An additive manufacturing system

Abstract

The invention relates to a body (2), a table (3) that is located on the body (2), multiple powder grains (4) that are located on the table (3) and are made of metal material, a heater (H) that is positioned on the body (2) with a distance to the powder grains (4) and ensures the fusing of the powder grains (4), a molten pool (5) formed by the phase change by heating the powder grains (4) by the heater (H), a rod (6) that is located on the body (2) and applies vibration into the molten pool (5), and at least one fluid channel (601 ) that is located on the rod (6), through which the cooling fluid, the temperature of which is lower than the molten pool (5) temperature, passes, allowing the rod (6) to cool down.

Description

[0001] AN ADDITIVE MANUFACTURING SYSTEM

[0002] The present invention relates to an additive manufacturing system in which improvements are provided in production of components using ultrasonic vibration.

[0003] Internal channel and complex geometry parts are produced in additive manufacturing machines. In addition to the many advantages it promises, metal additive manufacturing still has problems that need to be solved when it is desired to produce as a final product. These can be listed as high heat input, distortion, porosity, and anisotropy in microstructure. In order to solve these problems, many auxiliary processes are worked on and integrated into the systems. One of these is ultrasonic vibration. Ultrasonic vibration increases both the flow motion by means of the pressure waves it creates in the molten pool during the solidification of the molten metal and ensures that the solidified metal is broken again and included in the melt as nucleation. As a result of this situation, the process can be carried out with less heat input, distortion decreases, porosity decreases by means of the motion, and also the grain size decreases and the grains become equiaxial by means of the increase in nucleation. As a result of this, anisotropy is reduced.

[0004] In the Chinese patent application document numbered CN116494533A in the state of the art, an ultrasonic vibration device called a powder feeding nozzle in order to prevent problems that occur as a result of the non-homogeneous distribution and sintering of the powders transferred to the surface during the additive manufacturing process is mentioned. In said invention, material feeding channels that pass over the rod and are directed to the material transfer needle are described.

[0005] In the Japanese patent application document numbered JP2008142738A in the state of the art, an apparatus developed to prevent the accumulation of the main material at the welding tip during welding is mentioned. Said document mentions that cooling fluid is used to prevent or reduce the heat generated on the "horn" to which ultrasonic vibrations are transmitted. The document explains that the cooling channels within the horn's own structure are used to provide cooling as a result of the horn located in the ultrasonic vibration device located on the welding unit overheating during the process. It is explained that exit channels are created in order to ensure that the cooling air is blown towards the surfaces of the material to which the weld is applied after the channels.

[0006] By means of an additive manufacturing system developed with the present invention, the rod providing ultrasonic vibration is effectively cooled in the molten pool and its life is extended.

[0007] Another aim of this invention is to ensure that the part produced on the additive manufacturing bench has a more durable structure with a regular cooling gradient.

[0008] Another aim of this invention is to provide a more durable structure by adding nano or micro sized particles to the parts produced on the additive manufacturing machine.

[0009] The additive manufacturing system defined in the first claim and the claims dependent on this claim, which is realised to achieve the aim of the invention, comprises a table that is located on the body. The powder grains or metal wires placed on the table are heated by a heater and fused and melted with each other. A molten pool is formed by heating the powder grains. A rod applying ultrasonic vibration is dipped into the molten pool. A fluid channel is preferably passed through the rod, through which cold fluid passes.

[0010] The additive manufacturing system, which is the subject of the invention, comprises more than one particle produced from different materials than powder grains blown to the surface of the molten pool by blowing through the fluid channel and by means of the rod. A mixture pool is obtained by mixing and fusing the molten powder grains and particles in the molten pool homogeneously with each other by means of the vibration provided by the rod. The mixture pool has a different material composition than the powder grains and particles. There is a mixture pool to which a regular cooling gradient is provided by means of the cold fluid transfer of the fluid channel. The part is obtained by solidifying the mixture pool.

[0011] In one embodiment of the invention, the additive manufacturing system comprises a dendritic region formed as a result of irregular cooling in the parts close to the cold surfaces of the molten pool.

[0012] In one embodiment of the invention, the additive manufacturing system comprises an actuator that is located on the body and triggers the rod to produce ultrasonic vibration. The actuator produces ultrasonic vibration and ensures the dispersion of the dendritic regions formed in the melt region. The actuator rotates the rod radially in the molten pool.

