voltage than the sensor module, in particular a lower voltage.
- the reference sensor module includes a reference gas as a gas sample in a reference chamber (preferably in the case of a potentiometrically measuring sensor module).
- the reference sensor module includes a reference measuring cell, preferably a solid cell made of palladium/palladium oxide, for example.
- This embodiment preferably relates to an amperometrically measuring sensor module.
- the reference sensor module is arranged in such a way that the gas sample entering the reference sensor module was not filtered by the filter element.
- the reference sensor module comprises a reference filter element, which differs from the filter element in terms of its material and/or its structure, which filters the gas sample which penetrates into the sensor module.
- a preferred device includes a gas pump. This means an element with which a gas can be pressurized or gas can be moved. The gas can be moved much better through the filter element to the sensor module with a pressure, since the filter element opposes a flow resistance to the gas flow. When the gas flows through the filter element, those components are then filtered out that would falsify the measurement signal.
- a pressure difference can be realized, for example, by the filter system of an inert gas circuit.
- the device is preferably designed in such a way that a gas sample is moved to the sensor arrangement by means of the gas pump, preferably with the gas pump being designed to circulate the gas volume in a process space of the device, to discharge a gas volume from the process space or to pump a gas, in particular an inert gas, into introduce the process space.
- a preferred device includes tubing.
- the sensor module of the sensor arrangement is arranged in this pipeline, so that a gas flowing through the pipeline serves as a gas sample for a measurement.
- the filter element is preferably arranged in the pipeline in such a way that the gas flowing through the pipeline is filtered before it hits the sensor module.
- a preferred apparatus includes a forced air system connected to the process chamber by tubing.
- the air circulation system may include a gas pump that can be operated in such a way that a volume of gas can be removed from the process chamber and an inert gas can be introduced into the process chamber.
- inlet and/or outlet valves can be arranged, which can implement and/or facilitate the gas removal and/or supply.
- the circulating air system includes a filter system (not to be confused with the filter element of the sensor arrangement) which can clean the volume of gas removed from the process chamber.
- the sensor assembly is located in a duct connecting the circulating air system to the process chamber, and the filter element is arranged in the duct such that the gas flowing through the duct is filtered before it hits the sensor module.
- the sensor array is located near the inlet and/or outlet of a pipeline.
- the gas flow is regulated based on the sensor signal.
- the gas flow is increased when the sensor signal rises above a predefined threshold or falls below a predefined threshold.
- the construction process of the device is preferably carried out as a function of the sensor signal. For example, if the oxygen concentration is too high, the manufacturing process is interrupted at least for a predetermined time.
- the oxygen partial pressure in the sensor module is reduced to a predetermined minimum concentration for a reference measurement.
- This is preferably done by pumping with a voltage or an oxygen adsorber or by purging the sample gas in a targeted manner.
- Pumping with a voltage can be done by applying a voltage to the (platinum) electrodes of the sensor module, which can be higher than the operating voltage for measuring the oxygen concentration, for example, whereby these act as an oxygen pump (through the ionization and movement in the electric field). Oxygen from the atmosphere to be measured is conducted through the electrolyte.
- the voltage applied to the electrodes can be inverted compared to the operating voltage, so that the oxygen content in the reference sensor module is reduced.
- the sensor arrangement comprises a movement device, by means of which the filter element can be moved from a rest position to a filter position, eg in front of the sensor module (and back). This happens preferentially based on the sensor signal.
- the filter element is preferably moved into the filter position, for example in front of the sensor element.
- different filter elements are present, which can be moved into the filter position depending on a state derived from the sensor signal.
- FIG. 1 shows a schematic view, shown partially in section, of an exemplary embodiment of a device for additive manufacturing with a sensor arrangement according to the invention
- FIG. 2 shows an example of a sensor arrangement according to the invention with a surrounding filter element
- FIG. 3 shows an example of a sensor arrangement according to the invention with a built-in filter element
- FIG. 4 shows another example of a sensor arrangement according to the invention in a pipeline
- FIG. 5 shows a block diagram of a possible method sequence of a preferred measuring method.
