Method and device for producing a material layer
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- PROBEAM AG & CO KGAA
- Filing Date
- 2024-07-30
- Publication Date
- 2026-06-10
Smart Images
Figure EP2024071566_13022025_PF_FP_ABST
Abstract
Description
[0001] Method and device for producing a material layer
[0002] The invention relates to a method for producing a material layer from a first metal material and from a second metal material.
[0003] Furthermore, the invention is directed to a device for producing a material layer from a first metal material and from a second metal material.
[0004] Processes in which materials are applied layer by layer are also referred to as additive or generative manufacturing processes. The materials can be provided in the form of powder or wire. Such processes are characterized by the fact that a three-dimensional component to be produced is assembled from individual volume elements with a near-net shape. If, as is the case here, two or more starting materials are processed, they are also referred to as multi-material processes. In this context, a metal material is understood to be a material that comprises a metal. A metal material can therefore comprise or consist of a single metal or a single metal alloy. Furthermore, the term metal material also includes composite materials with a metallic matrix, which are also known as metal matrix composites (MMC).Filled wires, whose sheath comprises a metal and whose core comprises a non-metallic material, such as a ceramic material, are also considered metal materials. Filled wires, whose sheath comprises a metal and whose core comprises a metallic material, such as in powder form or as wire, are also considered metal materials.
[0005] In the area of multi-material processes, it is also known that only those
[0006] Starting materials can be processed into a three-dimensional component, the
[0007] TOP:TOP are similar in terms of their melting properties. This is also referred to as compatibility of the starting materials. In other words, in multi-material processes, the starting materials used cannot be freely combined. Therefore, only certain combinations of starting materials are available for multi-material processes. This applies particularly to metals used as starting materials.
[0008] The object of the present invention is therefore to further develop methods for producing a material layer from a first metal material and a second metal material such that an increased range of metal materials can be combined with one another.
[0009] The object is achieved by a method for producing a material layer from a first metal material and a second metal material. The method comprises
[0010] - Providing the first metal material and the second metal material in a process zone, wherein the first metal material assumes a solid state of aggregation and wherein the second metal material assumes a solid state of aggregation,
[0011] - directing an energy beam onto a section of the first metal material to be liquefied and heating the section of the first metal material to be liquefied by means of the energy beam,
[0012] - directing the energy beam onto a portion of the second metal material to be liquefied and heating the portion of the second metal material to be liquefied by means of the energy beam, and
[0013] - introducing the section of the first metal material to be liquefied and the section of the second metal material to be liquefied into a common molten bath and mixing the first metal material and the second
[0014] Metal material in the common melt pool or
[0015] Heating the section of the first metal material to be liquefied and the section of the second metal material to be liquefied by means of the energy beam until the first metal material and the second metal material are liquefied and mixed.
[0016] In this method, the energy beam is directed one after the other, i.e. sequentially, at a section of the first metal material to be liquefied and at a section of the second metal material to be liquefied. The first metal material and the second metal material are heated by the energy beam. It is understood that the energy beam is not directed at the second metal material when it is directed at the first metal material. Likewise, the energy beam is not directed at the first metal material when it is directed at the second metal material. In other words, the energy beam is only directed at one of the first metal material and the second metal material at any one time and never at the first metal material and the second metal material at the same time. The focus of the energy beam is not important.This means that the energy beam can be focused on the first metal material when directed at the first metal material, or defocused relative to the first metal material when directed at the first metal material. The same applies to the second metal material. This means that the energy beam can be focused on the second metal material when directed at the second metal material, or defocused relative to the second metal material when directed at the second metal material. To make this geometrically possible, at least those sections of the first...