[0013] In one embodiment of the invention, the additive manufacturing system comprises a pump that pumps cold fluid into the fluid channel. The end of the fluid channel that is closer to the table is transferred towards the surface of the cold fluid in a way that there is a distance between the molten pool and the mixture pool.

[0014] In one embodiment of the invention, the additive manufacturing system comprises a first position (I) where the rod is not inside the molten pool, the dendritic region is fixed on the inner surfaces of the molten pool and the particles are on the surface of the molten pool without mixing with the molten pool. There is a second position (II) where the rod is partially immersed in the molten pool and the actuator generates ultrasonic vibration by triggering the rod, the pump delivers cold fluid to the fluid channel and the mixture pool is formed.

[0015] In one embodiment of the invention, the additive manufacturing system comprises a tank in which particles are stored. A mixing unit mixes the particles with the cold fluid coming from the tank and pump.

[0016] In one embodiment of the invention, the additive manufacturing system comprises a molten pool formed as a result of melting powder grains or wires on the table with a heater. When the rod is in the first position (I), a dendritic region is formed in the molten pool. When the rod is brought from the first position (I) to the second position (II), the actuator triggers the rod and thus the rod sends ultrasonic vibrations into the molten pool. The dendritic region is dispersed by being affected by said ultrasonic waves and mixes into the molten pool. The particles blown to the surface are also dispersed into the molten pool by the triggering of the rod. In order to protect the rod from high heat, the pump pumps cold fluid through the fluid channel.

[0017] In one embodiment of the invention, the additive manufacturing system comprises a control unit with artificial intelligence and machine learning features that controls the functions of the tank, pump and mixing unit. There is a sensor that detects the formation of dendritic zones in the molten pool and transmits it to the control unit, and can make visual, auditory, heat and radiation detections. In one embodiment of the invention, the additive manufacturing system comprises a control unit that optimises and makes adjustments to the particle and cold fluid parameters according to the visual, auditory, heat and radiation data received from the sensor.

[0018] In one embodiment of the invention, the additive manufacturing system comprises fluid channels positioned within the rod in a coaxial or spiral manner.

[0019] In one embodiment of the invention, the additive manufacturing system comprises a heater containing an electron beam or laser and a body that allows the production of complex geometry and internal channel parts for aircraft.

[0020] In one embodiment of the invention, the additive manufacturing system comprises particles that are nano or micro sized.

[0021] The additive manufacturing system realised to achieve the aim of the present invention is shown in the attached figures, and of these figures;

[0022] Figure 1 is a schematic view of the additive manufacturing system.

[0023] Figure 2 is a schematic view of the additive manufacturing system.

[0024] Figure 3 is a schematic view of the molten pool, dendritic region, rod and particles in the first position (I).

[0025] Figure 4 is a schematic view of the mixture pool, powder grain, particle and rod in the second position (II).

[0026] The parts in the figures are numbered one by one and the equivalents of these numbers are given below.

[0027] 1. Additive manufacturing system

[0028] 2. Body

[0029] 3. Table

[0030] 4. Powder grain

[0031] 5. Molten pool

[0032] 501 . Mixture pool

[0033] 502. Dendritic region

[0034] 6. Rod 601 . Fluid channel

[0035] 7. Particle

[0036] 8. Actuator

[0037] 9. Pump

[0038] 10. Mixing unit

[0039] 11. Control unit

[0040] 1101. Sensor

[0041] (I) First Position

[0042] (II) Second Position

[0043] (A) Tank

[0044] (H) Heater

[0045] (P) Part

[0046] Additive manufacturing system (1 ) comprises a body (2), a table (3) that is located on the body (2), multiple powder grains (4) that are located on the table (3) and are made of metal material, a heater (H) that is positioned on the body (2) with a distance to the powder grains (4) and ensures the fusing of the powder grains (4), a molten pool (5) formed by the phase change by heating the powder grains (4) by the heater (H), a rod (6) that is located on the body (2) and applies vibration into the molten pool (5), and at least one fluid channel (601 ) that is located on the rod (6), through which the cooling fluid, the temperature of which is lower than the molten pool (5) temperature, passes, allowing the rod (6) to cool down.

