Method for taking at least one sample of metal powder and capsule for a sample of metal powder

Abstract

The invention relates to a method for taking a sample of metal powder (12A) during the manufacture of a part (50) by additive manufacturing from a metal powder (12), for example by laser melting on a bed of metal powder, the method comprising at least one manufacturing step, during which at least one capsule (30) containing metal powder (12A) is manufactured simultaneously with the manufacture of the part (50). Figure for the abstract: Fig. 1.

Description

Title of the invention: Method for taking at least one sample of metal powder and capsule for a sample of metal powder. Technical field

[0001] The present description relates to a method for taking at least one sample of metal powder during the manufacture of a part by additive manufacturing from metal powder. The present description also relates to a capsule for a sample of metal powder obtained by such a sampling method. Previous technique

[0002] Taking a sample of material during the manufacture of a part makes it possible to trace the different elements used for the manufacture of the part and to be able to carry out subsequent analyses, for example to try to identify the origin of a mechanical or physico / chemical behavior, an aging or even the origin of a possible defect of the part, and this throughout the entire life of the part.

[0003] In the context of parts manufactured by additive manufacturing from metal powder, metal powder is usually taken at the end of manufacturing, from the upper layers of powder or during the recovery of unsolidified powder.

[0004] Indeed, in additive manufacturing processes using metal powder, it is only possible to take samples of powder at the end of the manufacturing of the part, so as not to disrupt the manufacturing of the part itself, for example so as not to disrupt the controlled atmosphere in which the part is manufactured.

[0005] However, such sampling of known material is not faithfully representative of the material actually used in the part or in a specific area of ​​the part, so that possible analyses from such samples can only provide relatively approximate results.

[0006] There is therefore a need for sampling to enable more detailed and representative analyses. Description of the invention

[0007] One embodiment relates to a method of taking at least one sample of metal powder during the manufacture of a part by additive manufacturing from a metal powder, for example by laser melting on a bed of metal powder.

[0008] More particularly, the sampling process includes at least one manufacturing step during which at least one capsule containing metal powder is manufactured simultaneously with the manufacture of the part.

[0009] An additive manufacturing process by laser powder bed fusion is also known to those skilled in the art by the acronym "LBM" for "Laser Beam Melting" in English.

[0010] For example, a metal powder is a powder comprising at least 50% by mass of metal in powder form.

[0011] It is then possible to manufacture a single capsule, or a plurality of capsules to multiply the sampling areas of the metal powder. Hereafter, and unless otherwise indicated, "the capsule" means "at least one capsule".

[0012] The capsule manufactured simultaneously with the part fills, as the part is manufactured, in an internal volume of the capsule, with the successive layers of metal powder used for the manufacture of the part and the capsule.

[0013] Furthermore, slag and other projections may also be found in the capsule, within the sample of metal powder.

[0014] In other words, the capsule forms a receptacle, manufactured and filled with metal powder, slag, and projections, simultaneously with the manufacturing of the part. Upon completion of the part's manufacture, the capsule therefore contains a sample of metal powder and any slag and other projections, arranged layer by layer, corresponding to the layers of metal powder that were successively and selectively melted for the manufacture of the part.

[0015] Such a sample of metal powder is representative of the layers of metal powder used to manufacture the part. Furthermore, a subsequent analysis of any slag and projections can provide additional information on the quality of the material obtained after melting to produce the part.

[0016] In some embodiments, the capsule may extend over all or part of the height of the part, the height being the direction of stacking of successive layers of powder. In other embodiments, the capsule may extend beyond the height of the part, the height being the direction of stacking of successive layers of powder.

[0017] It is thus possible to obtain a representative sample of metal powder, according to the direction of the height, of only a portion or of the whole part, thanks to which it is possible to refine the fineness of the sampling according to the needs.

[0018] In some embodiments, the sampling process may include at least one sealing step, during which the capsule is sealed simultaneously with or after the manufacture of the part.

[0019] By sealing the capsule, that is, an internal volume of the capsule receiving the metal powder, any slag, and projections, the metal powder sample is hermetically sealed. This can make it possible to secure the collection of the metal powder, and in particular to ensure that the metal powder sample will not be accidentally spilled.

[0020] This can also allow the metal powder sample to be stored in a controlled atmosphere, or at least isolated from the outside. This makes it possible to better preserve the physicochemical characteristics of the metal powder thus collected for subsequent analysis. In particular, this can be especially advantageous when the metal powder contains metals susceptible to oxidation, such as aluminum, titanium, certain steels, etc.