- laser sintering device 1 for the additive manufacturing of components in the form of a laser sintering or laser melting device 1, it being explicitly pointed out once again that the invention is not limited to laser sintering or laser melting devices.
- the device is therefore briefly referred to as “laser sintering device” 1 in the following—without any loss of generality.
- laser sintering device 1 is shown schematically in FIG.
- the device has a process chamber 3 or a process space 3 with a chamber wall 4 in which the manufacturing process essentially takes place.
- the process chamber 3 there is an upwardly open container 5 with a container wall 6.
- the upper opening of the container 5 forms the current working level 7.
- the area of this working level 7 lying within the opening of the container 5 can be used to build the object 2 and is therefore referred to as construction site 8.
- the container 5 has a base plate 11 movable in a vertical direction, which is arranged on a support 10 .
- This base plate 11 closes off the container 5 at the bottom and thus forms its bottom.
- the base plate 11 may be formed integrally with the carrier 10, but it may also be a plate formed separately from the carrier 10 and fixed to the carrier 10 or simply supported thereon.
- a construction platform 12 can be attached to the base plate 11 as a construction base, on which the object 2 is constructed. In principle, however, the object 2 can also be built on the base plate 11 itself, which then forms the building base.
- the basic construction of the object 2 takes place by first applying a layer of construction material 13 to the construction platform 12, then using a laser beam AL as an energy beam at the points which are to form parts of the object 2 to be produced, the construction material 13 is selectively solidified, then with the aid of carrier 10, base plate 11, and thus construction platform 12, is lowered and a new layer of construction material 13 is applied and selectively solidified, etc.
- FIG Intermediate state shown. It already has several solidified layers, surrounded by building material 13 that has remained unsolidified.
- Various materials can be used as building material 13, preferably powder, in particular metal powder, plastic powder, ceramic powder, sand, filled or mixed powder or pasty materials.
- the invention has a particularly advantageous effect on metallic structural materials 13 .
- Fresh construction material 15 is located in a storage container 14 of the laser sintering device 1. With the aid of a device that can be moved in a horizontal direction (double arrow). Coater 16, the construction material can be applied in the working plane 7 or within the construction area 8 in the form of a thin layer.
- an additional radiant heater 17 in the process chamber 3. can serve to heat the applied build-up material 13, so that the irradiation device used for the selective solidification does not have to introduce too much energy.
- An infrared radiator, for example, can be used as the radiant heater 17 .
- the laser sintering device 1 has an irradiation device 20 or specifically an exposure device 20 with a laser 21 .
- This laser 21 generates a laser beam EL, which is first fed to a beam-shaping device 30 (as an input energy beam EL or input laser beam EL).
- the beam shaping device 30 can be used to adjust the intensity distribution, i. H. to modify the intensity profile of the energy beam, for example also to superimpose a Gaussian profile on a top-hat profile.
- the beam shaping device 30 can be controlled with suitable intensity distribution control data VSD.
- DOE Diffractive Optical Element
- the (output) energy beam or laser beam AL optionally modified by the beam shaping device is then deflected via a subsequent deflection device 23 (scanner 23) in order to follow the solidification paths (ie exposure paths or tracks) provided according to the exposure strategy in the respective layer to be selectively solidified and selectively bring in the energy. i.e.
- the impact surface 22 of the energy beam AL is moved on the construction area 8 by means of the scanner 23, with the current movement vector or the movement direction (scanning direction) of the impact surface 22 on the construction area 8 being able to change frequently and quickly.
- this laser beam AL is suitably focused by a focusing device 24 onto the working plane 7 .
- the irradiation device 20 is preferably located outside of the process space 3 here, and the laser beam AL is guided into the process space 3 via an in-coupling window 25 mounted in the chamber wall 4 on the upper side of the process space 3 .
- the irradiation device 20 can, for example, comprise not only one but several lasers. Preferably, this can be gas or solid-state lasers or any other type of laser such.
