DEVICE AND METHOD FOR THE GENERATIVE MANUFACTURING OF AT LEAST A COMPONENT AREA OF A COMPONENT

Description

[0001] The invention relates to a device for the additive manufacturing of at least one component region of a component, in particular a component of a turbomachine. The invention further relates to a method for the additive manufacturing of at least one component region of a component, as well as to a suction and / or gas supply device for use in a device for the additive manufacturing of at least one component region of a component.

[0002] A wide variety of methods and devices for producing components are known. In particular, generative manufacturing methods (so-called rapid manufacturing or rapid prototyping methods) are known in which the component is built up layer by layer using powder-bed-based additive manufacturing processes. Primarily metallic components can be manufactured, for example, using laser or electron beam melting or sintering processes. In this process, at least one powdered component material is first applied layer by layer to a component platform in the area of ​​a build-up and joining zone of the device. The component material is then locally melted and / or sintered layer by layer by supplying energy to the component material in the area of ​​the build-up and joining zone using at least one high-energy beam, for example an electron beam or laser beam.The high-energy beam is controlled based on layer information for each component layer to be produced. After fusing and / or sintering, the component platform is lowered layer by layer by a predefined layer thickness. The above steps are then repeated until the component is finally completed.

[0003] In particular, generative manufacturing processes for the production of components of a turbomachine, such as components of an aircraft engine or a gas turbine, are also known from the prior art, e.g. the process described in DE 10 2009 051 479 A1 or a corresponding device for producing a component of a turbomachine.

[0004] In this process, a corresponding component is manufactured by layer-by-layer application of at least one powdered component material to a component platform in the area of ​​a build-up and joining zone, as well as layer-by-layer and local melting or sintering of the component material using energy supplied in the area of ​​the build-up and joining zone. The energy is supplied via laser beams, such as CO2 lasers, Nd:YAG lasers, Yb fiber lasers, and diode lasers, or by electron beams. In the process described in DE 10 2009 051 479 A1, the produced component or the build-up and joining zone is further heated to a temperature just below the melting point of the component material using a zone furnace in order to maintain a directionally solidified or monocrystalline crystal structure.

[0005] From DE 10 2006 058 949 A1, a device and a method for the rapid production and repair of blade tips of blades of a gas turbine, in particular of an aircraft engine, are also known, wherein an inductive heating is used together with laser or electron beam sintering.

[0006] Inductive heating of the component to be manufactured in connection with the generative production of a component using selective laser melting is also described in EP 2 359 964 A1.

[0007] WO 2008 / 071165 A1, in turn, describes a device and method for repairing gas turbine blades using powder deposition welding. A radiation source, such as a laser or an electron beam, is used for the deposition welding. At the same time, a heating device for heating the blade to be repaired is provided via an induction coil.

[0008] DE 10 2012 206 122 A1 describes a device for the additive manufacturing of components by means of laser powder deposition welding and / or selective irradiation of a powder bed. The device comprises at least one induction coil movably arranged relative to one or more powder bed chambers. The induction coils are linearly movable along separately formed rail arrangements. The local inductive heating of the component, which is individually adapted to the geometry of the component to be manufactured, makes it possible to reliably prevent hot cracking during component production, particularly when using high-temperature alloys for additive manufacturing.

[0009] WO 2006 / 121 797 A2 discloses a powder supply container that may include a cooling / heating device. Furthermore, openings or nipples, such as quick-release fasteners, may be arranged on the powder supply container for arranging a gas supply, an exhaust gas discharge, or an evacuation unit.

[0010] EP 2 857 139 A1 discloses a device for laser material processing, comprising a laser for generating a laser beam and a laser head movable along at least one spatial direction, connected to the laser via a fiber optic cable and emitting a laser beam with which a material can be processed. EP 2 857 139 A1 also relates to a device for selective laser melting or selective laser sintering, comprising such a device for laser material processing.

[0011] EP 3 131 740 A1 discloses a device for producing a three-dimensional object by layer-by-layer solidification of building material. It comprises a coating device for applying a layer of the building material to a working plane, as well as a solidification device for selectively solidifying the building material in the applied layer. A gas extraction nozzle is movably arranged, and the device is configured to control or regulate the movement and / or orientation of the gas extraction nozzle depending on a number of reference points.

[0012] A disadvantage of the known devices, however, is the fact that the removal of smoke, splashes, and process exhaust gases generated during the additive manufacturing process is either insufficient or requires relatively high equipment costs. The object of the present invention is therefore to create a device of the type mentioned above that enables improved removal of smoke, splashes, and / or process exhaust gases generated during an additive manufacturing process with relatively low equipment costs.

