DE102015216402A1 - Device and method for producing or repairing a three-dimensional object - Google Patents

Abstract

The invention relates to a device (10) for producing or repairing a three-dimensional object (36) comprising at least one installation space (12) for a layered, successive solidification of at least one solidifiable material (16) in predefined areas for the layered construction of the three-dimensional object (36). or for layer-wise repair of individual areas of the three-dimensional object (36) within the construction space (12) and at least one radiation source (18) for generating at least one high-energy beam (20), by means of which a material layer (22) in the region of a build-up and joining zone (28 ) is locally fusible to an object layer and / or versinterbar, wherein the radiation source (18) relative to a platform (14) within the space (12) is movable, wherein the device (10) and / or the radiation source (18) at least one Control device (24) for adjusting and / or changing the angle of incidence (α1, α2, α3) of the high energy beam (20) into the material layer (22) during fusing and / or sintering of the material layer (22) to a component layer of the object (36). The invention further relates to a method for producing or repairing a three-dimensional object (36).

Description

The invention relates to a device for producing or repairing a three-dimensional object according to the preamble of claim 1. The invention further relates to a method for producing or repairing a three-dimensional object according to the preamble of claim 8.

Methods and apparatus for making three-dimensional objects, particularly components, are known in a wide variety. In particular, generative manufacturing methods (so-called rapid manufacturing or rapid prototyping methods) are known in which the three-dimensional object or the component is built up in layers by powder-bed-based, additive manufacturing processes. Primarily metallic components can be produced, for example, by laser or electron beam melting or sintering methods. In this case, at least one powdered component material is first applied in layers to a construction platform in the region of a building and joining zone of the device. Subsequently, the component material is locally fused in layers and / or sintered by the component material in the assembly and joining zone energy is supplied by means of at least one high-energy beam, for example an electron or laser beam. The high-energy beam is controlled in dependence on a layer information of the component layer to be produced in each case. After fusing and / or sintering, the construction platform is lowered in layers by a predefined layer thickness. Thereafter, the said steps are repeated until the final completion of the component. Comparable additive processes are known for the production of ceramic or plastic elements.

From the prior art, in particular also generative manufacturing processes for the production of components of a turbomachine, such as components of an aircraft engine or a gas turbine are known, for example, in the DE 10 2009 051 479 A1 described method or a corresponding device for producing a component of a turbomachine. In this method, a corresponding component is produced by layer-wise application of at least one powdered component material on a construction platform in the region of a buildup and joining zone as well as layered and local melting or sintering of the component material by means of energy supplied in the region of the assembly and joining zone. The supply of energy takes place here via laser beams, such as CO ₂ laser, Nd: YAG laser, Yb fiber laser and diode laser, or by electron beams.

In known devices for the generative production of three-dimensional objects by means of laser energy (eg, selective laser melting systems), the laser beam strikes the pulverulent component material perpendicularly to the laser device within a construction space of the device only at a point. In the edge regions of the installation space, the laser beam strikes another, unfavorable angle. In a vertical impact of the laser beam, the resulting melting region is substantially circular. The further away from this ideal point the laser beam impinges on the powder surface, the more ellipsoid the melting range becomes. As the melting area is increased, areas on the object are created with significantly reduced quality. From the WO 02/36331 A1 is a movable relative to a construction platform laser device is known, wherein after the generative production of a component, a post-treatment of the manufactured component by means of laser energy. The angle of incidence of the laser energy on the component surface is adjustable. However, such a post-treatment can only be applied to component surfaces.

Object of the present invention is to provide a device and a method of the type mentioned, which allows an improved quality of the produced three-dimensional object with predefined material properties or a correspondingly advantageous repair of the three-dimensional object.

This object is achieved by a device for producing or repairing a three-dimensional object having the features of patent claim 1, a method having the features of claim 8 and a component having the features of claim 14. Advantageous embodiments with expedient developments of the invention are specified in the respective subclaims, wherein advantageous embodiments of the device are to be regarded as advantageous embodiments of the method or the component and vice versa.

