System and method for forming powder removal cap via additive manufacturing

Abstract

A method for trapping captured powder from a part during an additive manufacturing process includes defining a parameter of the part, the part defining an internal passage defined by an internal sidewall, defining a parameter of a powder removal cover, and defining an external passage defined by an external sidewall. And a powder removal cap comprising a body portion and a thin radial membrane connected to the interior sidewall of the part, creating the part and the powder removal cap simultaneously via additive manufacturing, where the powder removal cap is created within the interior channel, and upon completion of creation of the part and the powder removal cap, the powder removal cap is attached to the interior sidewall of the part. The powder removal cap captures excess powder within the internal channel, removes the powder removal cap from the internal channel by breaking the radial membrane from the internal sidewall to permit access to the internal channel, and captures excess powder within the internal channel.

Description

[0001] introduction

[0002] The information provided in this section is for the purpose of generally presenting the context of the present disclosure. The work of the presently named inventors, to the extent it is described in this section and in aspects of the description that may not qualify as prior art at the time of filing, is neither explicitly nor implicitly admitted to be prior art against the present disclosure. Technical Field

[0003] The present disclosure generally relates to systems and methods for forming a powder removal cover via additive manufacturing. Background Art

[0004] Additive manufacturing (AM), such as laser powder bed fusion (LPBF), is expensive in part due to the high cost of materials. Fortunately, unmelted powder can be reused if kept clean. Therefore, recycling clean powder can create a more positive business case for AM.

[0005] Certain die casting tools may use additively manufactured inserts / caps to improve quality and reduce scrap through conformal cooling channels. After printing, such large AM parts are separated from the build plate using electrical discharge machining (EDM). In some embodiments, the AM part can be completely submerged in the fluid, thereby safely containing otherwise airborne metal powder caused by the separation of the AM part from the build plate via EDM.

[0006] However, when the insert is immersed in a fluid bath, the conformal line filled with dry metal powder becomes saturated with the fluid. The fluid transforms the metal powder into a sludge that is difficult to remove.

[0007] Therefore, there is room for improvement in powder removal tools in parts produced by additive manufacturing. Summary of the invention

[0008] One aspect of the present disclosure provides a method for capturing captured powder from a part during an additive manufacturing process. The method includes defining parameters of a part, the part defining an internal channel defined by an internal sidewall, defining parameters of a powder removal cover, the powder removal cover including a body portion and a thin radial membrane connected to the internal sidewall of the part, the body portion defining a socket, forming the part and the powder removal cover simultaneously via additive manufacturing, wherein the powder removal cover is formed within the internal channel, and upon completion of the formation of the part and the powder removal cover, the powder removal cover captures excess powder within the internal channel, removing the powder removal cover from the internal channel by engaging a tool with the socket and twisting the powder removal cover until the radial membrane breaks relative to the internal sidewall to permit access to the internal channel, and capturing excess powder within the internal channel.

[0009] Implementations of the present disclosure include one or more of the following optional features. In some implementations, the socket is a hex socket and the tool is a hex key.

[0010] The parts can be used in a vehicle. The vehicle can be a car.

[0011] The radial membrane may include notches and / or perforations.

[0012] The part and the powder removal cover may be formed of the same material.

[0013] Another aspect of the present disclosure provides a method for capturing captured powder from a part during an additive manufacturing process. The method includes defining parameters of a part, the part defining an internal channel defined by an internal sidewall, defining parameters of a powder removal cover, the powder removal cover including a body portion and a thin radial membrane connected to the internal sidewall of the part, forming the part and the powder removal cover simultaneously via additive manufacturing, wherein the powder removal cover is formed within the internal channel, and after the formation of the part and the powder removal cover is completed, the powder removal cover captures excess powder within the internal channel. The powder removal cover is removed from the internal channel by breaking the radial membrane from the internal sidewall to allow access to the internal channel and capture excess powder within the internal channel.

[0014] Embodiments of the present disclosure include one or more of the following optional features. In some embodiments, the body portion defines a hexagonal socket, and a hexagonal key is used to torque the powder removal cap to break the radial membrane from the inner sidewall.

[0015] The part can be used in a vehicle, and the vehicle can be a car.

[0016] The radial membrane may include notches and / or perforations.

[0017] The part and the powder removal cover may be formed from the same material.