[0013] The object is achieved according to the invention by a device having the features of patent claim 1 for the generative production of at least one component region of a component and by a method having the features of claim 5. Advantageous embodiments with expedient further developments of the invention are specified in the respective subclaims, wherein advantageous embodiments of the devices are to be regarded as advantageous embodiments of the method and vice versa.

[0014] A first aspect of the invention relates to a device according to claim 1 for the additive production of at least one component region of a component, in particular a component of a turbomachine. The device comprises at least one coater for applying at least one powder layer of a component material to at least one build-up and joining zone of at least one lowerable component platform, wherein the coater is movable relative to the component platform, and at least one radiation source for generating at least one high-energy beam, by means of which the powder layer in the region of the build-up and joining zone can be locally fused and / or sintered to form a component layer.In addition, the device comprises at least one extraction and / or gas supply device that is mechanically connected to the coater such that a working and effective range of the high-energy beam in the region of the build-up and joining zone lies within an effective range of the extraction and / or gas supply device. By arranging the extraction and / or gas supply device on the movable coater, it is possible to reliably remove smoke, splashes, and / or process exhaust gases from the additive manufacturing process from the build-up and joining zone before, during, and / or after exposure to the radiation source or the high-energy beam in this area. The terms "arranged" or "arrangement" are understood to mean that the extraction and / or gas supply device is directly or indirectly connected to the coater. A mechanical connection to the coater is provided.In addition, existing devices for the generative production of components can be easily retrofitted with a corresponding extraction and / or gas supply device that is arranged on the coater. Since the extraction and / or gas supply device is mechanically connected to the movable coater, additional travel units for moving the extraction and / or gas supply device into the area of ​​the build-up and joining zone of the component can be dispensed with. It is also possible to supply gas to the build-up and joining zone of the component, i.e. a working and effective area of ​​the high-energy beam, in order to control the flow conditions in this area. It is also possible, however, to supply inert gas to the build-up and joining zone of the component via the gas supply device in order to improve the joining quality of the resulting component.The extraction and / or gas supply device is connected to the coater in such a way that the working and effective range of the high-energy beam in the build and joining zone lies at least predominantly or entirely within the effective range of the extraction and / or gas supply device. This enables particularly reliable removal of smoke, spatter, and / or process exhaust gases from the build and joining zone.

[0015] In further advantageous embodiments of the device according to the invention, the extraction and / or gas supply device is arranged on the coater so that it can be moved or immovable. The extraction and / or gas supply device can be arranged on the coater so that it is moved by the movement of the coater along or across the build-up and joining zone of the component platform. This results in a simple structural design of the device as a whole. Furthermore, it is possible to arrange the extraction and / or gas supply device so that it can be moved on the coater via a corresponding movement unit. This advantageously makes it possible to move the extraction and / or gas supply device counter to the direction of movement of the coater in order to increase the effective range of the extraction and / or gas supply device.

[0016] According to the invention, the device has at least one heating device for heating the powder layer of the component material at least in the region of the build-up and joining zone of the component platform, wherein the heating device is movable relative to the component platform. The heating device can be arranged on the coater in a non-movable manner, so that it is moved by the movement of the coater along or over the build-up and joining zone of the component platform. This results in a simple structural design of the device as a whole. Furthermore, existing devices for the generative production of components can be retrofitted with a corresponding heating device arranged on the coater. This is then moved with the coater over the build-up and joining zone of the component platform via a corresponding movement unit of the coater.Furthermore, the at least one heating device can be arranged so that it can be moved on the coater. The coater can comprise at least one moving unit, on which at least one heating device is arranged. This advantageously provides the possibility of moving the heating device counter to the direction of movement of the coater, thus allowing a wider area of ​​the build-up and joining zone to be heated by the heating device. Heating the component material by means of the heating device also reliably prevents the formation of hot cracks, particularly when using high-temperature alloys as the component material.

[0017] The relative mobility of the coater and / or the heating device relative to the component platform can be achieved either by moving the coater and / or the heating device using a corresponding traversing unit or by moving the component platform. In the latter embodiment, a separate traversing unit for the heating device or the coater can be omitted if necessary.

[0018] In further advantageous embodiments of the device according to the invention, the heating device is an induction coil. In the context of the present invention, an induction coil is understood to mean any device that can generate inductive heating, for example regardless of the number of turns, so that the induction coil can also be referred to as an induction loop, for example. It is possible for the device to comprise several movable or movable induction coils arranged in one or more planes parallel to a surface of the build-up and joining zone. In particular, two induction coils can be operated in a crossed arrangement, wherein the high-energy beam of the radiation source can be provided, particularly in the crossing region, for melting and / or sintering the powdered component material.In a further embodiment, an induction coil can be arranged non-movably on the coater and a further induction coil can be arranged movable on the coater via a movement unit.