[0021] By sealing the capsule, the internal volume of the capsule and the volume of metal powder collected are controlled. Knowing this internal volume, or predetermined volume, it is then possible, by simply measuring the mass of the capsule without opening it, to deduce the density of the metal powder, thus providing initial elements for analysis.

[0022] In some embodiments, the picking process may include at least one dispensing step, during which the capsule is dispensed from a manufacturing tray, in particular by cutting, notably by wire electrical discharge machining (EDM). Wire EDM is also known to those skilled in the art by the acronym "EMD" for "Electrical Discharge Machining".

[0023] The capsule can be attached to a build platform. The build platform can be an element of an additive manufacturing device in which the picking process is implemented. The part and / or the capsule can be manufactured attached to the build platform. When manufacturing is complete, the capsule can be removed from the platform, for example by cutting a base of the capsule attached to the platform using EMD.

[0024] In some embodiments, the removal step, during which the capsule is removed from the manufacturing platform, is prior to a heat treatment step of the part.

[0025] The final part can, for example, be subjected to heat treatment after its manufacture. Such heat treatment can take place while the part is still attached to the manufacturing platform, after the capsule has been previously deposited.

[0026] Depositing the capsule before any such heat treatment may help to preserve the metal powder and prevent possible alteration.

[0027] In certain embodiments, a laser powder bed fusion additive manufacturing device comprising at least one laser, in particular a plurality of lasers, can be used. The capsule containing the metal powder sample is then manufactured by the laser. In particular, each laser can be used to manufacture a capsule distinct from the capsules manufactured by the other lasers.

[0028] This can allow for further refined analysis, each capsule containing a sample of metal powder, slag and projections specific to each laser that was used to manufacture the part.

[0029] One embodiment relates to a capsule for a sample of metal powder obtained by the sampling process according to any of the embodiments described in this exposition.

[0030] It is understood that the capsule is filled with metal powder, slag, and spatter. For example, the capsule may be sealed. For example, the capsule is factory-sealed and forms a single unit containing a sample of metal powder, slag, and spatter. Such a capsule can be stored and archived for a long period before its contents are used for analysis.

[0031] In some embodiments, the capsule may comprise a base and a body delimiting an internal volume housing the metal powder sample. For example, the base may be more rigid than the body.

[0032] For example, the base may be more rigid than the body in compression, tension, torsion, and / or bending. Such a stiffness ratio may allow the base to withstand a cutting or removal step from a build platform of an additive manufacturing device without damaging the capsule, while still providing sufficient internal volume to hold the amount of metal powder required for subsequent analysis.

[0033] In some embodiments, the capsule may include a sealing plug for the internal volume housing the metal powder sample, in particular the sealing plug being able to be broken.

[0034] The sealing cap can be manufactured during a capsule sealing step.

[0035] Such a sealing cap can be configured so that, when separated from the rest of the capsule, it provides access to the internal volume and to the metal powder housed within the internal volume constituting the metal powder sample.

[0036] Such a configuration can, for example, prevent the metal powder sample housed within the capsule from being contaminated when the capsule is opened, such contamination being likely to occur if the capsule had to be machined, for example cut, to be opened.

[0037] In some embodiments, the sealing plug can be connected to a body, for example the body delimiting the internal volume housing the metal powder sample, by means of a sacrificial portion.

[0038] Such a sacrificial portion can, for example, form an intermediate portion, such as a bottleneck, connecting the sealing plug to the body, this intermediate portion having a thinned wall compared to the sealing plug and compared to the body, the thinned wall being able to be configured to break under the application of a predetermined mechanical stress on the sealing plug.

[0039] In some embodiments, the sealing plug may have a portion configured to be manipulated with a hand tool, the portion comprising, for example, at least one flat and / or at least one through hole.

[0040] For example, the sealing plug may have a general blade shape configured to be able to be gripped between the jaws of a clamp, or a screw head to be able to be manipulated with a wrench and / or a screwdriver.

[0041] For example, the sealing plug may have a through hole configured to receive the hand tool, for example a screwdriver shaft.