[0018] Another aspect of the present disclosure provides a method for capturing captured powder from a part during an additive manufacturing process. The method includes defining parameters of a part, the part defining an internal channel, defining parameters of a powder removal cover, the powder removal cover including a thin radial membrane disposed within the internal channel of the part, forming the part and the powder removal cover simultaneously via additive manufacturing, wherein the powder removal cover captures excess powder within the internal channel after forming of the part and the powder removal cover is completed, removing the powder removal cover from the internal channel by breaking the radial membrane to allow access to the internal channel, and capturing excess powder within the internal channel.

[0019] Implementations of the present disclosure include one or more of the following optional features. In some implementations, the powder removal cap includes a body portion defining a hexagonal socket, and the hexagonal key is used to twist the powder removal cap to break the radial membrane.

[0020] The part can be used in a vehicle, and the vehicle can be a car.

[0021] The radial membrane may include notches and / or perforations.

[0022] The details of one or more embodiments of the present disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

[0024] Figure 1 is a perspective view of an exemplary powder removal cover disposed within an exemplary part in accordance with the teachings of the present disclosure;

[0025] Figure 2A yes Figure 1 A magnified view of the powder removal cover;

[0026] Figure 2B is along Figure 2A A cross-sectional perspective view of the powder removal cover taken along line 2B-2B;

[0027] Figure 2C yes Figure 2A A cross-sectional plan view of a powder removal cover;

[0028] Figure 2D yes Figure 2B an enlarged view of a portion of a powder removal cover;

[0029] Figure 3A It has Figure 1 A plan view of the bottom of the perforated radial membrane powder removal cover;

[0030] Figure 3B It has Figure 1 A plan view of the bottom of the notched radial film powder removal cover;

[0031] Figure 4A is a perspective view of exemplary parts including a powder removal cover;

[0032] Figure 4B yes Figure 4A an enlarged view of a portion of;

[0033] Figure 4C is along Figure 4B A partial cross-sectional view of an exemplary part and powder removal cover taken along line 4C-4C of FIG. 4C; and

[0034] Figure 5 is a detailed description of the teachings of the present disclosure for creating Figures 1 to 4C A flow chart of an exemplary powder removal process for covers and parts.

[0035] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings. DETAILED DESCRIPTION

[0036] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that the present disclosure will be thorough and will fully convey the scope of the present disclosure to those of ordinary skill in the art. Specific details, such as examples of specific parts, devices, and methods, are set forth to provide a thorough understanding of the configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and example configurations should not be construed as limiting the scope of the present disclosure.

[0037] refer to Figure 1 , powder removal cover 100 is generally shown in an internal channel or conformal cooling line 50 of a part or mold insert 10 on a build plate 20. As will become apparent, the part 10 and the powder removal cover 100 are simultaneously created using additive manufacturing (AM). The part 10 and the powder removal cover 100 can be formed using any suitable material (e.g., titanium alloy, cobalt chrome, stainless steel, nickel alloy, aluminum alloy, etc.) and any suitable AM ​​process (e.g., laser powder bed fusion (LPBF)).

[0038] The part 10 may be a part for a vehicle, which may be an automobile. It should be understood that the vehicle may be any of a variety of different types of automobiles, such as a sedan, a four-wheeler, a truck, or a sport utility vehicle (SUV), and may be a two-wheel drive (2WD) (i.e., rear-wheel drive or front-wheel drive), a four-wheel drive (4WD), or an all-wheel drive (AWD), and / or various other types of vehicles in certain configurations. The vehicle may also include a truck, a boat, an airplane, and / or one or more other types of vehicles.

[0039] refer to Figures 2A-2D, the internal channel 50 of the part 10 includes an upper channel 52a and a lower channel 52b. Upon completion of the AM process, the upper channel 52a contains excess dry powder produced by the AM process, and the lower channel 52b contains powder sludge produced by excess dry powder from the AM process mixed with liquid when the part 10 is cut from the build plate 20 and the powder removal cover 100. The internal channel 50 is defined by an internal sidewall 54, as shown in FIG. Figures 1 to 2D As shown, the inner sidewall 54 may form a generally cylindrical shape.

