Method and apparatus for manufacturing a material layer

Abstract

A method for producing a material layer (12) from a first metallic material (14) and a second metallic material (16) is described. The first metallic material (14) and the second metallic material (16) are provided inside a process zone, and the first metallic material (14) and the second metallic material (16) are in a solid state. Next, an energy beam is directed to the liquefied portion of the first metallic material (14). Furthermore, an energy beam is directed to the liquefied portion of the second metallic material (16). Furthermore, the liquefied portions are introduced into a common molten bath (44) and mixed. Alternatively, the liquefied portions are heated by the energy beam until liquefied and then mixed. Furthermore, an apparatus configured to carry out such a method for producing a material layer (12) from a first metallic material (14) and a second metallic material (16) is provided.

Description

Technical Field

[0001] The present invention relates to a method for producing a material layer from a first metallic material and a second metallic material.

[0002] Furthermore, the present invention relates to an apparatus for producing a material layer from a first metallic material and a second metallic material.

Background Art

[0003] Methods in which materials are stacked layer by layer are also referred to as additive manufacturing processes or generative manufacturing processes. In this process, the material is provided in powder or wire form. This type of process is characterized in that the three-dimensional component to be manufactured is assembled from individual volume elements in a near-net shape (a shape close to the final shape). When two or more starting materials are processed as in the present case, this is referred to as a multi-material process. In this context, a metallic material means a material containing metal. Therefore, the metallic material can comprise or consist of a single metal or a single metal alloy. Furthermore, the term metallic material also includes composite materials having a metal matrix. These composite materials are also referred to as metal matrix composites (MMC). Filled wires in which the sheath comprises a metal and the core comprises a non-metallic material, for example a ceramic material, are also metallic materials. Likewise, filled wires in which the sheath comprises a metal and the core consists of a metallic material, for example in powder or wire form, are also metallic materials.

[0004] In the field of multi-material processes, it is further known that only starting materials having similar melting properties can be processed into a single three-dimensional component. This is also referred to as compatibility of the starting materials. In other words, in a multi-material process, the starting materials used cannot be freely combined. Therefore, only specific combinations of starting materials are available for multi-material processes. This applies in particular also to metallic materials used as starting materials.

Summary of the Invention

[0005] The object of the present invention is to further develop a method for manufacturing a material layer from a first metal material and a second metal material so that a wider variety of metal materials can be combined with each other. [Means for solving the problem]

[0006] This problem is solved by a method for manufacturing material layers from a first metallic material and a second metallic material. This method is - Providing a first metal material and a second metal material inside a process zone, wherein the first metal material is in a solid state and the second metal material is in a solid state. - Directing an energy beam towards the liquefied portion of the first metal material and heating the liquefied portion of the first metal material with the energy beam, - Directing an energy beam towards the liquefied portion of the second metal material, and heating the liquefied portion of the second metal material with the energy beam, - The liquefied portions of the first metal material and the liquefied portions of the second metal material are introduced into a common molten bath, and the first metal material and the second metal material are mixed in the common molten bath, or The liquefied portions of the first and second metal materials are heated with an energy beam until the first and second metal materials liquefy and mix. Includes. [Effects of the Invention]