[0047] The additive manufacturing system (1 ) which is the subject of the invention comprises more than one particle (7) that are made of different material than the powder grains (4) and are transferred to the surface of the molten pool (5) by means of the rod (6) passing through the fluid channel (601 ), a mixture pool (501 ) that is obtained by the homogeneous mixing and fusing of the powder grains (4) and particles (7) with each other in the molten pool (5) by means of the vibration provided by the rod (6), has a different material composition than the powder grains (4) and particles (7) and to which a regular cooling gradient is provided, and at least one part (P) obtained by the solidification of the mixture pool (501 ). There is a table (3) on the body (2) where part (P) production is provided with additive manufacturing. The powder grains (4) on the table (3) are heated and brought to molten form by the heater (H) that is located on the body (2) and are fused with each other. As a result of the fusion of the powder grains (4) and the phase change, the molten pool (5) is formed on the table (3). A rod (6) that applies ultrasonic vibration is immersed in the molten pool (5). The rod (6) applies ultrasonic vibration into the molten pool (5). The rod (6) is preferably prevented from being affected by the high temperature of the molten pool (5) by the cold fluid passing through it, which is located inside the rod (6).

[0048] The particles (7) are produced from materials with different compositions and different components than the powder grains (4). Particles (7) are transferred to the surface of the molten pool (5) by passing through the fluid channel (601 ) via the rod (6). As a result of the homogeneous mixing and fusion of particles (7) and powder grains (4) in the molten pool (5), a mixture pool (501 ) containing different material components and compositions is formed from powder grains (4) and particles (7). A part (P) is obtained by solidification of the mixture pool (501 ). In this way, both the production of a more durable part (P) and a regular cooling gradient in the mixture pool (501 ) are obtained. (Figure-1 , Figure-2)

[0049] In one embodiment of the invention, the additive manufacturing system (1 ) comprises a dendritic region (502) formed near the surface of the molten pool (5) as a result of the solidification of the powder grains (4) in the molten pool (5). A dendritic region (501 ) is formed in the molten pool (5) due to the solidification in dendritic form, especially on the colder surfaces.

[0050] In one embodiment of the invention, the additive manufacturing system (1 ) comprises an actuator (8) that is located on the body (2) and triggers the rod (6) to produce ultrasonic vibration and adjust the angle of immersion in the molten pool (501 ); a rod (6) that allows the dendritic region (502) to mix into the molten pool (5) with the triggering of the actuator (8), thus creating a regular cooling gradient; and an actuator (8) that rotates the rod (6) around its own axis, thus ensuring that the particles (7) are distributed homogeneously in the radial direction. The detrital region (501 ) formed in the molten pool (5) is dispersed and distributed to the interior of the molten pool (5) by means of the ultrasonic vibrations provided by the rod (6) activated by the actuator (8). In this way, the production of a part (P) with a regular structure is achieved. In one embodiment of the invention, the additive manufacturing system (1 ) comprises a pump (9) that is located on the body (2), is connected to the rod (6) and provides the blowing of cold fluid from the fluid channel (601 ), and a fluid channel (601 ) that is located on the surface of the molten pool (5) with the end close to the table (3), transferring the cold fluid and particles (7) to the molten pool (5) and the mixture pool (501 ) at a distance from the surface. Cooling of the rod (6) is provided by the cold fluid pumped by the pump (9). One end of the fluid channel (601 ) is connected to the pump (9) and the other end is on the surface of the molten pool (5).

[0051] In one embodiment of the invention, the additive manufacturing system (1 ) comprises a first position (I) in which the rod (6) is located outside the molten pool (5), the detrital region (502) is located on the inner wall of the molten pool (5) and the particles (7) are located fixedly on the surface of the molten pool (5), a second position (II) in which a portion of the rod (6) is immersed in the molten pool (5), the actuator (8) triggers the rod to produce ultrasonic vibrations and the pump (9) pumps cold fluid into the fluid channel (501 ) and the mixture pool (501 ) is formed. In the first position (I), the rod (6) is outside the molten pool (5). In the first position (I), the dendritic region (501 ) is located fixedly on the inner surfaces of the molten pool (5). The particles (7) are not mixed with the molten pool (5). When the rod (6) is brought to the second position (II), it is immersed in the molten pool (5) in such a way that the tip of the fluid channel (601 ) remains outside the molten pool (5). The actuator (8) triggers the rod (6) while it is in the molten pool, providing ultrasonic vibration production. In this way, the dendritic region (502) formed in the molten pool (5) is dispersed and a homogeneous mixture of the particles (7) is provided. In this way, the mixture pool (501 ) can be obtained. (Figure-3, Figure-4)

[0052] In one embodiment of the invention, the additive manufacturing system (1 ) comprises a tank (A) that is located on the body (2) where particles (7) are stored, and a mixing unit (10) that is connected to the tank (A) and to the pump (9), and allows the particles coming from the tank (A) to mix with the cold air coming from the pump (9). In this way, the mixing of the cold fluid and particles (7) passing through the tank (A) and pump (9) is ensured.