[0040] The powder removal cover 100 includes a body portion 102, which may include a generally cylindrical shape or any other suitable shape. The powder removal cover 100 includes a thin radial membrane 104 connected to the body portion 102 by a flange portion 106. The diameter of the body portion 102 may be smaller than the diameter of the radial membrane 104. The radial membrane 104 may be formed so that it is attached to the inner sidewall 54 of the inner channel 50, and may be a thin portion of the material, for example, between about 0.1 mm and 0.5 mm. The thickness of the radial membrane 104 may be adjusted to any suitable thickness to allow the radial member 104 to break from the inner sidewall 54 under sufficient torque.

[0041] The body portion 102 includes a socket sidewall 110 that defines a socket 108. In some embodiments, the socket 108 is hexagonal. In other embodiments, the socket 108 can be threaded, splined, or have any other suitable configuration, such as a Philips head, a Robertson head, a flat head, etc. The socket 108 is configured to receive any suitable tool, such as a hex key, a Philips head screwdriver, a Robertson head screwdriver, a flat head screwdriver, etc. The powder removal cover 100 extends from a bottom surface 112 cut out of the build plate 20 to a top surface adjacent to the upper channel 52a of the internal channel 50.

[0042] Reference Figure 3A In some embodiments, the radial member 104 may include one or more perforations 116 located at or near the connection with the inner sidewall 54. The perforations 116 may be a thinner layer of material than the radial membrane 104, or may be gaps in the material of the radial membrane 104. The perforations 116 may be used to weaken the radial membrane 104 to reduce the torque force required to break the radial membrane 104 from the inner sidewall 54.

[0043] refer to Figure 3BIn some embodiments, the radial membrane 104 can include a notch 118 located at or near the connection with the inner sidewall 54. The notch 118 can be a thinner layer of material than the radial membrane 104, or can be a gap in the material of the radial membrane 104. The notch 118 can be used to weaken the radial membrane 104 to reduce the torque force required to break the radial membrane 104 from the inner sidewall 54.

[0044] refer to Figure 4A In some embodiments, the powder removal cap 100 may include a body portion 102 without a socket 108. Instead, the body portion 102 may be formed as a hexagon or any other suitable shape to receive, for example, a hexagonal socket or any other suitable tool to twist or apply torque to the powder removal cap 100.

[0045] refer to Figure 5 , generally showing a method 500 for capturing trapped powder from a part 10 during an AM process. The method 500 includes a first step 502, whereby a computer system or any other suitable machine defines parameters of the part 10 and the powder removal cover 100. At steps 504 and 506, the AM machine simultaneously prints the part 10 and the powder removal cover 100 within the internal channel 50. At step 508, the part 10 and the powder removal cover 100 are removed from the build plate 20 by any suitable process, such as electrical discharge machining (EDM). At step 510, any suitable machining operation may be performed to, for example, remove burrs from the part 10 and the powder removal cover 100.

[0046] At step 512, the part 10 can be moved to a designated area to capture the powder. For example, the part 10 can be moved to a location with a recovery bin or other suitable capture device below the internal passage 50. At step 514, the powder removal cover 100 can be separated from the inner sidewall 54 of the internal passage 50. For example, a hexagonal key can be inserted into the socket 108, and the hexagonal key can be twisted until the torque force breaks the radial membrane 104 from the inner sidewall 54. At step 516, excess powder within the internal passage 50 can be captured in a recovery bin or other suitable capture device. In some embodiments, a vacuum, a blower, or any other suitable mechanism can be used to facilitate the retrieval of powder from the internal passage 50. At step 518, the powder can be reused for another AM process.

[0047] The terms used herein are only used for the purpose of describing specific exemplary configurations and are not intended to be limiting. As used herein, the singular articles "a", "an" and "the" may also be intended to include plural forms unless the context clearly indicates otherwise. The terms "comprises", "comprising", "including" and "having" are inclusive and therefore specify the presence of features, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements, parts and / or groups thereof. The method steps, processes and operations described herein should not be interpreted as necessarily requiring them to be performed in the specific order discussed or shown, unless specifically identified as an execution order. Additional or alternative steps may be adopted.

[0048] When an element or layer is referred to as being "on another element or layer," "engaged to," "connected to," "attached to," or "coupled to" another element or layer, it may be directly on, directly engaged with, connected to, attached to, or coupled to another element or layer, or there may be intermediate elements or layers. Conversely, when an element is referred to as being "directly on another element or layer," "directly engaged to," "directly connected to," "directly attached to," or "directly coupled to" another element or layer, there may be no intermediate elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more associated listed items.