[0007] Therefore, in such a process, the energy beam is directed sequentially to the liquefied portion of the first metal material, and then to the liquefied portion of the second metal material. The first and second metal materials are heated by the energy beam. Needless to say, when the energy beam is directed to the first metal material, it is not directed to the second metal material. Similarly, when the energy beam is directed to the second metal material, it is not directed to the first metal material. In other words, at each point in time, the energy beam is directed to only one of the metal materials, the first or the second, and is never directed to both simultaneously. The focus of the energy beam is not important here. That is, when the energy beam is directed to the first metal material, it may be focused on the first metal material, or it may be out of focus relative to the first metal material. The same applies to the second metallic material. That is, when the energy beam is directed towards the second metallic material, it may be focused on the second metallic material, or it may be defocused from the second metallic material. To make this geometrically possible, at least the portions of the first and second metallic materials to which the energy beam is directed are arranged side by side when viewed along the direction of irradiation of the energy beam. In this case, the energy beam may be directed alternately to the first and second metallic materials. By sequentially directing the energy beam to the first and second metallic materials, the energy and / or power introduced into the first and second metallic materials by the energy beam can be controlled independently and with high precision. This also means that the energy and / or power introduced into the first metallic material by the energy beam and the energy and / or power introduced into the second metallic material by the energy beam can be significantly different from each other. As a result, metallic materials with significantly different properties, specifically significantly different melting properties, can be processed into a single part.Therefore, the method according to the present invention makes it possible to process metal materials that were previously considered incompatible or unsuitable into a material layer. In this case, the processing into a material layer can be carried out based on two embodiments. According to the first embodiment, the first metal material and the second metal material are heated by an energy beam, but are not directly melted by the energy beam. In such an embodiment, the melting of the first and second metal materials is carried out by introducing the first and second metal materials into a common melting bath. In this case, it can be understood that the first and / or second metal materials can be heated by the energy beam to a temperature lower than their respective melting points, but preferably close to their respective melting points. According to the second embodiment, the first and second metal materials are heated until they liquefy, i.e., until they melt by the energy beam. In such an embodiment, a liquid crosslink is formed between the remaining melting bath and the first and second metal materials, respectively. The first and second metal materials are then introduced into a common melting bath via their respective liquid crosslinks. Therefore, a material layer containing both the first and second metallic materials can be manufactured. The manufacture of such a material layer 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.

[0008] In the method according to the present invention, the fact that at least portions of the first metallic material and the second metallic material to which the energy beam is directed are adjacent when viewed along the direction of irradiation of the energy beam should be understood to mean that these portions do not overlap with each other when viewed along the direction of irradiation of the energy beam. If the first metallic material and the second metallic material are provided in the form of wires or rods, the orientation or arrangement of each wire or rod is not important.

[0009] It will be understood that the method according to the present invention can also process three or more types of metal materials into a single part. In such a case, the energy beam is directed at only one of the metal materials at a time for heating. The energy beam then moves back and forth between the three or more types of metal materials.

[0010] Furthermore, the method according to the present invention can be carried out multiple times, thereby enabling the manufacture of multiple material layers. These multiple material layers may be arranged three-dimensionally to obtain a three-dimensional multilayer workpiece. Therefore, the method according to the present invention can also be described as a method for manufacturing a workpiece comprising multiple material layers or a single component.

[0011] In the present invention, a material layer can be constructed on a substrate. The substrate may be a component or a part of a component, for example, a part manufactured by the method according to the present invention. Alternatively, the substrate may be formed from a support different from the component.

[0012] According to one embodiment, the method includes adjusting a first process parameter while an energy beam is directed towards the liquefied portion of a first metallic material. A second process parameter is adjusted while the energy beam is directed towards the liquefied portion of a second metallic material. The first and second process parameters are different from each other. In such a case, the concept of adjusting the process parameters can be understood as meaning that each process parameter is already adjusted when the energy beam is directed towards the liquefied portion of the first or second metallic material. Therefore, the process parameters are constant while the energy beam is directed towards the liquefied portion of the first or second metallic material. Furthermore, the concept of adjusting the process parameters can be understood as meaning that the adjustment of the process parameters is performed while the energy beam is directed towards the liquefied portion of the first or second metallic material. In other words, in such a case, the process parameters change while the energy beam is directed towards the liquefied portion of the first or second metallic material. The first process parameter is specifically the first output parameter of the energy beam. The second process parameter is specifically the second output parameter of the energy beam. In other words, the output of the energy beam is preferably different when it is directed towards the first metallic material and when it is directed towards the second metallic material. Therefore, the energy and / or power introduced into the first metallic material by the energy beam and the energy and / or power introduced into the second metallic material can be adjusted independently of each other. As a result, metallic materials with significantly different properties, specifically significantly different melting points, can be processed into material layers or workpieces. Similarly, the first process parameter may include a first supply parameter, which describes the supply characteristics for the first metallic material. The second process parameter may include a second supply parameter, which describes the supply characteristics for the second metallic material.When the first supply parameter and the second supply parameter are different from each other, the first and second metal materials are supplied in different conditions, for example, at different supply rates. In this way, metal materials having significantly different properties, specifically significantly different melting properties, can be processed into a material layer or workpiece.