[0019] In further advantageous embodiments of the device according to the invention, the high-energy beam is a laser or electron beam.

[0020] A second aspect of the invention relates to a method according to claim 5 for the generative production of at least one component region of a component, in particular a component of a turbomachine. The method according to the invention comprises at least the following steps: a) applying at least one powder layer of a component material to at least one build-up and joining zone of at least one lowerable component platform; b) layer-by-layer and local melting and / or sintering of the component material by supplying energy by means of at least one high-energy beam in the region of the build-up and joining zone to form a component layer; c) layer-by-layer lowering of the component platform by a predefined layer thickness; and d) repeating steps a) to c) until the component region is completed.Before, during, and / or after exposure to the high-energy beam, in particular smoke, spatter, and / or process exhaust gases from the additive manufacturing process are removed from the build-up and joining zone by means of at least one extraction and / or gas supply device arranged on at least one coater movable relative to the component platform for applying the component material. The extraction and / or gas supply device is mechanically connected to the coater in such a way that a working and effective range of the high-energy beam in the build-up and joining zone lies within an effective range of the extraction and / or gas supply device. This enables particularly reliable removal of smoke, spatter, process exhaust gases, and other undesirable gases or particles from the build-up and joining zone.According to the invention, at least one heating device for heating the component material is arranged on the coater in a movable or non-movable manner at least in the region of the build-up and joining zone of the component platform.

[0021] Further features of the invention emerge from the claims, the exemplary embodiment of the device according to the invention described below, and the drawings. The features and combinations of features mentioned above in the description, as well as the features and combinations of features mentioned below in the exemplary embodiments, can be used not only in the respective specified combinations, but also in other combinations without departing from the scope of the invention. The drawings show: Fig. 1 is a schematic plan view of an apparatus according to the invention for producing at least one component region of a component; Fig. 2 is a schematic sectional view of the apparatus according to Figure 1; and Fig. 3 an enlarged schematic representation of a portion of the Figure 2 device shown in a sectional view.

[0022] Fig. 1shows a schematic plan view of a device 10 according to the invention for the generative production of at least one component region of a component, in particular a component of a turbomachine. In particular, this can be a component of a turbine or a compressor of an aircraft engine. The device 10 also has a coater 14 for applying at least one powder layer of a component material (not shown) to at least one build-up and joining zone 20 of a lowerable component platform 16. It can be seen that the coater 14 can be moved by means of a travel unit 30, which is connected to a machine frame 32 of the device 10. The movement of the coater 14 takes place over and along the component platform 16, so that a uniform and layer-by-layer application of the powdered component material to the component platform 16 is possible.

[0023] Furthermore, it can be seen that a first induction coil 24 is arranged on the travel unit 30 of the coater 14. Approximately perpendicular to the first induction coil 24, a second induction coil 28 is arranged on a travel unit 26. The travel unit 26 is in turn arranged on the coater 14, so that the second induction coil 28 can be moved along a longitudinal extent of the coater 14. In the illustrated embodiment, the two induction coils are arranged in a crossed arrangement. It can be seen that with such an arrangement, the entire area of ​​the component platform 16 can be covered by the induction coils 24, 28 and thus heated. Furthermore, it is clear that a high-energy beam 22, in particular a laser or electron beam, can be directed between the induction coils 24, 28 onto the powder layer of the component material in the area of ​​a build-up and joining zone 20 (see Figure 2). In particular, the high-energy beam 22 is directed such that it can penetrate between an intersection area of ​​the induction coils 24, 28. It can also be seen that by arranging the induction coils 24, 28 on the coater 14, they no longer have to be removed from the work area of ​​the coater 14 for coating. By heating the powder layer by means of the induction coils 24, 28 in the area of ​​the build-up and joining zone 20, it is possible, on the one hand, to achieve consistent induction conditions before, during, and after the melting of the component material by means of the high-energy beam 22 and as the solidification front progresses, so that consistent melting conditions with defined, local temperature gradients can be set at high production speeds. On the other hand, the formation of cracks and the like during solidification is avoided at the same time.

[0024] It can be seen that an extraction and / or gas supply device 36 is arranged on the first induction coil 24. By arranging the extraction and / or gas supply device 36 on the first induction coil 24, it is possible to reliably remove, in particular, smoke, splashes, and / or process exhaust gases from the generative manufacturing process before and / or during and / or after exposure by means of the radiation source or the high-energy beam 22 from the build-up and joining zone 20. An effective region 34 of the extraction and / or gas supply device 36, i.e., the region of the extraction and / or gas supply, extends in the illustrated embodiment in particular to the intersection region of the induction coils 24, 28.