[0053] In one embodiment of the invention, the additive manufacturing system (1 ) comprises - the molten pool (5) where the powder grains (4) are heated by the heater (H) on the table (3),

[0054] - a dendritic region (502) that is formed on the surfaces as a result of irregular solidification of powder grains (4) in molten form in the molten pool (5), the rod (6) in the first position (I),

[0055] - the rod (6) which is brought from the first position (I) to the second position (II) and produces ultrasonic waves as a result of the triggering of the actuator (9), the dendritic region (502) which is distributed from the inner wall of the molten pool (5) towards its centre by being triggered by the ultrasonic waves produced by the rod (6),

[0056] - the particles (7) that are distributed from the outer wall of the molten pool (5) to the inner part, mixing homogeneously within the molten pool (5) and forming the mixture pool (501 ), and

[0057] - the actuator (6) that enables the rod (6) to move towards the dendritic regions (502) formed in the molten pool (5).

[0058] - the pump (9) which allows cold fluid to pass through the fluid channel (6) when the rod (6) is in the second position (II), preventing the rod (6) from being affected by high temperatures.

[0059] The powder grains (4) that are located on the table (3) become molten by means of the heating of the heater (H). The powder grains (4) that become molten form the molten pool (5). When the rod (6) is in the first position (I), the dendritic region (502) is formed by the irregular solidification of the powder grains (4) on the inner surfaces of the molten pool (5). When the rod (6) reaches the second position (II), it generates an ultrasonic wave with the trigger of the actuator (8) and ensures the dispersion of the dendritic region (502). The particles (7) that are located on the surface mix homogeneously with the powder grains (4) with the trigger of the rod (6) and form the mixture pool (501 ). In order to protect the rod (6) from high temperatures, the pump (9) allows the pumping of cold fluid from the fluid channel (601 ). During the solidification of the part (P), the actuator (9) ensures that the rod (6) is removed from the molten pool (501 ). In this way, both the protection of the rod (6) from high heat and the production of a durable part (P) are provided. In one embodiment of the invention, the additive manufacturing system (1 ) comprises a control unit (11 ) that is located on the body (2) and controls the fluid transfer to the fluid channel (601 ) of the pump (9), the tank (A), and the mixing unit (10), and a sensor (1101 ) that is located in the molten pool (5), detects the formation of the dendritic region (501 ) in the molten pool (5) and transmits the data it detects to the control unit (11 ). In this way, the sensor (1101 ) and the control unit provide automation and optimisation of the fluid transfer to the fluid channel (601 ) of the pump (9), the tank (A), and the mixing unit (11 ).

[0060] In one embodiment of the invention, the additive manufacturing system (1 ) comprises a control unit (11 ) that operates the pump (9), the tank (A) and the mixing unit (10) in accordance with the data it receives from the sensor (1101 ), enabling the fluid temperature, particle (7) amount and transmission speed to be applied variably. In this way, the sensor (1101 ) and the control unit provide automation and optimisation of the fluid transfer to the fluid channel (601 ) of the pump (9), the tank (A), and the mixing unit (11 ).

[0061] In one embodiment of the invention, the additive manufacturing system (1 ) comprises fluid channels (601 ) that are parallel to each other in their directions within the rod (6) and are spaced apart or in a spiral form on the rod wall, providing effective cooling of the rod (6).

[0062] In one embodiment of the invention, the additive manufacturing system (1 ) comprises a heater (H) with an electron beam or laser beam, and a body (2) that allows the production of parts with complex geometry and internal channels for aircraft.

[0063] In one embodiment of the invention, the additive manufacturing system (1 ) comprises particles (7) in nano or micro sizes.