[0013] When the energy source is an electron beam, one example of output parameters is the current level and acceleration voltage required to generate the energy beam.

[0014] An example of an output parameter in such a case is the irradiation time, i.e., the length of the time span during which the energy beam is directed towards the first or second metallic material. In such a case, it is also possible that the output parameter of the energy beam changes while it is directed towards the first or second metallic material. For example, the output parameter may change periodically. In such a case, the output parameter can be expressed as a frequency.

[0015] The energy beam may be directed towards the liquefied portion of the first metallic material using a first irradiation pattern. Furthermore, the energy beam may be directed towards the liquefied portion of the second metallic material using a second irradiation pattern. The first and second irradiation patterns may be different from each other. In such cases, the irradiation pattern means a path on the surface of the first or second metallic material along which the energy beam moves while it is directed onto the first or second metallic material. A simple example of an irradiation pattern is a point or a line. A further example of an irradiation pattern is a circle or an ellipse. In such cases, the energy beam is guided along a circular line or an elliptical line on the surface of the first or second metallic material while it is directed onto the first or second metallic material. Alternatively, the irradiation pattern may consist of two or more circles arranged concentrically, for example, nested within each other. In this case, the irradiation pattern may consist of a plurality of points or lines. Another concept of irradiation patterns is a raster pattern (rastermuster), or vibration pattern. The parameter of the irradiation pattern in this case is the irradiation frequency or vibration frequency. The irradiation frequency or vibration frequency represents the frequency at which the irradiation pattern cycles (abfahren), i.e., the number of times per unit time. If the irradiation pattern consists of multiple points or lines, the irradiation frequency or vibration frequency can also be the number of points of the irradiation pattern that are irradiated (anfahren) per unit time. By appropriately selecting the irradiation pattern, the power or energy and its local distribution in the first or second metallic material can be adjusted. If different irradiation patterns are selected for the first and second metallic materials, this allows for consideration of the different properties of the first and second metallic materials, specifically their different melting properties, and the first and second metallic materials can be processed into a single material layer or workpiece.

[0016] For example, the energy beam is directed alternately at the first and second metallic materials at least 10 times per second. Therefore, the alternating irradiation frequency (Wechselfrequenz) is at least 10 Hz. In other words, the energy beam oscillates between the first and second metallic materials. When an alternating irradiation frequency of at least 10 Hz is selected, the first and second metallic materials can be heated by the energy beam almost simultaneously. Furthermore, an alternating frequency of at least 10 Hz enables precise and reliable heating.

[0017] It should be noted that the concept of multi-beam technology (Mehrstrahltechnik) is often used in beam-based manufacturing processes where an energy beam is alternately directed at a first metallic material and a second metallic material. However, this is not strictly accurate; only a single energy beam is used, and the impression that two independent beams are being applied is created simply by moving it back and forth between the first and second materials.

[0018] According to one embodiment, a first metallic material may be characterized by a first melting parameter. A second metallic material may be characterized by a second melting parameter. The first and second melting parameters may be different from each other. Examples of melting parameters include melting point, vapor pressure, evaporation temperature, and melting energy. By sequentially directing an energy beam over time to the first and second metallic materials, different melting parameters can be taken into account during the manufacturing of the material layer so that the first and second metallic materials are present in the material layer in a predetermined ratio. In particular, undesirable evaporation of either the first or second metallic material can be prevented. As a result, a material layer or workpiece having desired material properties can be obtained.

[0019] Preferably, when the first metallic material and the second metallic material are mixed, an alloy and / or intermetallic compound is formed. In other words, the alloy and / or intermetallic compound is formed during the production of the material layer. This is also referred to as the "in situ" formation of the alloy and / or intermetallic compound. As already mentioned, this method makes it possible to produce a material layer consisting of an alloy and / or intermetallic compound made from a first metallic material and a second metallic material, which have significantly different properties, specifically melting properties. Furthermore, this method also makes it possible to produce a material layer consisting of an alloy and / or intermetallic compound that is not commercially available as a starting material.