- VCSEL Vertical Cavity Surface Emitting Laser
- VECSEL Very External Cavity Surface Emitting Laser
- One or more unpolarized single-mode lasers e.g. B. a 3 kW fiber laser with a wavelength of 1070 nm can be used.
- an optional, preferably movable and/or adjustable nozzle D is arranged in the process chamber 3, which can be used to locally feed a gas or a gas mixture into the area of the impingement surface of the laser beam AL on the construction site 8, in order to thereby to influence the target welding depth.
- the laser sintering device 1 also contains a detector arrangement 18 which is suitable for detecting process radiation emitted during the impingement of the laser beam AL on the building material in the working plane.
- This detector arrangement 18 works in a spatially resolved manner, ie it is able to capture a type of emission image of the respective layer.
- an image sensor or a camera 18 is used as the detector arrangement 18, which is sufficiently sensitive in the area of the emitted radiation.
- one or more sensors could also be used to detect an optical and/or thermal process radiation, for example photodiodes which detect electromagnetic radiation emitted by a melt pool under the impinging laser beam AL, or temperature sensors for detecting emitted thermal radiation (so-called melt pool monitoring).
- the detector arrangement 18 is arranged within the process chamber 3 in FIG. However, it could also be located outside of the process chamber 3 and then capture the process radiation through a further window in the process chamber 3 .
- the signals detected by the detector arrangement 18 can be transferred here as a process space sensor data set or slice image SB to a control device 50 of the laser sintering device 1, which is also used to control the various components of the laser sintering device 1 for the overall control of the additive manufacturing process.
- control device 50 includes a control unit 51, which controls the components of the irradiation device 20 via a radiation control interface 53, namely here to the laser 21 transmits laser control data LS, to the beam shaping device 30 intensity distribution control data VSD, to the deflection device 23 scan control data SD and to the focusing device 24 focus control data FS sent. All of this data can be referred to as exposure control data BSD.
- the control unit 51 also controls the radiant heater 17 by means of suitable heating control data HS, the coater 16 by means of coating control data ST and the movement of the carrier 10 by means of carrier control data TSD and thus controls the layer thickness. Furthermore, it also controls the nozzle D with the aid of nozzle control data DS.
- control device 50 here has a quality data determination device 52, which receives the process space sensor data record SB and determines quality data QD based thereon, which can be transferred to the control unit 51, for example, in order to be able to intervene in the additive manufacturing process in a regulating manner.
- the control device 50 is here z. B. via a bus 60 or other data connection coupled to a terminal 61 with a display or the like. Over An operator can use this terminal to control the control device 50 and thus the entire laser sintering device 1, e.g. B. by transmission of process control data PSD.
- a sensor arrangement 9 which measures the oxygen concentration in the process space 3 , is arranged in the process space 3 in the upper right corner.
- the oxygen concentration in the process space 3 can increase or fluctuate due to the supply of protective gas due to leaks in the gas supply of the process space 3 or due to the splitting of moisture in the construction material 13 by the energy beam AL.
- the structure of this sensor arrangement 9 is described in more detail below.
- the sensor arrangement 9 includes a control device 94, which is designed to control the operating voltage and/or operating temperature of the sensor module 90 and/or the operating temperature of the filter element F, so that ionization, accumulation or storage of gaseous water is avoided there.
- FIG. 2 shows an example of a sensor arrangement 9 according to the invention with a surrounding filter element F, as can be used for a device 1 according to FIG.
- the sensor arrangement 9 comprises a gas-permeable sensor housing 90 on the outside (which also represents the sensor module 90 here with the components it contains), which is covered by a cover 93 .
- the sensor arrangement 9 can be attached to the chamber wall 4 of the process chamber 3 on this cover 93 .
- Lines L of the sensor module 90 can be routed to the outside through a hole in the chamber wall 3 .
- the cover 93 it is also possible for the cover 93 to be somewhat longer and to be provided with a thread, so that the sensor module 90 can be inserted through a hole in the chamber wall 4 from the outside and screwed in there.