[0042] Such a configuration allows for easy handling and removal of the sealing plug relative to the rest of the capsule. Brief description of the drawings

[0043] The purpose of this presentation and its advantages will be better understood upon reading the detailed description below of various embodiments given by way of non-limiting examples. This description is made with reference to the accompanying figures, in which:

[0044] [Fig-1] The [Fig. 1] represents a perspective view of a step in a process for taking a sample of metal powder according to the invention;

[0045] [Fig.2] [Fig.2] represents a partial cross-sectional view along plane II of [Fig.1]; and

[0046] [Fig.3] Fig.3 represents a capsule obtained by the sampling process illustrated in Figures 1 and 2. Description of the implementation methods

[0047] Figures 1 and 2 respectively represent a perspective view and a partial cross-sectional view of a step in a metal powder sampling process according to the invention, in particular during the manufacture of a part by additive manufacturing from a metal powder.

[0048] More specifically, Figures 1 and 2 represent an additive manufacturing device 10 using metal powder 12. In the example shown, the device Additive manufacturing 10 is an additive manufacturing device using laser melting on a bed of metal powder.

[0049] In particular, the additive manufacturing device 10 includes - a manufacturing platform 14, - at least one laser 16, in particular a plurality of lasers 16, for example three lasers 16, and - at least one 18-powder-depositing blade of 12 metal powder.

[0050] The dispensing blade 18 may include a powder reservoir 18A. In addition, the dispensing blade 18 may have a powder dispensing nozzle 18B and at least one scraper 18C.

[0051] The squeegee 18C is configured to even out a layer of deposited metal powder 12.

[0052] Such an additive manufacturing device 10 is known elsewhere by those skilled in the art and is not described in further detail.

[0053] The additive manufacturing device 10 may also include any other powder deposition device.

[0054] On [Fig. 1], a volume of deposited metal powder 12 is symbolically represented by discontinuous lines 11.

[0055] To manufacture a part 50 using the additive manufacturing device 10, for example during manufacturing as shown in Figures 1 and 2, a first layer of metal powder 12 is deposited directly onto the manufacturing platform 14 using the depositing blade 18, to then be selectively melted using the laser 16, in particular the plurality of lasers 16.

[0056] Next, a new layer of metal powder 12 is deposited using the depositing blade 18, to then be selectively melted using the laser 16, in particular the plurality of lasers 16, and so on.

[0057] Figures 1 and 2 represent an intermediate manufacturing step of part 50. Of course, part 50 shown is purely illustrative and can have all sorts of shapes and sizes.

[0058] Furthermore, any metal powder suitable for such a type of additive manufacturing can be used.

[0059] A method for taking a sample of metal powder and an associated capsule 30 according to the present exposition will now be described in more detail with reference to Figures 1 to 3.

[0060] In Figures 2 and 3, only one capsule 30 is shown, but of course the following description applies to all the capsules 30 shown in [Fig. 1].

[0061] Figures 1 and 2 illustrate a method for taking at least one sample of metal powder 12A during the manufacture of part 50 by additive manufacturing from metal powder 12, for example by laser melting on a bed of metal powder.

[0062] More specifically, the process comprising at least one manufacturing step of at least one capsule 30 containing metal powder 12 simultaneously with the manufacturing of part 50.

[0063] In the example of [Fig.2], the capsule 30 in manufacture defines an internal volume V containing slag and projections 13, resulting from the manufacture of the part 50.

[0064] In the example shown, a capsule 30 containing metal powder 12 is manufactured by laser, namely three capsules 30 respectively manufactured with a laser 16.

[0065] Fig. 3 represents the capsule 30 obtained by the sampling process illustrated in Figures 1 and 2, in particular before the removal of the manufacturing tray 14.

[0066] More specifically, [Fig.3] represents capsule 30 when it is finished, part 50 also being finished.

[0067] In [Fig. 3], all the metal powder 12 that was not melted to make part 50, capsule 30, or that is not enclosed in capsule 30 has been removed. Therefore, only part 50 and capsule 30 filled with a sample of metal powder 12A remain.

[0068] According to the example shown in [Fig.3], the part 50 and the capsule 30 are still attached to the tray 14. In other words, [Fig.3] represents the capsule 30 containing the sample of metal powder 12A obtained by the sampling process according to the invention.

[0069] Furthermore, the sampling process may include a step of removing the capsule 30 from the tray 14, for example by wire electrical discharge machining (EDM). For this purpose, a cutting device 40, in particular a wire EDM device, may be used during the removal of the capsule 30.

[0070] According to an alternative embodiment, during the removal step, the part 50 can also be removed from the plate 14, simultaneously with the capsule 30, or sequentially, i.e. before or after the capsule 30.