[0020] Therefore, for example, the following intermetallic compounds can be produced: aluminides, specifically iron aluminides, titanium aluminides, nickel-based superalloys such as Ni3Al or NiAl, shape memory alloys such as nitinol (NiTi), high-alloy chromium steel and chromium-nickel steel, or copper or niobium-tin phases.

[0021] Preferably, the first metallic material and / or the second metallic material include titanium and / or copper.

[0022] For example, the first and / or second metallic material is supplied in the form of a wire. That is, a portion of the wire is heated by an energy beam and then directly or indirectly melted. Such a manufacturing process is also called a wire-based additive manufacturing process. This process allows for the production of a three-dimensional workpiece close to the final shape in a relatively short time.

[0023] As already mentioned, when the first metallic material and / or the second metallic material are provided in wire form, the orientation and arrangement of the respective wires or rods are not critical. In a first preferred embodiment, in which both the first metallic material and the second metallic material are provided in wire form, the respective wires form an acute angle. In a second preferred embodiment, the respective wires are provided substantially perpendicular to each other. In a third preferred embodiment, the respective wires are arranged in opposite directions, that is, they form an angle of substantially 180°. In a first modification of such an embodiment, the wires are arranged along the material lamination direction or the movement direction. Accordingly, one of the first metallic material and the second metallic material is provided trailing (schleppend), and the other of the first metallic material and the second metallic material is provided piercing (stechend). In a second modification of such an embodiment, both wires are arranged substantially perpendicular to the material lamination direction or the movement direction. When the process for producing a material layer is a welding process, the material lamination direction can be referred to as the welding direction.

[0024] As another example, when the first metallic material and the second metallic material are provided in wire form, such wires may differ from each other not only in the metallic material itself, but also in their diameter and / or cross-section. In this way, the ratio of the first metallic material to the second metallic material in the material layer can be easily controlled.

[0025] This process may further comprise irradiating an energy beam onto a common molten bath. This means that the energy beam is sequentially directed in time toward the first metallic material, the second metallic material, and the molten bath. The energy beam may, of course, be directed multiple times to each of the first metallic material, the second metallic material, and the molten bath. In this case, the order in which the energy beam is sequentially directed in time toward the first metallic material, the second metallic material, and the molten bath may always be the same, or may change during the implementation of the process. By directing the energy beam onto the molten bath, predetermined energy or power can be introduced into the molten bath. More generally speaking, the molten bath can be controlled by the energy beam. This particularly relates to the temperature of the molten bath. In this way, the mixing of the first metallic material and the second metallic material and / or the chemical or physical reaction between the first metallic material and the second metallic material can be influenced, and in particular, controlled. This enables the production of a high-quality material layer.

[0026] It will be understood that the energy beam can irradiate the molten bath using a third irradiation pattern. In a preferred embodiment, the energy beam is directed toward the first metallic material while using a first irradiation pattern, is directed toward the second metallic material while using a second irradiation pattern, and is directed toward the molten bath while using a third irradiation pattern. Accordingly, the input of energy or power to each of the first metallic material, the second metallic material, and the molten bath can be adjusted accurately and with high precision, whereby a high-quality material layer can be produced.

[0027] The energy beam may be an electron beam. The advantage of such an energy beam is that it can be directed with high precision to a first metallic material, a second metallic material, and / or a molten bath. Furthermore, such an energy beam has a relatively high energy density. In addition, the direction of the energy beam can be changed, i.e., deflected, at high speed and with high precision. Therefore, the electron beam is particularly suitable for this method, where it is essential to sequentially direct the energy beam over time to the first metallic material, the second metallic material, and optionally the molten bath.