A first aspect of the invention relates to a device for producing or repairing a three-dimensional object comprising at least one installation space for a layered, successive solidification of at least one solidifiable material in predefined areas for the layered construction of the three-dimensional object or for the layered repair of individual areas of the three-dimensional object within the construction space and at least one radiation source for generating at least one high-energy beam by means of which a material layer in the region of a build-up and joining zone can be fused and / or sintered locally to form an object layer, wherein the Radiation source is movable relative to a building platform within the space. In this case, the device and / or the radiation source comprises at least one control device for adjusting and / or changing the angle of incidence of the high-energy beam in the material layer during the fusing and / or sintering of the material layer to an object layer of the object. By the possibility of changing the angle of incidence of the high energy beam during the layered structure of the three-dimensional object is advantageously achieved that the high energy beam is introduced into the object or component volume and not in the surrounding powder bed of the material. This reliably minimizes surface roughness of the manufactured object in these areas, a subsequent treatment of the surfaces of the object is not or only minimally necessary. The quality of the produced three-dimensional object is thereby significantly improved. In addition, by adjusting and / or changing the angle of incidence of the high-energy beam during the melting and / or sintering of the material layer, the melt bath geometry can advantageously be influenced. This advantageously results in the possibility of influencing the texture of the material. For example, cracking within the object to be produced can be prevented or at least minimized. Furthermore, according to the invention there is the advantage that defined Gefügerungen in the component or object can be generated by adjusting the angle of incidence of the high energy beam. As a result, direction-dependent material properties or object properties can be generated in a defined manner. Finally, by the device according to the invention advantageously component or object geometries can be produced with relatively small mounting angles, without the need for supports on the object. Usually, in this case, a critical angle according to the prior art is about 45 °. With the method according to the invention, this critical angle can be reduced to at least 30 °. In addition, the device according to the invention makes it possible for process by-products resulting from the adjustment of the angle of incidence of the high-energy beam, such as smoke, smoke, ejection, etc., to exert less influence on the production process, so that the quality of the object to be produced can also be significantly improved can.

The installation space of the device described above is usually a process chamber for carrying out the additive manufacturing or repair process. The three-dimensional object to be produced or repaired may be a component or a component region of an aircraft engine, in particular a compressor or a turbine. The material used can be powdery, liquid or pasty and usually consists of metal, a metal alloy, ceramic or plastic or a mixture thereof. The high energy beam is usually a laser or electron beam. Radiation source is to be understood as meaning direct and indirect radiation sources. Indirect radiation sources may comprise, for example, movable optical systems which deflect a high-energy beam generated by a direct radiation source in the direction of the material layer.

In further advantageous embodiments of the device according to the invention, the control device is designed such that the angle of incidence of the high-energy beam is adjustable and / or variable within a respective build-up area of the object as a function of a surface geometry of the object to be manufactured or repaired. By adapting the angle of incidence of the high-energy beam to the surface geometry of the object to be manufactured or repaired, the high-energy beam can in turn advantageously be directed into the object or component volume and not into the surrounding powder bed of the material. This in turn minimizes surface roughness in these areas. Furthermore, there is the possibility that the control device is designed to adjust the angle of incidence such that it corresponds to a component angle of a surface of the object to be manufactured or repaired in the respective assembly region of the object with a maximum angular deviation of ± 10 percent. The angle of incidence can advantageously be aligned in the direction of the overhang as a function of an overhang angle of the object surface or component surface by the orientation of the high-energy beam. By adjusting the angle of incidence of the high energy beam in the angular range of the overhang is again ensured that the high energy beam is introduced into the object volume and not in the surrounding powder bed of the material. Surface roughness is thereby minimized in these areas.

In a further advantageous embodiment of the device according to the invention, the device comprises at least one data storage device and / or a data processing device, wherein the data storage device and / or data processing device with the control device for adjusting and / or changing the angle of incidence of the high energy beam at least for the transmission of geometric data of the produced or connected to the repairing object. By transmitting the three-dimensional geometric data of the manufactured or to repairing object, which are also needed for the generative production or repair of the object, the required angle of incidence during the generative production or repair of the object can be automatically transferred to the control device. In addition, there is the possibility that the irradiation angles thus generated are changed manually or by adding correction factors.