- the sensor module 90 (or the sensor housing 90) is surrounded by the filter element F on all sides except for the cover 93, so that gas. which enters the sensor module 90 as a gas sample P (see FIG. 5) is filtered.
- the filter element F is selective and only filters out gaseous water. It can also filter out hydrogen.
- the functional components of the sensor module 90 are arranged inside the sensor housing 90 . These are the anode A and the cathode K, which are separated by a solid electrolyte E, eg zirconium dioxide, and the heater H for heating the inner chamber 91 in which the cathode K is arranged.
- This functional structure corresponds to the prior art and is held in place by two fixing elements 92, for example glass wool.
- the voltages or currents at the electrodes A, K are conducted to the outside by means of the lines L, where they can be further processed.
- the heater H also has two lines for energy supply, which however are not drawn for the sake of clarity.
- the filter element F surrounds the entire sensor arrangement in FIG. 2, it can also comprise only part of the sensor module.
- the filter element F is directly in contact with the sensor module 90 in FIG. 2 , it can also be at least partially in contact with the sensor module 90 .
- the filter element F and the sensor module 90 can also not be in contact.
- the filter element F can also be sufficiently close to the sensor module 90 so that the action of the filter element keeps the concentration of gas components that can corrupt the signal from the sensor module 90 low enough.
- FIG. 3 shows an example of a sensor arrangement 9 according to the invention with a built-in filter element F. Only the functional structure with inner chamber 91, anode A, solid electrolyte E and cathode K is shown here.
- the filter element F is arranged here on the solid electrolyte E and preferentially filters out hydroxide ions .
- FIG. 4 shows another example of a sensor arrangement 9 according to the invention in a pipeline R.
- the sensor module 90 shown in FIG. 2 (the sensor arrangement 9 from FIG. 2 without the surrounding filter element F) can be assumed to be the sensor module 90 .
- the filter element F is arranged here in the pipeline R and gas which flows through the pipeline R (arrow) must first pass through the filter element F before it hits the sensor module 90 .
- the pipeline R is connected to a gas pump. With the help of the gas pump, a gas can be pressurized through the pipeline R or gas can be moved through the pipeline R. The gas can be moved much better through the filter element F to the sensor module 90 with a pressure, since the filter element F opposes a flow resistance to the gas flow.
- the gas pump to which the pipeline R is connected can be designed to circulate a volume of gas in a process chamber of the device, to discharge a volume of gas from the process chamber through the pipeline R or a gas, in particular a Inert gas to be introduced into the process space through the pipeline R.
- the filter element F and the sensor module 90 are preferably arranged in the pipeline R, with a gas volume being discharged from the process chamber through the pipeline R with the aid of the gas pump.
- the sensor module 90 and the filter element F are arranged in such a way that the discharged gas volume first acts on the filter element and then penetrates into the sensor module. When the gas flows through the filter element F, those components are then filtered out which would falsify the measurement signal.
- the pipeline R connects the process chamber to an air circulation system.
- the circulating air system to which the pipeline R is connected can be designed, preferably with the aid of a gas pump, to discharge a volume of gas from the process chamber through the pipeline R or to introduce a gas, in particular an inert gas, through the pipeline R into the process chamber.
- the filter element F and the sensor module 90 are preferably arranged in the pipeline R, with a volume of gas being discharged from the process chamber through the pipeline R.
- the sensor module 90 and the filter element F are arranged in such a way that the discharged gas volume first acts on the filter element and then penetrates into the sensor module. When the gas flows through the filter element F, those components are then filtered out which would falsify the measurement signal.
- FIG. 5 shows a block diagram of a possible method sequence of a preferred measuring method with a sensor arrangement 9 as shown, for example, in the preceding figures, in a device 1 as shown, for example, in FIG.
- step I a gas flow is generated in the process chamber 3 of the device 1, so that a gas sample P impinges on the sensor module 90 through the gas flow.
- step II a sensor signal S is generated by the sensor module 90 of the sensor arrangement 9 .