[0028] Furthermore, the problems of the present invention are solved by an apparatus for producing material layers from a first metal material and a second metal material. This apparatus is configured to carry out the method according to the present invention. Accordingly, such an apparatus is configured to direct an energy beam sequentially, i.e., in time, to the liquefied portion of the first metal material and then to the liquefied portion of the second metal material. As already stated, when the energy beam is directed to the first metal material, it is not directed to the second metal material. Similarly, when the energy beam is directed to the second metal material, it is not directed to the first metal material. In other words, the apparatus is configured to direct the energy beam to only one of the first and second metal materials at any given time, and never to irradiate both the first and second metal materials simultaneously. In this case, the apparatus may be configured to alternately irradiate the first and second metal materials with the energy beam. To make this geometrically possible, the first and second metallic materials are arranged adjacent to each other, at least in the portion to which the energy beam is directed, when viewed along the direction of irradiation of the energy beam. By sequentially irradiating the first and second metallic materials with the energy beam, the energy and / or power introduced into the first and second metallic materials by the energy beam can be controlled independently and with high precision. This also means that the energy and / or power introduced into the first metallic material by the energy beam and the energy and / or power introduced into the second metallic material by the energy beam may be significantly different from each other. As a result, metallic materials with significantly different properties, particularly significantly different melting points, can be processed into a single material layer or workpiece. Therefore, the apparatus according to the present invention makes it possible to process metallic materials that were previously considered incompatible or unsuitable into a single material layer. Thus, a material layer containing both the first and second metallic materials can be manufactured.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.

[0029] Based on the various embodiments shown in the attached drawings, the present invention will be described in detail below. [Brief explanation of the drawing]

[0030] [Figure 1] Figure 1 shows an apparatus according to the present invention for manufacturing a material layer from a first metal material and a second metal material, and the apparatus is used to carry out the method according to the present invention for manufacturing a material layer from a first metal material and a second metal material. [Figure 2] Figure 2 shows a detailed view of the process zone of the apparatus in Figure 1, along direction II in Figure 1. [Figure 3] Figure 3 shows another embodiment of the apparatus, corresponding to Figure 2. [Figure 4] Figure 4 shows another embodiment of the apparatus corresponding to Figure 2. [Figure 5] Figure 5 shows another embodiment of the apparatus, corresponding to Figure 2. [Modes for carrying out the invention]

[0031] Figure 1 shows an apparatus 10 for manufacturing a material layer 12 from a first metal material 14 and a second metal material 16. In the illustrated embodiment, the first metal material 14 is aluminum and the second metal material 16 is titanium.

[0032] In the embodiment shown in Figure 1, a three-dimensional component 18 is manufactured from multiple such material layers 12. Needless to say, the illustrated material layers 12 have only illustrative properties.

[0033] As will be described later, the material layer 12, and by extension the three-dimensional component 18, is composed of titanium aluminide, that is, an intermetallic compound of titanium and aluminum. This is a material with low density and extremely good strength and rigidity properties. Titanium aluminide is also suitable for use in high-temperature applications with ambient temperatures up to 750°C. One example of its application is in gas turbines.

[0034] The apparatus 10 includes a vacuum chamber 20. A workbench 22 is positioned inside the vacuum chamber. A lift unit 24 is provided below the workbench 22 for moving the workbench 22 vertically. Furthermore, the workbench 22 can be rotated around the vertical and moved in the horizontal plane. Optionally, the workbench 22 can be tilted horizontally.

[0035] Component 18 is formed on the upper side of the workbench 22, which also functions as a base 26 for stacking component 18.

[0036] A portion of the inside of the vacuum chamber 20 is partitioned downwards by the upper side of the workbench 22, forming a construction space 28. It will be understood that the construction space 28 also has boundaries on the top and sides. These boundaries are determined by the relative range of movement of the workbench 22 with respect to the supply units 30 and 32, as will be described later.

[0037] The apparatus 10 further comprises a first supply unit 30. The first supply unit is configured to transport the first metal material 14 into the construction space 28, or more precisely, into the process zone. Here, the first metal material 14 is supplied in wire form. Therefore, the first supply unit 30 can be called a first wire conveyor.

[0038] Furthermore, the apparatus 10 includes a second supply unit 32. The second supply unit is configured to transport the second metal material 16 into the construction space 28, or more precisely, into the process zone. In the illustrated embodiment, the second metal material 16 is supplied in wire form. Therefore, the second supply unit 32 can be called a second wire conveyor.