[0017] The metal material and the second metal material, at which the energy beam is directed, are arranged next to one another when viewed along a beam direction of the energy beam. The energy beam can also be directed alternately at the first metal material and the second metal material. By directing the energy beam sequentially at the first metal material and the second metal material, the energy and / or power introduced into the first metal material and the second metal material by means of the energy beam can be adjusted independently of one another with high precision. This also means that the energy and / or power introduced into the first metal material by means of the energy beam and the energy and / or power introduced into the second metal material by means of the energy beam can be very different.This means that metal materials with very different properties, in particular very different melting properties, can be processed into a component. Consequently, using the method according to the invention, metal materials that were previously considered incombinable or incompatible can be processed into a material layer. The processing to form the material layer can take place according to two alternatives. According to the first alternative, the first metal material and the second metal material are heated by means of the energy beam, but not directly melted by means of the energy beam. In this alternative, the melting of the first metal material and the second metal material takes place by introducing the first metal material and the second metal material into a common molten pool.It is understood that in this context the first metal material and / or the second metal material are heated by means of the energy beam to a temperature which is below the respective melting temperature, but preferably close to the respective melting temperature. According to a second alternative, the first metal material and the second metal material are heated by means of the energy beam until they liquefy, i.e. are melted by means of the energy beam. In this alternative, a liquid bridge forms between the still existing molten pool and each of the first metal material and the second metal material. The first metal material and the second metal material are thus introduced into the shared molten pool via the respective liquid bridge. Consequently, a material layer can be produced which comprises both the first metal material and the second metal material.The production of such material layers is particularly advantageous when the resulting material mixture, alloy or intermetallic compound is difficult to process mechanically and / or when it is not available as a starting material. In connection with the method according to the invention, the fact that at least those sections of the first metal material and the second metal material at which the energy beam is directed are arranged next to one another when viewed along a beam direction of the energy beam is to be understood such that these sections do not overlap when viewed along the beam direction of the energy beam. In a case in which the first metal material and the second metal material are provided in wire form or in rod form, an orientation or alignment of the respective wires or rods is not important.
[0018] It goes without saying that the method according to the invention can also be used to process three or more metal materials into a single component. In this case, the energy beam is directed at only one of the metal materials at a time to heat it. The energy beam thus bounces back and forth between the three or more metal materials.
[0019] It is further understood that the method according to the invention can also be carried out multiple times, so that multiple material layers can be produced. The multiple material layers can be arranged three-dimensionally to result in a three-dimensional, multi-layer workpiece. The method according to the invention can thus also be referred to as a method for producing a workpiece or component comprising multiple material layers.
[0020] In the context of the present invention, the material layer can be built up on a substrate. The substrate can be a component or a section of a component, for example, a section produced using the method according to the invention. Alternatively, the substrate can be formed by a carrier different from the component.
[0021] According to one embodiment, the method comprises setting a first
[0022] Process parameter, while the energy beam is directed at the section of the first metal material to be liquefied. While the energy beam is directed at the section of the second metal material to be liquefied, a second process parameter is set. The first process parameter and the second process parameter are different. In this context, the term setting a process parameter can be understood to mean that the respective process parameter is already set when the energy beam is directed at the section of the first metal material or the second metal material to be liquefied. The process parameter is therefore constant while the energy beam is directed at the section of the first metal material or the second metal material to be liquefied.Furthermore, the term “adjusting a process parameter” can be understood to mean that the process parameter is adjusted while the energy beam is directed at the section of the first metal material or the second metal material to be liquefied. In this context, the process parameter therefore changes while the energy beam is directed at the section of the first metal material or the second metal material to be liquefied. The first process parameter is, in particular, a first performance parameter of the energy beam. The second process parameter is, in particular, a second performance parameter of the energy beam. In other words, the power of the energy beam is preferably different when it is directed at the first metal material and when it is directed at the second metal material.Consequently, the energy and / or power introduced into the first metal material by means of the energy beam and introduced into the second metal material can be adjusted independently of one another. This means that metal materials can be processed into a material layer or a workpiece that have very different properties, in particular very different melting properties. Likewise, the first process parameter can comprise a first feed parameter that describes a feed characteristic for the first metal material. The second process parameter can comprise a second feed parameter that describes a feed characteristic for the second metal material. If the first feed parameter and the second feed parameter are different, the first metal material and the second metal material are fed in different ways, for example at different feed speeds.In this way, metal materials can also be used.