In further advantageous embodiments of the device according to the invention, the radiation source comprises at least one controllable and / or controllable optical system for deflecting and / or focusing the generated high-energy beam. As a result, it is possible, inter alia, to set the angle of incidence of the high energy beam in the material layer exactly. The control and regulation of the optical system can be carried out via the control device.

In a further advantageous embodiment of the device according to the invention, the latter comprises at least one traversing unit for moving the radiation source within the installation space. Corresponding movement units are known from the prior art and will therefore not be described in detail at this point. However, it is crucial that the positioning unit ensures that the radiation source, in particular a laser device, can be moved over at least the entire area of the construction platform.

A second aspect of the invention relates to a method for producing or repairing a three-dimensional object, wherein the method according to the invention comprises at least the following steps: a) layer-wise application of at least one material to at least one construction platform arranged within a construction space in the region of a build-up and joining zone; b) layer-by-layer and local melting and / or sintering of the material by supplying energy by means of at least one high-energy beam in the region of the assembly and joining zone for forming a layer of the object, wherein a radiation source generating the high-energy beam is movable relative to the construction platform at least within the construction space ; c) layer-by-layer lowering of the build platform by a predefined layer thickness: and d) repeating steps a) to c) until completion of the object. In this case, during the layered and local fusing and / or sintering of the material, an angle of incidence of the high energy beam into the material layer can be set and / or changed. Due to the inventive possibility of changing the angle of incidence of the high energy beam in the material layer during the melting and / or sintering of the material is achieved that the high energy beam is introduced into the object or component volume and not in the surrounding powder bed of the material. In order to minimize surface roughness of the object in these areas, a subsequent treatment of the surfaces of the object is not or only minimally necessary. This results in a significant improvement in the quality of the object to be manufactured or repaired. Furthermore, there is advantageously the possibility that the melting bath geometry can be influenced by adjusting the angle of incidence of the high-energy beam. This can influence the texture of the material of the object. For example, cracking can be influenced and possibly reduced. In addition, by setting and / or changing the angle of incidence of the high-energy beam in the material layer of the beam path of the radiation source can be oriented so that resulting process by-products, such as smoke, smoke, emissions, etc., may have less or no influence on the generative manufacturing process. This also provides a significant improvement in quality with regard to the object to be manufactured or repaired. Finally, by the method according to the invention advantageously component or object geometries can be generated with relatively small mounting angles, without the need for supports on the object. Usually, in this case, a critical angle according to the prior art is about 45 °. With the method according to the invention, this critical angle can be reduced to at least 30 °. Furthermore, by adjusting and / or changing the angle of incidence of the high-energy beam into the material layer during the layer-by-layer local melting and / or sintering of the material, not only the surface geometry of the object to be manufactured or repaired but also defined structural directions in the component or object can be generated. For example, direction-dependent material properties or component and object properties can be generated defined. Such is not possible by a post-treatment of component surfaces after the preparation of the component or object according to the prior art.

The construction space described above is usually a process chamber for carrying out the additive manufacturing or repair process. The three-dimensional object to be produced or repaired may be a component or a component region of an aircraft engine, in particular a compressor or a turbine. The material used can be powdery, liquid or pasty and usually consists of metal, a metal alloy, ceramic or plastic or a mixture thereof. Of the High energy beam can be a laser or electron beam. When using a laser beam, a selective laser melting or laser sintering method is usually performed. Radiation source is to be understood as meaning direct and indirect radiation sources. Indirect radiation sources may comprise, for example, movable optical systems which deflect a high-energy beam generated by a direct radiation source in the direction of the material layer.

In further advantageous embodiments of the method according to the invention, the angle of incidence of the high-energy beam is set and / or changed in dependence on a surface geometry of the object to be manufactured or repaired within a respective build-up area of the object. By adapting the angle of incidence of the high-energy beam to the surface geometry of the object to be manufactured or repaired, the high-energy beam can in turn advantageously be directed into the object or component volume and not into the surrounding powder bed of the material. This in turn minimizes surface roughness in these areas, a possible aftertreatment of the surfaces is not or only minimally necessary. In addition, there is the possibility that the angle of incidence is adjusted so that it corresponds to a component angle of an area of the object to be manufactured or repaired in the respective construction area of the object with a maximum angular deviation of ± 10 percent. This also ensures a safe introduction of the high-energy beam into the component or object volume. In addition, the said surface may be an overhang surface of the object, so that the high-energy beam is oriented in the direction of the overhang in dependence on an overhang angle of this overhang surface of the object by the orientation of the high-power laser.