[0039] Furthermore, the apparatus includes a beam generation unit 34. The beam generation unit is configured to generate an energy beam 36. In the illustrated embodiment, the energy beam is an electron beam.

[0040] Furthermore, the beam generation unit 34 includes a deflection unit 38. The deflection unit 38 includes multiple magnetic coils. These magnetic coils allow the energy beam 36 to be directed within the construction space 28. This means that the deflection unit 38 can selectively irradiate the energy beam 36 to different points within the construction space 28.

[0041] The apparatus 10 is further configured to carry out a method for manufacturing a material layer 12 from a first metal material 14 and a second metal material 16.

[0042] This method will be described in detail below with reference to Figure 2. Figure 2 is a detailed diagram of the process zone shown along direction II in Figure 1. In what is shown in Figure 2, the material layer 12 is generated from left to right. This should be understood as merely an example.

[0043] In the first step S1, the first metal material 14 and the second metal material 16 are supplied into the process zone. At this time, the first metal material 14 and the second metal material 16 are in a solid state.

[0044] As already mentioned, both the first metal material 14 and the second metal material 16 are supplied in wire form. Therefore, Figure 2 shows the ends of the wire made of the first metal material 14, i.e., the ends of the aluminum wire, and the ends of the wire made of the second metal material 16, i.e., the ends of the titanium wire.

[0045] Figure 2 shows the energy beam 36 along its beam direction, with the wire ends arranged in parallel. This means that the wire ends do not overlap or touch in this figure.

[0046] In the embodiment shown in Figure 2, the wires form an acute angle.

[0047] In the second step S2, the energy beam 36 is directed by the deflection unit 38 towards the liquefied portion of the first metallic material 14. The liquefied portion of the first metallic material 14 is substantially the corresponding wire end.

[0048] Furthermore, a first irradiation pattern 40 is used for this purpose. In the illustrated embodiment, the first irradiation pattern 40 is indicated by a rectangle enclosed by a dashed line. The first irradiation pattern 40 includes a path on the surface of the first metallic material 14. The energy beam 36 is guided along this path while it is directed toward the first metallic material 14.

[0049] The energy beam 36 is characterized by a first output parameter. In the illustrated embodiment, the first output parameter relates to the energy density. For simplicity, such an energy density is constant throughout the irradiation pattern 40. Therefore, 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.

[0050] The first metallic material 14, or more precisely, the liquefied portion thereof, is heated by the energy beam 36.

[0051] Since the second metallic material 16 is positioned alongside the first metallic material 14 along the beam direction, the energy beam 36 cannot be directed towards the second metallic material 16.

[0052] In the third step S3, the energy beam 36 is directed by the deflection unit 38 towards the liquefied portion of the second metallic material 16. The liquefied portion of the second metallic material 16 is substantially the associated wire end.

[0053] A second irradiation pattern 42 is used. In the illustrated embodiment, the second irradiation pattern 42 is indicated by a dashed rectangle. The second irradiation pattern 42 comprises a path on the surface of the second metallic material 16. The energy beam 36 is guided along this path while directed toward the second metallic material 16.

[0054] The energy beam 36 is characterized by a second power parameter. In the illustrated embodiment, the second power parameter relates to the energy density. For simplicity, such an energy density is constant throughout the irradiation pattern 42. Therefore, 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.

[0055] In this way, the second metallic material 16, or more precisely, the liquefied portion thereof, is heated by the energy beam 36.

[0056] In the fourth step S4, the energy beam 36 is then directed towards the melting bath 44 by the deflection unit 38.

[0057] Here, a third irradiation pattern 46 is used. In the illustrated embodiment, the third irradiation pattern 46 is indicated by a dashed rectangle. The third irradiation pattern 46 comprises a path on the surface of the melting bath 44. The energy beam 36 is guided along this path while it is directed towards the melting bath 44.

[0058] The energy beam 36 is characterized by a third power parameter. In the illustrated embodiment, the third power parameter relates to the energy density. For simplicity, such an energy density is constant throughout the irradiation pattern 46. Therefore, the energy density does not change while the energy beam is guided along the irradiation pattern 46. This may, of course, be different in other embodiments.