[0071] According to another embodiment, during the removal step, the capsule 30 is only removed from the manufacturing platform 14, while the part 50 is left attached to the manufacturing platform 14, for example to then undergo a heat treatment step once the capsule 30 has been removed from the manufacturing platform 14.

[0072] In other words, in such another embodiment, the capsule 30 is deposited from the manufacturing platform 14 before a heat treatment step of the part 50 is carried out.

[0073] In the example of [Fig.3], the capsule 30 extends over the entire height H of the part 50, the height H extending along a stacking direction of the successive layers of metal powder 12.

[0074] During the manufacture of the capsule 30, during the sampling process of the present example, a sealing cap 30A is manufactured during a sealing step of the capsule 30.

[0075] According to one embodiment, during the sealing step, the sealing plug 30A is manufactured after the manufacturing of part 50 is completed.

[0076] In other words, in such an embodiment, the capsule 30 includes in a sealing cap 30A the internal volume V housing the sample of metal powder 12A.

[0077] Alternatively, according to another embodiment, during the sealing step, the sealing plug 30A is manufactured simultaneously with the completion of the manufacturing of the part 50. In particular, the sealing plug 30A may be breakable. For this purpose, the sealing plug 30A may be connected to a body 30B of the capsule 30, delimiting the internal volume V housing the metal powder sample 12A, via a sacrificial portion 30C. Specifically, the sacrificial portion 30C may form an intermediate portion, such as a neck, having a wall PI that is thinner than a wall PB of the sealing plug 30A and than a wall PC of the body 30B.

[0078] Thus, the thinned wall PI of the sacrificial portion 30C can be configured to break under the application of a predetermined mechanical stress on the sealing plug 30A.

[0079] The sealing cap 30A may also have a portion 30A1 configured to be manipulated with a hand tool (not shown), such as pliers, a wrench, a screwdriver, a rod, etc.

[0080] In the example of [Fig.3], the portion 30A1 comprises two flats 30A11 formed on two opposite faces of the sealing plug 30A. In particular, the flats 30A11 are, for example, parallel to the plane of [Fig.3].

[0081] Furthermore, portion 30A1 also includes a through hole 30A12, into which the hand tool can be inserted and used as a lever to detach the sealing plug 30A from the body 30B.

[0082] Furthermore, the capsule 30 may include a base 30D. The base 30D and the body 30B delimit the internal volume V housing the metal powder sample 12A.

[0083] In particular, the 30D base is more rigid than the 30B body.

[0084] According to one embodiment, the body 30B has a cylindrical shape with its axis extending along the direction of the height H, and may have a circular cross-section. However, any other shape is possible.

[0085] The base 30D can substantially have a solid disc shape, allowing the rigidity of the base 30D to be greater than the rigidity of the body 30B.

[0086] The internal volume V of capsule 30 is predetermined.

[0087] Although the present invention has been described with reference to specific embodiments, it is evident that modifications and changes can be made to these examples without departing from the general scope of the invention as defined by the claims. In particular, individual features of the various embodiments illustrated / mentioned can be combined in additional embodiments. Therefore, the description and drawings should be considered in an illustrative rather than a restrictive sense.

[0088] It is also evident that all the characteristics described with reference to a sampling process are transposable, alone or in combination, to the additive manufacturing device 10, and conversely, all the characteristics described with reference to an additive manufacturing device 10 are transposable, alone or in combination, to a sampling process.

Claims

Demands

1. A method for taking at least one sample of metal powder (12A) during the manufacture of a part (50) by additive manufacturing from metal powder (12), for example by laser melting on a metal powder bed, the method comprising at least one manufacturing step, during which at least one capsule (30) containing metal powder (12) is manufactured simultaneously with the manufacture of the part (50), and comprising at least one deposition step, during which the capsule (30) is deposited from a manufacturing platform (14), in particular by cutting, in particular by wire electrical discharge machining, in which the deposition step is prior to a heat treatment step of the part (50).

2. A sampling method according to claim 1, comprising at least one sealing step, during which the capsule (30) is sealed simultaneously with or after the manufacture of the part (50).

3. Sampling method according to claim 1 or 2, wherein a laser powder bed fusion additive manufacturing device (10) comprising at least one laser (16) is used, and wherein the capsule (30) containing the metal powder sample (12A) is manufactured by the laser (16).

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