[0023] material layer or a workpiece which have very different properties, in particular very different melting properties.
[0024] In a case where the energy beam is an electron beam, exemplary performance parameters are a current for generating the energy beam and an accelerating voltage.
[0025] An example of a performance parameter in this context is an irradiation time, i.e., the length of a period during which the energy beam is directed at the first metal material or the second metal material. In this context, it is also conceivable for a performance parameter of the energy beam to change while the energy beam is directed at the first metal material or the second metal material. For example, a performance parameter can change periodically. In this context, the performance parameter can be expressed as a frequency.
[0026] The energy beam can be directed at the section of the first metal material to be liquefied using a first irradiation pattern. The energy beam can also be directed at the section of the second metal material to be liquefied using a second irradiation pattern. The first irradiation pattern and the second irradiation pattern can be different. In this context, an irradiation pattern is understood to be a path on a surface of the first metal material or the second metal material along which the energy beam moves while being directed at the first metal material or the second metal material. A simple example of an irradiation pattern is a point or a line. Another example of an irradiation pattern is a circle or an ellipse.In this context, the energy beam is guided along a circular line or along an elliptical line on the surface of the first metal material or the second metal material, while being directed at the first metal material or the second metal material. Alternatively, an irradiation pattern can also comprise two or more nested, for example concentrically arranged, circles. An irradiation pattern can also be made up of a plurality of points or lines. An alternative term for an irradiation pattern is a raster pattern or an oscillation pattern. One parameter of an irradiation pattern is an irradiation frequency or oscillation frequency. The irradiation frequency or oscillation frequency describes the frequency, i.e. how often per unit of time, with which an irradiation pattern is traversed.In a case where the irradiation pattern is composed of a plurality of points or lines, the irradiation frequency or oscillation frequency can also specify the number of points of the irradiation pattern that are approached per unit of time. By selecting an appropriate irradiation pattern, the power or energy, as well as its local distribution in the first metal material or the second metal material, can be precisely adjusted. If different irradiation patterns are selected for the first metal material and the second metal material, different properties, in particular different melting properties of the first metal material, can be achieved.
[0027] metal material and the second metal material are taken into account and the first metal material and the second metal material are still processed into a material layer or into a workpiece.
[0028] For example, the energy beam is directed alternately at the first metal material and the second metal material, with at least ten alternations occurring per second. The alternating frequency is therefore at least 10 Hz. In other words, the energy beam oscillates between the first metal material and the second metal material. If an alternating frequency of at least 10 Hz is selected, the first metal material and the second metal material can be heated virtually simultaneously by the energy beam. Furthermore, the alternating frequency of at least 10 Hz enables precise and reliable heating. It should be noted that the term "multi-beam technology" is often used for beam-based manufacturing processes in which the energy beam is directed alternately at a first material and a second material.However, this is not strictly correct, since only a single beam of energy is used, but it jumps back and forth between the first material and the second material in such a way that the impression of two separate beams is created.
[0029] According to one variant, the first metal material can be characterized by a first melting parameter. The second metal material can be characterized by a second melting parameter. The first melting parameter and the second melting parameter can differ. Example melting parameters are a melting temperature, a vapor pressure, an evaporation temperature, and a melting energy. By directing the energy beam sequentially onto the first metal material and the second metal material, the different melting parameters can be taken into account during production of the material layer such that the first metal material and the second metal material are present in a predetermined ratio in the material layer. In particular, this can prevent one of the first metal material and the second metal material from undesirably evaporating.The result is a material layer or a workpiece with the desired material properties.
[0030] Preferably, an alloy and / or an intermetallic compound is formed when the first metal material and the second metal material are mixed. In other words, an alloy and / or an intermetallic compound is formed when the material layer is produced. This is also referred to as the alloy and / or the intermetallic compound being formed “in situ.” As already mentioned, this method can be used to produce material layers from alloys and / or intermetallic compounds whose components in the form of the first metal material and the second metal material have very different properties, in particular very different melting properties. Furthermore, this method can be used to produce material layers from alloys and / or intermetallic compounds that are not available on the market as starting materials.