[0025] Fig. 2 shows a schematic sectional view of the device 10 along the line AA in Fig. 1It can be seen that the second induction coil 28, arranged on the coater 14 by means of the travel unit 26, is arranged in a plane below the first induction coil 24, arranged on the travel unit 30 of the coater 14, relative to the component platform 16. The extraction and / or gas supply device 36 is arranged within a winding formed by the first induction coil 24, so that its effective area 34 coincides at least with the area of ​​the build and joining zone 20. The high-energy beam 22 is aligned such that it can penetrate between the intersection area of ​​the induction coils 24, 28.

[0026] It can also be seen that the coater 14 has a blade 18 for the layer-by-layer application of the powdered component material (not shown) to the component platform 16. The blade 18 is designed to be movable, such that it can be at least partially retracted into the coater 14 during exposure of the powder layer in the region of the build-up and joining zone 20 by means of the high-energy beam 22. As an alternative to the blade 18, other smoothing devices such as doctor blades, lips, combs, or rollers can also be used.

[0027] Fig. 3 shows an enlarged schematic representation of a section of the Figure 2Device 10 shown in a sectional view. The extraction and / or gas supply device 36 is shown in the embodiment shown here as an extraction device that extracts process exhaust gases 12 that arise during the additive manufacturing of the component from a powder bed 38 of the component material. The powder bed 38 is applied to the component platform 16. The high-energy beam 22 is, in turn, directed such that it can penetrate between the intersection area of ​​the induction coils 24, 28 to the powder bed 38 in the area of ​​the build-up and joining zone 20.

[0028] The Fig. 1 to 3The illustrated embodiment of the device 10 may additionally comprise a control and / or regulating device and / or a temperature detection device, wherein the position and / or power of the induction coil(s) 24, 28 can be controlled and / or regulated as a function of the measurement results of the temperature detection device with the control and / or regulating device.

Claims

1. A device (10) for generatively producing at least one component area of a component, in particular of a component of a fluid-flow machine, comprising: - at least one coater (14) for applying at least one powder layer of a component material onto at least one construction and joining zone (20) of at least one lowerable component platform (16), wherein the coater (14) is movable in relation to the component platform (16); and - at least one radiation source for generating at least one high-energy beam (22), by means of which the powder layer can be locally melted and / or sintered to a component layer in the area of the construction and joining zone (20); wherein at least one suction and / or gas supply device (36) is mechanically connected to the coater (14), wherein the suction and / or gas supply device (36) is connected to the coater (14) such that a working and effective area of the high-energy beam (22) in the area of the construction and joining zone (20) is in an effective area (34) of the suction and / or gas supply device (36), characterized in that at least one heating device (24, 28) for heating the component material at least in the area of the construction and joining zone (20) of the component platform (16) is arranged at the coater (14) in displaceable or non-displaceable manner.

2. The device (10) according to claim 1, characterized in that the coater (14) includes at least one displacing unit (26), at which the at least one heating device (28) is arranged.

3. The device (10) according to claim 1 or 2, characterized in that the heating device (24, 28) includes an induction coil.

4. The device (10) according to any one of claims 1 to 3, characterized in that the high-energy beam (22) includes a laser or electron beam.

5. A method for generatively producing at least one component area of a component, in particular of a component of a fluid-flow machine, comprising at least the following steps: a) applying at least one powder layer of a component material onto at least one construction and joining zone (20) of at least one lowerable component platform (16); b) locally melting and / or sintering the component material in layers by supplying energy by means of at least one high-energy beam (22) in the area of the construction and joining zone (20) for forming a component layer; c) lowering the component platform (16) in layers by a predefined layer thickness; and d) repeating the steps a) to c) until completion of the component area, wherein before and / or during and / or after exposure by means of the high-energy beam (22), in particular fume deposits, spatter and / or process exhaust gases of the generative production process are removed from the construction and joining zone (20) by means of at least one suction and / or gas supply device (36), which is arranged on at least one coater (14) movable in relation to the component platform (16) for applying the component material, wherein the suction and / or gas supply device (36) is mechanically connected to the coater (14) such that a working and effective area of the high-energy beam (22) in the area of the construction and joining zone (20) is in an effective area (34) of the suction and / or gas supply device (36), characterized in that at least one heating device (24, 28) for heating the component material at least in the area of the construction and joining zone (20) of the component platform (16) is arranged at the coater (14) in displaceable or non-displaceable manner.