[0049] The terms first, second, third, etc. can be used to describe various elements, parts, regions, layers and / or parts in this article. These elements, parts, regions, layers and / or parts should not be limited by these terms. These terms can only be used to distinguish an element, part, region, layer or part from another region, layer or part. Unless the context clearly indicates, terms such as "first", "second" and other numerical terms do not imply order or sequence. Therefore, without departing from the teaching of the example configuration, the first element, part, region, layer or part discussed below can be referred to as the second element, part, region, layer or part.

[0050] The apparatus and methods described in this application may be implemented in part or in whole by one or more computer programs executed by one or more processors. The computer program includes processor executable instructions stored on at least one non-transitory tangible computer readable medium. The computer program may also include and / or rely on stored data.

[0051] Software applications (i.e., software resources) may refer to computer software that enables a computing device to perform tasks. Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and gaming applications.

[0052] Non-transitory memory can be a physical device used to temporarily or permanently store programs (e.g., sequences of instructions) or data (e.g., program state information) for use by a computing device. Non-transitory memory can be volatile and / or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM) / programmable read-only memory (PROM) / erasable programmable read-only memory (EPROM) / electrically erasable programmable read-only memory (EEPROM) (e.g., commonly used for firmware, such as bootloaders). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase change memory (PCM), and disk or tape.

[0053] These computer programs (also referred to as programs, software, software applications, or code) include machine instructions for a programmable processor and may be implemented in high-level procedural and / or object-oriented programming languages ​​and / or assembly / machine languages. As used herein, the terms "machine-readable medium" and "computer-readable medium" refer to any computer program product, non-transitory computer-readable medium, apparatus, and / or device (e.g., disk, optical disk, processor, programmable logic device (PLD)) for providing machine instructions and / or data to a programmable device, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term "machine-readable signal" refers to any signal for providing machine instructions and / or data to a programmable processor.

[0054] Many embodiments have been described. However, it should be understood that various modifications can be made without departing from the spirit and scope of the present disclosure. Therefore, other embodiments are within the scope of the appended claims.

[0055] The foregoing description is provided for the purpose of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. The individual elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable where applicable and can be used in a selected configuration, even if not specifically shown or described. It can also be varied in many ways. Such variations should not be considered as departing from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A method for capturing captured powder from a part during an additive manufacturing process, the method comprising: defining parameters of a part, the part defining an interior passage defined by an interior sidewall; defining parameters of a powder removal cover comprising a body portion defining a socket and a thin radial membrane connected to an interior sidewall of the part; creating the part and the powder removal cover simultaneously via additive manufacturing, wherein the powder removal cover is created within the internal passage, and upon completion of the creation of the part and the powder removal cover, the powder removal cover captures excess powder within the internal passage; removing the powder removal cover from the interior passage by engaging a tool with the socket and twisting the powder removal cover until the radial membrane breaks relative to the interior sidewall to permit access to the interior passage; and Excess powder is captured within the internal passage.

2. The method according to claim 1, wherein: The socket is a hex socket and the tool is a hex key.

3. The method according to claim 1, wherein: The parts are used in vehicles.

4. The method according to claim 3, wherein: The vehicle is a car.

5. The method according to claim 1, wherein: The radial membrane includes a notch.

6. The method according to claim 1, wherein: The radial membrane includes perforations.

7. The method of claim 1, wherein the part and the powder removal cover are formed of the same material.

8. A method for capturing captured powder from a part during an additive manufacturing process, the method comprising: defining parameters of a part, the part defining an interior passage defined by an interior sidewall; defining parameters of a powder removal cover comprising a body portion and a thin radial membrane connected to an interior sidewall of the part; creating the part and the powder removal cover simultaneously via additive manufacturing, wherein the powder removal cover is created within the internal passage, and upon completion of the creation of the part and the powder removal cover, the powder removal cover captures excess powder within the internal passage; removing the powder removal cover from the interior passage by rupturing the radial membrane from the interior sidewall to permit access to the interior passage; and Excess powder is captured within the internal passage.

9. The method according to claim 8, wherein: The body portion defines a hexagonal socket, and a hexagonal key is used to torque the powder removal cap to break the radial membrane from the inner sidewall.

10. The method according to claim 8, wherein: The parts are used in vehicles.

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