In a further advantageous embodiment of the method according to the invention, the angle of incidence is determined by means of geometrical data of the object to be produced or to be repaired stored in at least one data storage device and / or data processing device. As a result, an automatic and accurate adjustment of the angle of incidence is possible. However, there is also the possibility that the angle of incidence is changed manually or by means of correction factors.

In a further advantageous embodiment of the method according to the invention, the high-energy beam is deflected and / or focused via at least one controllable and / or controllable optical system of the radiation source. For an exact alignment of the high energy beam in the direction of the material layer is possible.

The features and advantages resulting from the use of the device according to the first aspect of the invention can be taken from the descriptions of the first aspect of the invention, advantageous embodiments of the first aspect of the invention being regarded as advantageous embodiments of the second aspect of the invention and vice versa.

A third aspect of the invention relates to a component for a turbine or a compressor, which component is obtainable and / or produced by means of a device according to the first aspect of the invention and / or by a method according to the second aspect of the invention. The features and advantages resulting from the device according to the first aspect of the invention and the method according to the second aspect of the invention can be taken from the descriptions of the first and second aspects of the invention, with advantageous embodiments of the first and / or second aspect of the invention to be considered as advantageous embodiments of the third aspect of the invention and vice versa are.

Further features of the invention will become apparent from the claims, the embodiment and the drawings. The features and feature combinations mentioned above in the description as well as the features and combinations of features mentioned below in the exemplary embodiment can be used not only in the respectively specified combination but also in other combinations without departing from the scope of the invention.

It shows

1 a schematic representation of an apparatus for producing or repairing a three-dimensional object according to the prior art; and

2 a schematic representation of a device according to the invention for the production or repair of a three-dimensional object.

1 shows a schematic representation of a device 1 for making or repairing a three-dimensional object 36 according to the prior art. One recognizes that over a stationary over a component platform 14 arranged laser device 2 a laser beam 3 on a material layer 22 of the material 16 is directed. The material 16 or the object 36 lie on a building platform 14 on. Within a construction space 12 a layer-by-layer local melting and / or sintering of the solidifiable material takes place 16 in predefined areas. through of the laser beam 3 is in the range of a construction and joining zone 28 the material layer 22 fused and / or sintered locally to an object layer. It can be seen that the angle of incidence of the laser beam 3 varies depending on position and composition. It can be seen that in this known device 1 for generative production of the three-dimensional object 36 the laser beam 3 within the installation space 12 only at one point perpendicular to the laser device 2 on the powdery material 16 or the material layer 22 incident. In a vertical impact of the laser beam 3 the resulting melting range is substantially circular. The further away from this ideal point the laser beam 3 on the material layer 22 the more ellipsoid the melting range becomes. As the melting area is increased, areas are created on the object 36 with significantly reduced quality. In addition, the angle of incidence of the laser beam 3 completely independent of a surface geometry of the object to be produced 36 , so that laser beams that impinge in peripheral areas of the object on the enlarged, ellipsoidal melting zone in many areas in the surrounding powder bed of the material 16 penetrate and thus undesirable areas of the respective material layer 22 fused and / or sintered. This leads to surface roughness, which can only be minimized by means of correspondingly expensive subsequent treatments.