[0031] Thus, for example, the following intermetallic compounds can be produced: aluminides, in particular iron aluminides, titanium aluminides, nickel-based superalloys such as Ni3Al or NiAl, shape memory alloys such as Nitinol (NiTi), high-alloyed chromium and chromium-nickel steels, or even copper or niobium-tin phases.
[0032] Preferably, the first metal material and / or the second metal material comprises titanium and / or copper.
[0033] In one example, the first metal material and / or the second metal material is / are provided in wire form. Using the energy beam, sections of the wire are heated and melted directly or indirectly. Such manufacturing processes are also referred to as wire-based additive manufacturing processes. Such processes allow for the production of near-net-shape, three-dimensional workpieces in a comparatively short time.
[0034] As already explained, in cases in which the first metal material and / or the second metal material are provided in wire form, the orientation or alignment of the respective wires is not important. In a first preferred embodiment in which both the first metal material and the second metal material are provided in wire form, the respective wires enclose an acute angle. In a second preferred embodiment, the respective wires are provided substantially at right angles to one another. In a third preferred embodiment, the respective wires are oriented opposite to one another, thus enclosing an angle of substantially 180°. In a first variant of this embodiment, the wires are oriented along a material application direction or travel direction.Thus, one wire, made of the first metal material and the second metal material, is provided in a trailing manner, and the other, made of the first metal material and the second metal material, is provided in a piercing manner. In a second variant of this embodiment, both wires are oriented essentially perpendicular to the material deposition direction or travel direction. In a case where the method for producing a material layer is a welding process, the material deposition direction can also be referred to as the welding direction.
[0035] In another example, in which the first metal material and the second metal material are provided in wire form, these wires can differ not only in terms of the metal material but also in terms of their diameter and / or cross-section. In this way, the ratio of the first metal material to the second metal material in the material layer can be easily influenced.
[0036] The method can also include directing the energy beam at the shared molten pool. This means that the energy beam is directed sequentially at the first metal material, the second metal material, and the molten pool. The energy beam can of course also be directed multiple times at each of the first metal material, the second metal material, and the molten pool. The order in which the energy beam is directed sequentially at the first metal material, the second metal material, and the molten pool can always be the same, or it can change during the process. By directing the energy beam at the molten pool, a defined energy or power can be introduced into the molten pool. More generally, the molten pool can be controlled using the energy beam. This particularly concerns the temperature of the molten pool.In this way, the mixing of the first metal material and the second metal material and / or a chemical or physical reaction between the first metal material and the second metal material can be influenced, in particular controlled. Thus, a high-quality material layer can be produced.
[0037] It is understood that the energy beam can be directed at the molten pool using a third irradiation pattern. In a preferred example, the energy beam is directed at the first metal material using the first irradiation pattern, at the second metal material using the second irradiation pattern, and at the molten pool using the third irradiation pattern. Consequently, the energy or power input into each of the first metal material, the second metal material, and the molten pool can be precisely and reliably adjusted, allowing a high-quality material layer to be produced.
[0038] The energy beam can be an electron beam. Such an energy beam has the advantage that it can be directed with the utmost precision onto the first metal material, the second metal material, and / or the molten pool. Furthermore, such an energy beam has a relatively high energy density. Furthermore, its orientation can be changed—i.e., deflected—with high speed and precision. This makes the electron beam particularly well-suited for the present process, which requires directing the energy beam sequentially onto the first metal material, the second metal material, and optionally also onto the molten pool.
[0039] In addition, the object is achieved by a device for producing a
[0040] Material layer made of a first metal material and a second metal material. The device is designed to carry out a method according to the invention. Such a device is consequently designed to direct the energy beam sequentially, ie sequentially, onto a section of the first metal material to be liquefied.
