HYBRID MANUFACTURING METHOD THAT ENABLES AUTOMATIC SEPARATION OF SUPPORT STRUCTURES USING SHAPE MEMORY ALLOYS IN ADDITIVE MANUFACTURING.

Abstract

The invention relates to a manufacturing method that enables the creation of support structures of parts produced in metal additive manufacturing (Laser Powder Bed Fusion / SLM) using shape memory powders (9) and their automatic separation after manufacturing.

Description

1 TARIFF SUPPORT USING SHAPE MEMORY ALLOYS IN ADDITIVE MANUFACTURING HYBRID PRODUCTION METHOD THAT ENABLES AUTOMATIC SEPARATION OF ITS STRUCTURES Technical Area The invention relates to the production of parts using metal additive manufacturing (Laser Powder Bed Fusion / SLM). Formation of support structures with shape memory powders and post-production It relates to a manufacturing method that enables automatic separation. State of the Art Selective Laser Melting (SLM) is a method for melting fine metal powders. laid out in layers and selectively removed completely with a high-energy laser 10 It is an additive manufacturing method in which the material is melted and then solidified. In the process, the 3D CAD model of the part to be produced is sliced, and a laser is used for each layer. It scans only the relevant section. After each layer is completed, a new powder is applied. A layer is laid and the process is repeated. The SLM method is suitable for titanium, aluminum, and stainless steel. 15 complex geometries with high-performance metals such as steel and nickel-based alloys It enables its production. In the method mentioned, support structures are a critical part of the production process. The supports provide mechanical support, heat management, and during production. It secures the part to the production table. Support structures are usually lattice, tree-like. They are designed in a (tree-like) or block type and mechanically processed after production in 20 It is removed from the part by (cutting, breaking) or processing methods. In the current powder bed laser melting (SLM) method, excessive protrusions and localized heat generation are problematic. due to accumulation and residual stresses between layers, support structures The use of these support structures is essential for most geometries. These support structures are used during the production of the part. Although they ensure geometric stability, they are manufactured from the same metal powder as the main part. 25 This leads to significant technical and economic disadvantages. The supports... This process leads to increased material consumption, extends printing time, and improves production. This subsequently necessitates mechanical, chemical, or thermal post-processing operations. These processes both increase production costs and cause damage to the surface of the main part. This brings with it the risk of loss of tolerance and deterioration in surface roughness. 30 2 In the known state of the art, thin-section steel is used to improve the support removal process. support geometries, fractured supports, reduced or partial support density Support-free design approaches are suggested. However, these solutions involve metal additions. It does not yield satisfactory results in manufacturing; inadequate mechanical support during production of thin supports. demonstrating durability, the inability to remove heavy or inaccessible supports, and the supports being 5 This creates new problems, such as the inability to completely remove it. Furthermore... supports that cannot be removed or are only partially attached, recoater impact, process stoppage, and This leads to risks that affect production safety, such as a general decrease in efficiency. However, the SLM process includes sub-processes such as powder deposition, laser scanning, and atmosphere control. systems depend on numerous process-specific parameters (laser power, scanning 10 (speed, layer thickness, spot size, etc.) to ensure stable output quality. This makes it more difficult. The support geometries are directly related to these precise process parameters. The fact that they are related makes support design even more complex. For these reasons, In current techniques, support structures undergo an external mechanical or chemical post-production process. 15 from the main part in a controlled and reliable manner without the need for intervention. New solutions are needed to enable their separation. As a result of research conducted on this subject, the code CN120286835A was encountered. The relevant... This document describes a method for preparing a NiTi-based shape memory alloy. It is related. However, the current technique is in metal additive manufacturing (Laser Powder Bed Fusion / SLM). The support structures of the manufactured parts are formed with shape memory powders and 20 Information about a system that enables automatic detachment after production. It does not include. In conclusion, due to the negative aspects described above and the current solutions being the subject of discussion... Due to its shortcomings, an improvement is needed in the relevant technical field. It has been made. 25 Purpose of the Invention The invention was created by drawing inspiration from existing situations and overcoming the aforementioned drawbacks. It aims to solve the problem. The main purpose of the invention is to produce shape memory lasers using the powder bed laser melting (SLM) method. The aim is to present a hybrid additive manufacturing method using alloys (SMA) together. 30 3 Another objective of the invention is to make the support areas from a different material than the main part. The chosen material is a shape memory alloy. Another objective of the invention is to provide shape memory alloy support after production is complete. their structures from any mechanical cutting, breaking or chemical dissolution from the main part The goal is to ensure that it separates spontaneously without the need for any intervention. 