[0059] The molten bath 44 is then maintained at the desired temperature by the energy beam 36.

[0060] In the method described herein, the first metallic material 14, which is aluminum, and the second metallic material 16, which is titanium, are processed into a material layer 12 consisting of titanium aluminide. Therefore, the titanium aluminide material layer 12 must have the exact stoichiometric ratio of aluminum to titanium.

[0061] In this case, we must consider the fact that the melting parameters of the first metal material 14 and the second metal material 16 are significantly different. Here, the melting parameter refers to the melting point. The melting point is 660°C for aluminum and 1668°C for titanium.

[0062] In order to produce the desired titanium aluminide within the material layer 12, both the first metal material 14 and the second metal material 16 must be in liquid form. At the same time, it is necessary to prevent evaporation of the metal material with the lower melting point, i.e., the first metal material 14. Otherwise, it may not be possible to maintain the precise stoichiometric ratio of aluminum to titanium.

[0063] In this method, the objective is achieved by having a first output parameter, a second output parameter, and a third output parameter that are different from each other. The second output parameter, i.e., the second energy density of the energy beam 36, is higher than the first and third output parameters, and therefore higher than the first and third energy densities of the energy beam 36.

[0064] Furthermore, the first output parameter, i.e., the first energy density of the energy beam 36, is higher than the third output parameter, i.e., the third energy density of the energy beam 36.

[0065] Furthermore, the first irradiation pattern 40, the second irradiation pattern 42, and the third irradiation pattern 46 are all different from each other.

[0066] In particular, the path of the energy beam 36 shown by the first irradiation pattern 40 is shorter than the path shown by the second irradiation pattern 42. The path shown by the third irradiation pattern 46 is even shorter than the path described by the first irradiation pattern 40.

[0067] In this way, in the fifth step S5, both the liquefied portion of the first metal material 14 and the liquefied portion of the second metal material 16 are heated by the energy beam 36 until they liquefy and are mixed in the molten bath 44. This creates a so-called liquid crosslink between the solid portion of the wire made up of the first metal material 14 and the second metal material 16 and the molten bath 44. To maintain this liquid crosslink, the wire made up of the first metal material 14 is transported towards the molten bath 44 by the first supply unit 30, and the wire made up of the second metal material 16 is transported towards the molten bath 44 by the second supply unit 32. In this case, the supply speeds are approximately the same.

[0068] In another embodiment of the fifth step S5, the liquefied portions of the first metal material 14 and the second metal material 16 are heated by the energy beam 36 only to a temperature below their respective melting points. Actual melting occurs only after the liquefied portions of the first metal material 14 and the second metal material 16 enter the molten bath 44.

[0069] Here, in order to enable the manufacture of the entire part 18 from the material layer 12, the energy beam 36 is directed sequentially and alternately over time to the first metallic material 14, the second metallic material 16, and the molten bath 44. This is done periodically. The energy beam is directed at the first metallic material 14 at least 10 times within 1 second, at the second metallic material 16 at least 10 times, and at the molten bath 44 at least 10 times, utilizing the corresponding first irradiation pattern 40, second irradiation pattern 42, or third irradiation pattern 46, respectively.

[0070] The position of the workbench 22 is adjusted by the lift unit 24 during the construction of the part 18.

[0071] Figures 3 to 5 show another embodiment of the apparatus 10. Each shows one process zone corresponding to Figure 2. Consequently, the process for manufacturing the material layer 12, carried out by the apparatus 10, also changes.

[0072] Below, we will only describe the differences between the embodiment of the apparatus 10 and the embodiment of the method, as explained with reference to Figures 1 and 2.

[0073] The difference always concerns the orientation or supply direction of the first metal material 14, which is provided in wire form, and the second metal material 16, which is also provided in wire form.

[0074] In the embodiment shown in Figure 3, the ends of the wires face each other. The supply directions of the wires, i.e., the first metal material 14 and the second metal material 16, are opposite to each other. Within the region of the molten bath 44, the wire made of the first metal material 14 and the wire made of the second metal material 16 are arranged in a nearly straight line, with their respective ends facing each other.