[0041] metal material and onto a section of the second metal material to be liquefied. As already mentioned, it is understood that the energy beam is not directed at the second metal material when it is directed at the first metal material. Likewise, the energy beam is not directed at the first metal material when it is directed at the second metal material. In other words, the device is designed to direct the energy beam at only one of the first metal material and the second metal material at any one time, and never at the first metal material and the second metal material at the same time. The device can also be designed to direct the energy beam alternately at the first metal material and the second metal material.To make this geometrically possible, at least those sections of the first metal material and the second metal material onto which the energy beam is directed are arranged next to one another when viewed along a beam direction of the energy beam. By directing the energy beam sequentially onto the first metal material and onto the second metal material, the energy and / or power introduced into the first metal material and the second metal material by means of the energy beam can be adjusted independently of one another with high precision. This also means that the energy and / or power introduced into the first metal material by means of the energy beam and the energy and / or power introduced into the second metal material by means of the energy beam can be very different.This means that metal materials can be processed into a material layer or a workpiece that have very different properties, in particular very different melting properties. Consequently, using the device according to the invention, metal materials that were previously considered incompatible or incompatible can be processed into a material layer. Consequently, a material layer can be produced that comprises both the first metal material and the second metal material. The production of such material layers is particularly advantageous when the resulting material mixture, alloy, or intermetallic compound is difficult to process mechanically and / or when it is not available as a starting material.
[0042] The invention is explained below using various embodiments shown in the accompanying drawings. They show:
[0043] Figure 1 shows a device according to the invention for producing a
[0044] Material layer made of a first metal material and a second metal material, by means of which a method according to the invention for producing a material layer made of a first metal material and a second metal material is carried out,
[0045] Figure 2 is a detailed view of a process zone of the device of Figure 1 along a direction II in Figure 1, and
[0046] Figures 3 to 5 of Figure 2 corresponding views of alternative embodiments of the device.
[0047] Figure 1 shows a device 10 for producing a material layer 12 from a first metal material 14 and a second metal material 16. In the example shown, the first metal material 14 is aluminum and the second metal material 16 is titanium.
[0048] In the example shown in Figure 1, a three-dimensional component 18 is manufactured from a plurality of such material layers 12. It is understood that the material layers 12 shown are merely illustrative.
[0049] As will be explained in more detail later, the material layers 12 and thus the three-dimensional component 18 are made of titanium aluminide, an intermetallic compound of titanium and aluminum. This is a low-density material with very good strength and rigidity properties. Titanium aluminide is also suitable for use in high-temperature applications with ambient temperatures of up to 750°C. One example of this application is gas turbines.
[0050] The device 10 comprises a vacuum chamber 20 in which a work table 22 is positioned. A lifting unit 24 is provided on the underside of the work table 22, by means of which the work table 22 can be moved in the vertical direction. Furthermore, the work table 22 can be rotated about the vertical direction and moved within a horizontal plane. Optionally, the work table 22 can be tilted about a horizontal direction. The component 18 is built on an upper side of the work table 22, so that the work table 22 can also be regarded as a substrate 26 for the layer-by-layer construction of the component 18.
[0051] A section of the interior of the vacuum chamber 20, which is bounded at the bottom by the top of the work table 22, thus represents a construction space 28. It is understood that the construction space 28 is also bounded at the top and to the sides. These limitations result from the limits of the relative mobility of the work table 22 with respect to the feed units 30, 32, which will be explained in more detail below.
[0052] The device 10 further comprises a first feed unit 30, which is designed to convey the first metal material 14 into the build space 28, more precisely into a process zone. In this case, the first metal material 14 is provided in the form of a wire. The first feed unit 30 can therefore also be referred to as a first wire conveyor.
[0053] Furthermore, the device 10 comprises a second feed unit 32, which is designed to convey the second metal material 16 into the build space 28, more precisely into the process zone. In the example shown, the second metal material 16 is also provided in the form of a wire. The second feed unit 32 can therefore be referred to as a second wire conveyor.
[0054] The device also includes a beam generating unit 34 configured to generate an energy beam 36. In the illustrated embodiment, the energy beam is an electron beam.