- step III the sensor signal S is used to control or regulate the device 1, with a gas flow in the process chamber 3 being regulated based on the sensor signal S, for example, so that the gas flow is increased when the sensor signal S rises above a predefined threshold.
- the process is continuously repeated, which is illustrated by a backwards-directed arrow.
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EP22789494.6A EP4405677A1 (de) | 2021-09-21 | 2022-09-13 | Sensoranordnung für eine vorrichtung zur additiven fertigung, vorrichtung zur additiven fertigung und messverfahren |
CN202280061233.5A CN117916588A (zh) | 2021-09-21 | 2022-09-13 | 用于增材制造的设备的传感器装置、用于增材制造的设备和测量方法 |
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Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
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JPS5754856A (en) * | 1980-09-19 | 1982-04-01 | Matsushita Electric Ind Co Ltd | Oxygen concentration detector |
DE10153735A1 (de) * | 2001-10-31 | 2003-05-22 | Bosch Gmbh Robert | Meßfühler |
WO2005121763A1 (de) * | 2004-06-05 | 2005-12-22 | Robert Bosch Gmbh | Messfühler zur bestimmung der sauerstoffkonzentration im abgas von brennkraftmaschinen |
DE202016004832U1 (de) * | 2016-08-06 | 2016-09-13 | Eos Gmbh Electro Optical Systems | Gasüberwachungssystem zur Überwachung von Gaskonzentrationen in einer additiven Fertigungsvorrichtung |
US20180117675A1 (en) * | 2016-11-02 | 2018-05-03 | Pierre Foret | Method for the generative manufacture of a 3-dimensional component |
EP3797902A1 (de) * | 2019-09-25 | 2021-03-31 | Linde GmbH | Verfahren und system für die atmosphäre bei der generativen fertigung |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
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JP2002174620A (ja) | 2000-12-07 | 2002-06-21 | Denso Corp | ガスセンサ素子及びガスセンサ |
DE202004015400U1 (de) | 2004-10-04 | 2004-12-16 | Aceos Gmbh | Sensor sowohl zur Sauerstoffmessung als auch zur Volumenstrom- und/oder Anströmmessung |
US10675854B2 (en) | 2015-01-16 | 2020-06-09 | Raytheon Technologies Corporation | Additive processing apparatus and method |
DE102016012116A1 (de) | 2016-10-10 | 2018-04-12 | Linde Aktiengesellschaft | Verfahren zur generativen Fertigung eines 3-dimensionalen Bauteils |
-
2021
- 2021-09-21 DE DE102021124442.0A patent/DE102021124442A1/de active Pending
-
2022
- 2022-09-13 WO PCT/EP2022/075442 patent/WO2023046539A1/de active Application Filing
- 2022-09-13 EP EP22789494.6A patent/EP4405677A1/de active Pending
- 2022-09-13 CN CN202280061233.5A patent/CN117916588A/zh active Pending
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS5754856A (en) * | 1980-09-19 | 1982-04-01 | Matsushita Electric Ind Co Ltd | Oxygen concentration detector |
DE10153735A1 (de) * | 2001-10-31 | 2003-05-22 | Bosch Gmbh Robert | Meßfühler |
WO2005121763A1 (de) * | 2004-06-05 | 2005-12-22 | Robert Bosch Gmbh | Messfühler zur bestimmung der sauerstoffkonzentration im abgas von brennkraftmaschinen |
DE202016004832U1 (de) * | 2016-08-06 | 2016-09-13 | Eos Gmbh Electro Optical Systems | Gasüberwachungssystem zur Überwachung von Gaskonzentrationen in einer additiven Fertigungsvorrichtung |
US20180117675A1 (en) * | 2016-11-02 | 2018-05-03 | Pierre Foret | Method for the generative manufacture of a 3-dimensional component |
EP3797902A1 (de) * | 2019-09-25 | 2021-03-31 | Linde GmbH | Verfahren und system für die atmosphäre bei der generativen fertigung |
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CN117916588A (zh) | 2024-04-19 |
EP4405677A1 (de) | 2024-07-31 |
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