2 shows a schematic representation of a device 10 for making or repairing a three-dimensional object 36 which in a known device 1 overcome disadvantages described in the prior art. The device 10 also includes a space 12 for a layered, successive solidification of a solidifiable material 16 in predefined areas for the layered construction of the three-dimensional object 36 or for layered repair of individual areas of the three-dimensional object 36 , Furthermore, the illustrated device comprises 10 a radiation source 18 for generating at least one high energy beam 20 , In the illustrated embodiment, the radiation source is 18 around a laser device for generating a laser beam 20 , One recognizes that the radiation source 18 by means of a positioning unit 26 at least in one area above a build platform 14 the device 10 is movable (see double arrow). By means of the high energy beam 20 becomes a material layer 22 in the area of a construction and joining zone 28 fused and / or sintered locally to an object layer. In addition, the device includes 10 a control device 24 for adjusting and / or changing the angle of incidence α ₁ , α ₂ , α _{3 of} the high-energy beam 20 in the material layer 22 during fusing and / or sintering of the material layer 22 to an object layer of the object 36 , Depending on a surface geometry of the object 36 become the Einstrahlwinkel α ₁ , α ₂ , α _{3 of} the high energy beam 20 within exemplarily selected and represented construction areas 30 . 32 . 34 of the object 36 set and / or changed. It becomes clear that the angles of incidence α ₁ and α ₃ each correspond to a corresponding component angle β ₁ , β _{2 of} a respective surface 40 . 42 of the object to be produced 36 in the respective construction area 30 . 34 correspond. In this case, the irradiation angles α1, α3 can have a maximum angular deviation of ± 10 percent with respect to the respective component angle β ₁ , β ₂ . Furthermore, it is clear that the angle of incidence α _{2 of} the high-energy beam 20 perpendicular to the material layer 22 runs. But there is also the possibility that the Einstrahlwinkel α ₁ , α ₂ , α ₃ not only depending on the surface geometry of the object to be manufactured or repaired 36 can be set and / or changed, but that within the object volume during construction, the Einstrahlwinkel α ₁ , α ₂ , α _{3 of} the high energy beam 20 to be changed. In this case, the setting of the Einstrahlwinkels the Schmelzbadgeometrie be influenced, which advantageously has the ability to influence the texture of the material of the object 36 to take. For example, objects or components with defined structural directions can be generated within the component or object. This results in direction-dependent material and component properties that can be generated in a defined manner.

Furthermore, one recognizes that the control device 24 with the radiation source 18 or the laser device, is connected data-conducting. The corresponding control commands or control data are in the illustrated embodiment by a data storage device 38 provided. In the data storage device 38 are geometric data of the object to be manufactured or repaired 36 stored and are corresponding to the control device 24 transfer. Based on this geometric data are transmitted via the control device 24 the corresponding angle of incidence α ₁ , α ₂ , α _{3 of} the high energy beam 20 in the material layer 22 during fusing or during sintering of the material layer 22 to an object layer of the object 36 set and / or changed.

In the represented object 36 it may be, for example, a component of a turbomachine, in particular a component of a turbine or a compressor.

LIST OF REFERENCE NUMBERS

1

contraption

2

laser device

3

laser beam

10

contraption

12

space

14

building platform

16

material

18

radiation source

20

High energy beam

22

Material layer

24

control device

26

traversing

28

Assembly and joining zone

30

construction area

32

construction area

34

construction area

36

object

38

Data storage device, data processing device

40

area

42

area

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102009051479 A1 [0003]
• WO 02/36331 A1 [0004]

Claims (14)