[0055] In addition, the beam generation unit 34 also includes a deflection unit 38. The deflection unit 38 includes a plurality of magnetic coils, by means of which the energy beam 36 can be oriented within the construction space 28. This means that the energy beam 36 can be selectively directed to different points within the construction space 28 by means of the deflection unit 38. The device 10 is further configured to carry out a method for producing a material layer 12 from the first metal material 14 and from the second metal material 16.
[0056] This method is explained below with reference to Figure 2. Figure 2 shows a detailed view of a process zone along a direction II in Figure 1. The
[0057] Material layer 12 is generated from left to right in the representation according to Figure 2, which is to be understood purely as an example.
[0058] In a first step S1, the first metal material 14 and the second metal material 16 are provided in the process zone. Both the first metal material 14 and the second metal material 16 assume a solid state.
[0059] As already mentioned, both the first metal material 14 and the second metal material 16 are provided in wire form. Figure 2 therefore shows one end of the wire made of the first metal material 14, i.e., one end of an aluminum wire, and one end of the wire made of the second metal material 16, i.e., one end of a titanium wire.
[0060] The ends of the wires are arranged side by side in the view of Figure 2, which corresponds to a view along a beam direction of the energy beam 36. This means that the ends of the wires neither overlap nor touch in this view.
[0061] In the embodiment shown in Figure 2, the wires form an acute angle.
[0062] In a second step S2, the energy beam 36 is directed by the deflection unit 38 onto a section of the first metal material 14 to be liquefied. The section of the first metal material 14 to be liquefied is essentially the corresponding wire end.
[0063] For this purpose, a first irradiation pattern 40 is used, which is symbolized by a dashed rectangle in the illustrated embodiment. The first irradiation pattern 40 comprises a path on a surface of the first metal material 14 along which the energy beam 36 is guided while being directed onto the first metal material 14.
[0064] The energy beam 36 is characterized by a first power parameter. In the illustrated embodiment, the first power parameter relates to an energy density. For ease of explanation, this energy density is constant for the entire irradiation pattern 40. Thus, the energy density does not change while the energy beam 36 is guided along the irradiation pattern 40. This may, of course, be different in other embodiments.
[0065] The first metal material 14, more precisely its section to be liquefied, is thus heated by means of the energy beam 36.
[0066] Since the second metal material 16 is arranged along the beam direction next to the first metal material 14, the energy beam 36 is not directed at the second metal material 16.
[0067] In a third step S3, the energy beam 36 is directed by means of the deflection unit 38 onto a section of the second metal material 16 to be liquefied. The section of the second metal material 16 to be liquefied is essentially the corresponding wire end.
[0068] A second irradiation pattern 42 is used, symbolized by a dashed rectangle in the illustrated embodiment. The second irradiation pattern 42 comprises a path on a surface of the second metal material 16 along which the energy beam 36 is guided while being directed onto the second metal material 16.
[0069] The energy beam 36 is characterized by a second performance parameter. In the illustrated embodiment, the second performance parameter relates to an energy density. For ease of explanation, this energy density is constant for the entire irradiation pattern 42. Thus, the energy density does not change while the energy beam 36 is guided along the irradiation pattern 42. This may, of course, be different in other embodiments.
[0070] The second metal material 16, more precisely its section to be liquefied, is thus heated by means of the energy beam 36.
[0071] In a fourth step S4, the energy beam 36 is subsequently directed onto a melt pool 44 by means of the deflection unit 38.
[0072] A third irradiation pattern 46 is used, symbolized by a dashed rectangle in the illustrated embodiment. The third irradiation pattern 46 comprises a path on a surface of the melt pool 44 along which the energy beam 36 is guided while being directed onto the melt pool 44.
[0073] The energy beam 36 is characterized by a third performance parameter. In the illustrated embodiment, the third performance parameter relates to an energy density. For ease of explanation, this energy density is constant for the entire irradiation pattern 46. The energy density therefore does not change while the energy beam is guided along the irradiation pattern 46. This may, of course, be different in other embodiments.