[0075] Therefore, in the embodiment shown in Figure 3, the first metal material 14 is introduced behind the molten bath 44 (schleppend), and the second metal material 16 is introduced through the molten bath 44 (stechend).

[0076] In the embodiment shown in Figure 4, the wire made of the first metal material 14 and the wire made of the second metal material 16 are arranged in a nearly straight line within the region of the molten bath 44. However, in this case, the wires are oriented perpendicular to the material stacking direction or the direction of movement.

[0077] Figure 5 shows a further embodiment. Here, the wire made of the first metal material 14 and the wire made of the second metal material 16 are arranged perpendicular to each other. The second metal material 16 is introduced into the molten bath 44 from the rear, and the first metal material 14 is introduced into the molten bath 44 from the side.

[0078] For other points, please refer to the explanation above. [Explanation of Symbols]

[0079] 10 equipment 12 material layers 14. First metallic material 16. Second Metallic Material 18 parts 20 Vacuum Chamber 22 Workbenches 24 Lift Units 26 Base 28 Constructed Space 30 First supply unit 32 Second supply unit 34 Beam generation unit 36 Energy beams 38 Deflection Units 40. First irradiation pattern 42 Second irradiation pattern 44 Melting Bath 46 Third irradiation pattern S1 First process S2 Second process S3 Third Process S4 Fourth Process S5 Fifth Process

Claims

1. A method for producing a material layer (12) from a first metal material (14) and a second metal material (16), - Providing the first metal material (14) and the second metal material (16) inside the process zone, wherein the first metal material (14) is in a solid state and the second metal material (16) is in a solid state (S1), - Directing the energy beam (36) towards the liquefied portion of the first metal material (14), and heating the liquefied portion of the first metal material (14) with the energy beam (36) (S2), - The energy beam (36) is directed towards the liquefied portion of the second metal material (16), and the liquefied portion of the second metal material (16) is heated by the energy beam (36) (S3), - The liquefied portion of the first metal material (14) and the liquefied portion of the second metal material (16) are introduced into a common melting bath (44), and the first metal material (14) and the second metal material (16) are mixed in the common melting bath (44), or The first metal material (14) and the second metal material (16) are heated by the energy beam (36) until they liquefy and mix (S5). Methods that include...

2. While the energy beam (36) is directed towards the liquefaction portion of the first metal material (14), the first process parameter, specifically the first output parameter of the energy beam (36), is adjusted. While the energy beam (36) is directed towards the liquefied portion of the second metal material (16), the second process parameter, specifically the second output parameter of the energy beam (36), is adjusted. It further includes, The method according to claim 1, wherein the first process parameter and the second process parameter are different from each other.

3. The energy beam (36) is directed towards the liquefied portion of the first metal material (14) using the first irradiation pattern (40). The energy beam (36) is directed towards the liquefied portion of the second metal material (16) using the second irradiation pattern (42). The method according to claim 1 or claim 2, wherein the first irradiation pattern (40) and the second irradiation pattern (42) are different from each other.

4. The method according to any one of claims 1 to 3, wherein the energy beam (36) is directed alternately to the first metal material (14) and the second metal material (16) at least 10 times per second.

5. The method according to any one of claims 1 to 4, wherein the first metallic material (14) is characterized by a first melting parameter, and the second metallic material (16) is characterized by a second melting parameter, wherein the first melting parameter and the second melting parameter are different from each other.

6. The method according to any one of claims 1 to 5, wherein when the first metal material (14) and the second metal material (16) are mixed, an alloy and / or an intermetallic compound is formed.

7. The method according to any one of claims 1 to 6, wherein the first metal material (14) and / or the second metal material (16) are provided in the form of a wire.

8. The method according to any one of claims 1 to 7, further comprising directing the energy beam (36) towards the common melting bath (44) (S4).

9. The method according to any one of claims 1 to 8, wherein the energy beam (36) is an electron beam.

10. An apparatus (10) configured to carry out the method according to any one of claims 1 to 9, for manufacturing the material layer (12) from the first metal material (14) and the second metal material (16).

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