Contraption ( 10 ) for producing or repairing a three-dimensional object ( 36 ) comprising: - at least one installation space ( 12 ) for a layered, successive solidification of at least one solidifiable material ( 16 ) in predefined regions for the layered construction of the three-dimensional object ( 36 ) or for layerwise repair of individual areas of the three-dimensional object ( 36 ) within the installation space ( 12 ); and - at least one radiation source ( 18 ) for generating at least one high-energy beam ( 20 ), by means of which a material layer ( 22 ) in the region of a buildup and joining zone ( 28 ) is locally fusible and / or versinterbar to an object layer, wherein the radiation source ( 18 ) relative to a build platform ( 14 ) within the installation space ( 12 ), characterized in that the device ( 10 ) and / or the radiation source ( 18 ) at least one control device ( 24 ) for setting and / or changing the angle of incidence (α ₁ , α ₂ , α ₃ ) of the high energy beam ( 20 ) in the material layer ( 22 ) during fusing and / or sintering of the material layer ( 22 ) to an object layer of the object ( 36 ). Contraption ( 10 ) according to claim 1, characterized in that the control device ( 24 ) is formed such that the angle of incidence (α ₁ , α ₂ , α ₃ ) of the high-energy beam ( 20 ) depending on a surface geometry of the object to be manufactured or repaired ( 36 ) within a respective construction area ( 30 . 32 . 34 ) of the object ( 36 ) is adjustable and / or changeable. Contraption ( 10 ) according to claim 2, characterized in that the control device ( 24 ) is designed such that the angle of incidence (α ₁ , α ₃ ) is adjustable such that it corresponds to a component angle (β ₁ , β ₂ ) of a surface ( 40 . 42 ) of the object to be manufactured or repaired ( 36 ) in the respective construction area ( 30 . 34 ) of the object ( 36 ) with a maximum angular deviation of ± 10%. Contraption ( 10 ) according to one of the preceding claims, characterized in that the device ( 10 ) at least one data storage device and / or one data processing device ( 38 ), wherein the data storage device and / or data processing device ( 38 ) with the control device ( 24 ) at least for the transmission of geometric data of the object to be manufactured or repaired ( 36 ) connected is. Contraption ( 10 ) according to one of the preceding claims, characterized in that the radiation source ( 18 ) at least one controllable and / or controllable optical system for deflecting and / or focusing the generated high energy beam (US Pat. 20 ). Contraption ( 10 ) according to one of the preceding claims, characterized in that the high-energy beam ( 20 ) is a laser or electron beam. Contraption ( 10 ) according to one of the preceding claims, characterized in that the device ( 10 ) at least one trajectory ( 26 ) for moving the radiation source ( 18 ) within the installation space ( 12 ). Method for producing or repairing a three-dimensional object ( 36 ) comprising at least the following steps: a) layer by layer application of at least one material ( 16 ) to at least one within a construction space ( 12 ) construction platform ( 14 ) in the region of a buildup and joining zone ( 28 ); b) Layer by layer and local fusion and / or sintering of the material ( 16 ) by supplying energy by means of at least one high energy beam ( 20 ) in a material layer ( 22 ) in the area of the assembly and joining zone ( 28 ) for forming a layer of the object ( 36 ), wherein one of the high-energy beam ( 20 ) generating radiation source ( 18 ) relative to the build platform ( 14 ) at least within the construction space ( 12 ) is movable; c) Layer by layer lowering of the construction platform ( 14 ) by a predefined layer thickness; and d) repeating steps a) to c) until completion of the object ( 36 ), characterized in that during the layered and local fusing and / or sintering of the material ( 16 ) an angle of incidence (α ₁ , α ₂ , α ₃ ) of the high energy beam ( 20 ) in the material layer ( 22 ) is adjustable and / or changeable. Method according to Claim 8, characterized in that the angle of incidence (α ₁ , α ₂ , α ₃ ) of the high-energy beam ( 22 ) depending on a surface geometry of the object to be manufactured or repaired ( 36 ) within a respective construction area ( 30 . 32 . 34 ) of the object ( 36 ) is adjusted and / or changed. Method according to Claim 9, characterized in that the angle of incidence (α ₁ , α ₃ ) is set such that it corresponds to a component angle (β ₁ , β ₂ ) of a surface ( 40 . 42 ) of the object to be manufactured or repaired ( 36 ) in the respective construction area ( 30 . 34 ) of the object ( 36 ) with a maximum angular deviation of ± 10%. Method according to claim 10, characterized in that the angle of incidence (α ₁ , α ₂ , α ₃ ) by means of in at least one data storage device and / or data processing device ( 38 stored geometrical data of the object to be manufactured or repaired ( 36 ) is determined. Method according to one of claims 8 to 11, characterized in that the high-energy beam ( 20 ) via at least one controllable and / or controllable optical system of the radiation source ( 18 ) is distracted and / or focused. Method according to one of claims 8 to 12, characterized in that the high-energy beam ( 22 ) is a laser or electron beam. Component for a turbine or a compressor, characterized in that this is obtainable and / or produced by means of a device according to one of claims 1 to 7 and / or by a method according to one of claims 8 to 13.

Images