[0074] The melt pool 44 is thus kept at a desired temperature by means of the energy beam 36.
[0075] In the present process, the first metal material 14, which is aluminum, and the second metal material 16, which is titanium, are processed into a material layer 12 made of titanium aluminide. The material layer 12 made of titanium aluminide must therefore have a correct stoichiometric ratio of aluminum to titanium. The fact that the melting parameters of the first metal material 14 and the second metal material 16 differ significantly must be taken into account. In this case, the melting parameters relate to a melting temperature. This is 660°C for aluminum and 1668°C for titanium.
[0076] To produce the desired titanium aluminide in the material layer 12, both the first metal material 14 and the second metal material 16 must be liquid. At the same time, evaporation of the metal material with the lower melting temperature, i.e., the first metal material 14, must be avoided. Otherwise, the correct stoichiometric ratio of aluminum to titanium could not be maintained.
[0077] This is achieved in the present method by differentiating the first power parameter, the second power parameter, and the third power parameter. The second power parameter, i.e., the second energy density of the energy beam 36, is higher than the first power parameter and the third power parameter, i.e., higher than the first energy density and the third energy density of the energy beam 36.
[0078] Furthermore, the first performance parameter, i.e. the first energy density of the energy beam 36, is higher than the third performance parameter, i.e. the third energy density of the energy beam 36.
[0079] In addition, the first irradiation figure 40, the second irradiation figure 42 and the third irradiation figure 46 differ.
[0080] In particular, a path of the energy beam 36 described by the first irradiation figure 40 is shorter than a path described by the second irradiation figure 42. A path described by the third irradiation figure 46 is even shorter than the path described by the first irradiation figure 40. In this way, in a fifth step S5, both the section of the first metal material 14 to be liquefied and the section of the second metal material 16 to be liquefied are heated by means of the energy beam 36 until liquefaction and can be mixed in the molten bath 44. This creates so-called liquid bridges between the sections of the wires made of first metal material 14 and second metal material 16 in the solid state and the molten bath 44. In order to maintain these, the wires made of first metal material 14 and second metal material 16 are fed by means of the first feed unit 30 orby means of the second feed unit 32 towards the melt pool 44. The feed speed is essentially the same.
[0081] In an alternative embodiment of the fifth step S5, the sections of the first metal material 14 and the second metal material 16 to be liquefied are heated by the energy beam 36 only to a temperature below their respective melting temperature. The actual melting then only occurs when the sections of the first metal material 14 and the second metal material 16 to be liquefied enter the melt pool 44.
[0082] In order to produce the entire component 18 from the material layers 12, the energy beam 36 is directed sequentially and alternately at the first metal material 14, the second metal material 16, and the molten pool 44. This occurs periodically. Within one second, the energy beam is directed at least ten times at the first metal material 14, at least ten times at the second metal material 16, and at least ten times at the molten pool 44, using the respective first irradiation pattern 40, second irradiation pattern 42, and third irradiation pattern 46.
[0083] The position of the work table 22 is adjusted by means of the lifting unit 24 during the construction of the component 18. Figures 3 to 5 show alternative embodiments of the device 10, each showing a process zone in a view corresponding to Figure 2. Accordingly, the method for producing the material layer 12 carried out by means of the device 10 also changes.
[0084] In the following, only the differences from the embodiment of the device 10 and the method already explained with reference to Figures 1 and 2 will be discussed.
[0085] The differences always concern the orientation or feed direction of the first metal material 14 provided in the form of a wire and the second metal material 16 provided in the form of a wire.
[0086] In the embodiment according to Figure 3, the ends of the wires face each other, with the feed directions of the wires, ie, the first metal material 14 and the second metal material 16, being opposite each other. In the region of the molten pool 44, the wires made of the first metal material 14 and the second metal material 16 are thus arranged essentially in a line, with the respective ends facing each other.
[0087] Thus, in the variant of Figure 3, the first metal material 14 is introduced into the melt pool 44 in a dragging manner and the second metal material 16 is introduced in a piercing manner.