5 To fulfill the purposes described above, the invention is produced in additive manufacturing. the formation of the support structures of the parts with shape memory powders and post-production It is a manufacturing method that enables automatic separation, and its characteristic feature is;  The metal powder fed from the powder hopper is spread by the powder spreader mechanism. evenly spreading on the manufacturing surface via, 10  Selective melting of metal powder using a laser,  Layered creation of the workpiece's main geometry,  By a robotic arm with multi-axis movement capability With the positioned powder nozzle, shape memory powder is only supported. spraying into the regions and 15  Shape memory support by local incorporation of shape memory powder. controlled connection of the structures to the main part,  After production is complete, the workpiece and its associated shape memory module Placing the support structures in a hot / cold liquid bath and  Shape memory support via thermal triggering created by the liquid medium 20 their structures do not require any mechanical intervention from the main part spontaneous separation without remaining It includes the steps involved in the process. The structural and characteristic features and all the advantages of the invention are given in the figures below and 25 This becomes clearer thanks to the detailed explanation written with references to these figures. This will be understood as such, and therefore the evaluation will also take these forms and detailed explanations into account. This should be done taking that into consideration. Figures that will help understand the invention. Figure 1 shows a view of the system in which the production method described in the invention is carried out. 30 Figure 2 shows a post-production view of the workpiece and the shape memory support structure. 4 Figure 3 shows the hot / cold roughing of the workpiece and shape memory support structure after production. It is an appearance related to its placement. Figure 4 shows the separation of the workpiece and the shape memory support structure after manufacturing. It is an appearance of the situation. Description of Part References 5 1. Dust container 2. Dust spreading mechanism 3. Laser 4. Robotic arm 5. Dust nozzle 10 6. Shape memory support 7. Workpiece 8. Hot / cold liquid bath 9. Shape memory powder Detailed Description of the Invention 15 In this detailed explanation, the preferred configurations of the method in question are described only. This is explained to facilitate a better understanding of the subject. The invention describes a method with 4D behavior in metal additive manufacturing (SLM / L-PBF) processes. Hybrid that produces automatically detachable support structures (that change shape with time / stimulus) This relates to the SLM+DED method and is used in metal additive manufacturing (Laser Powder Bed 20). Support structures of parts produced using Fusion / SLM are made with shape memory powders. It deals with the creation and automatic separation of the components after production. The invention also covers the difficulties of removing support structures from the workpiece, and surface damage. In order to eliminate the risks, the shape is formed using the powder bed laser melting (SLM) method. A hybrid additive manufacturing solution using memory alloys (SMAs) together 25 It offers this. Accordingly, the main part is layered using the classic SLM process. During production, the support areas are made of a shape memory material that is different from the main part. It is made of alloy. In the invention method, the main production process is; metal powder fed from the powder hopper (1) The powder is evenly applied to the manufacturing surface by means of the powder spreading mechanism (2) (recoater) SLM method based on spreading and selective melting with laser (3) 5 This is done. At this stage, the main geometry of the workpiece (7) is layered. is created. Support structures are integrated alongside the machine housing and enable multi-axis movement. DED-like powder positioned via a robotic arm (4) with the capability It is produced through the nozzle (5). At this stage, NiTi-based shape memory powder (9) is produced by laser 10 (3) using coaxial feeding method with beam only to support regions It is sprayed and bonded locally. Thus, shape memory support (6) The structures are designed to provide sufficient mechanical adhesion to the main part during production. It is created in situ. After production is completed, the workpiece (7) and its attached shape memory support (6) 15 The structures are placed in a hot or cold liquid bath (8). The liquid medium formed Phase transformation occurs in shape memory support (6) structures with thermal triggering and These structures shrink, returning to their pre-programmed geometries. The resulting interior... As a result of stresses, shape memory support (6) structures, any part from the main part It separates spontaneously without the need for mechanical intervention (Figure 4). This is reflected in Figure 20. Memory-based support removal processes are automated, and the main surface and part surface are processed automatically. Its integrity is preserved.

Claims

6 REQUESTS 1. The support structures of parts produced in additive manufacturing are formed using shape memory powders. enabling its creation and automatic detachability after production. It is a production method, and its characteristic is;  The metal powder fed from the powder hopper (1) is spread by the powder spreading mechanism (2) 5 spreading evenly on the manufacturing surface via  Selective melting of metal powder by laser (3),  Layered creation of the main geometry of the workpiece (7),  By a robotic arm with multi-axis movement capability (4) With the positioned powder nozzle (5), shape memory powder (9) only 10 spraying onto support areas and  Shape memory powder (9) by local incorporation of shape memory powder Controlled connection of support (6) structures to the main part,  After production is completed, the workpiece (7) and the figure attached to it memory support (6) structures into hot / cold liquid bath (8) 15 taking and  Shape memory support with thermal triggering created by liquid medium (6) their structures do not require any mechanical intervention from the main part spontaneous separation without remaining It includes the steps of the process. 20

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