[0088] In the embodiment according to Figure 4, the wires made of first metal material 14 and second metal material 16 are also arranged essentially in a line in the region of the molten pool 44. However, the wires are now oriented perpendicularly with respect to a material application direction or travel direction.
[0089] Another embodiment is shown in Figure 5. Here the wires are made of first
[0090] Metal material 14 and second metal material 16 are oriented at right angles to each other. The second metal material 16 is introduced slowly into the molten pool 44, and the first metal material 14 is introduced laterally. For further details, please refer to the above explanations.
[0091] List of reference symbols
[0092] 10 Device
[0093] 12 material layers
[0094] 14 first metal material
[0095] 16 second metal material
[0096] 18 component
[0097] 20 V vacuum chamber
[0098] 22 work table
[0099] 24 lifting unit
[0100] 26 Substrat
[0101] 28 installation space
[0102] 30 first feed unit
[0103] 32 second feed unit
[0104] 34 Beam generation unit
[0105] 36 Energy Beam
[0106] 38 Deflection unit
[0107] 40 first irradiation figure
[0108] 42 second irradiation figure
[0109] 44 Melt bath
[0110] 46 third irradiation figure
[0111] SI first step
[0112] S2 second step
[0113] S3 third step
[0114] S4 fourth step
[0115] S5 fifth step
Claims
Patent claims 1. A method for producing a material layer (12) from a first metal material (14) and from a second metal material (16), comprising - Providing the first metal material (14) and the second metal material (16) in a process zone, wherein the first metal material (14) assumes a solid state of aggregation and wherein the second metal material (16) assumes a solid state of aggregation (S1), - directing an energy beam (36) onto a section of the first metal material (14) to be liquefied and heating the section of the first metal material (14) to be liquefied by means of the energy beam (36) (S2), - directing the energy beam (36) onto a section of the second metal material (16) to be liquefied and heating the section of the second metal material (16) to be liquefied by means of the energy beam (36) (S3), and - introducing the section of the first metal material (14) to be liquefied and the section of the second metal material (16) to be liquefied into a common melt bath (44) and mixing the first metal material (14) and the second metal material (16) in the common melt bath (44) or heating the section of the first metal material (14) to be liquefied and the section of the second metal material (16) to be liquefied by means of the energy beam (36) until the first metal material (14) and the second metal material (16) (S5).
2. The method according to claim 1, further comprising setting a first process parameter, in particular a first power parameter of the energy beam (36), while the energy beam (36) is directed onto the section of the first metal material (14) to be liquefied, and setting a second process parameter, in particular a second power parameter of the energy beam (36), while the energy beam (36) is directed onto the section of the second metal material to be liquefied (16), wherein the first process parameter and the second process parameter differ.
3. Method according to claim 1 or 2, wherein the energy beam (36) is directed onto the section of the first Metal material (14) is directed and wherein the energy beam (36) is directed onto the section of the second metal material (16) to be liquefied using a second irradiation pattern (42), wherein the first irradiation pattern (40) and the second irradiation pattern (42) differ.
4. Method according to one of the preceding claims, wherein the energy beam (36) is directed alternately onto the first metal material (14) and the second metal material (16), with at least ten alternations being carried out per second.
5. Method according to one of the preceding claims, wherein the first metal material (14) is characterized by a first melting parameter and the second Metal material (16) is characterized by a second melting parameter, wherein the first melting parameter and the second melting parameter differ.
6. Method according to one of the preceding claims, wherein an alloy and / or an intermetallic compound is formed when the first metal material (14) and the second metal material (16) are mixed.
7. Method according to one of the preceding claims, wherein the first metal material (14) and / or the second metal material (16) is / are provided in wire form.
8. The method according to any one of the preceding claims, further comprising directing the energy beam (36) onto the common molten pool (44) (S4).
9. Method according to one of the preceding claims, wherein the energy beam (36) is an electron beam.
10. Device (10) for producing a material layer (12) from a first metal material (14) and from a second metal material (16), arranged to carry out a method according to one of the preceding claims.