Claims

CLAIMS1. Additive manufacturing system (1 ) comprising a body (2), a table (3) that is located on the body (2), multiple powder grains (4) that are located on the table (3) and are made of metal material, a heater (H) that is positioned on the body (2) with a distance to the powder grains (4) and ensures the fusing of the powder grains (4), a molten pool (5) formed by the phase change by heating the powder grains (4) by the heater (H), a rod (6) that is located on the body (2) and applies vibration into the molten pool (5), and at least one fluid channel (601 ) that is located on the rod (6), through which the cooling fluid, the temperature of which is lower than the molten pool (5) temperature, passes, allowing the rod (6) to cool down, characterised by more than one particle (7) that are made of different material than the powder grains (4) and are transferred to the surface of the molten pool (5) by means of the rod (6) passing through the fluid channel (601 ), a mixture pool (501 ) that is obtained by the homogeneous mixing and fusing of the powder grains (4) and particles (7) with each other in the molten pool (5) by means of the vibration provided by the rod (6), has a different material composition than the powder grains (4) and particles (7) and to which a regular cooling gradient is provided, and at least one part (P) obtained by the solidification of the mixture pool (501 ).

2. Additive manufacturing system (1 ) according to Claim 1 , characterised by a dendritic region (502) formed near the surface of the molten pool (5) as a result of the solidification of the powder grains (4) in the molten pool (5).

3. Additive manufacturing system (1 ) according to Claim 1 or Claim 2, characterised by an actuator (8) that is located on the body (2) and triggers the rod (6) to produce ultrasonic vibration and adjust the angle of immersion in the molten pool (501 ); a rod (6) that allows the dendritic region (502) to mix into the molten pool (5) with the triggering of the actuator (8), thus creating a regular cooling gradient; and an actuator (8) that rotates the rod (6) around its own axis, thus ensuring that the particles (7) are distributed homogeneously in the radial direction.

4. Additive manufacturing system (1 ) according to Claim 4, characterised by a pump (9) that is located on the body (2), is connected to the rod (6) and provides the blowing of cold fluid from the fluid channel (601 ), and a fluid channel (601 ) that islocated on the surface of the molten pool (5) with the end close to the table (3), transferring the cold fluid and particles (7) to the molten pool (5) and the mixture pool (501 ) at a distance from the surface.

5. Additive manufacturing system (1 ) according to Claim 4 or Claim 5, characterised by a first position (I) in which the rod (6) is located outside the molten pool (5), the detrital region (502) is located on the inner wall of the molten pool (5) and the particles (7) are located fixedly on the surface of the molten pool (5), a second position (II) in which a portion of the rod (6) is immersed in the molten pool (5), the actuator (8) triggers the rod to produce ultrasonic vibrations and the pump (9) pumps cold fluid into the fluid channel (501 ) and the mixture pool (501 ) is formed.

6. Additive manufacturing system (1 ) according to any of the previois claims, characterised by a tank (A) that is located on the body (2) where particles (7) are stored, and a mixing unit (10) that is connected to the tank (A) and to the pump (9), and allows the particles coming from the tank (A) to mix with the cold air coming from the pump (9).

7. Additive manufacturing system (1 ) according to Claims 4 to 6, characterised by the molten pool (5) where the powder grains (4) are heated by the heater (H) on the table (3), a dendritic region (502) that is formed on the surfaces as a result of irregular solidification of powder grains (4) in molten form in the molten pool (5), the rod (6) in the first position (I), the rod (6) which is brought from the first position (I) to the second position (II) and produces ultrasonic waves as a result of the triggering of the actuator (9), the dendritic region (502) which is distributed from the inner wall of the molten pool (5) towards its centre by being triggered by the ultrasonic waves produced by the rod (6), the particles (7) that are distributed from the outer wall of the molten pool (5) to the inner part, mixing homogeneously within the molten pool (5) and forming the mixture pool (501 ), and the actuator (6) that enables the rod (6) to move towards the dendritic regions (502) formed in the molten pool (5).the pump (9) which allows cold fluid to pass through the fluid channel (6) when the rod (6) is in the second position (II), preventing the rod (6) from being affected by high temperatures.

8. Additive manufacturing system (1 ) according to Claim 6 or Claim 7, characterised by a control unit (11 ) that is located on the body (2) and controls the fluid transfer to the fluid channel (601 ) of the pump (9), the tank (A), and the mixing unit (10), and a sensor (1101 ) that is located in the molten pool (5), detects the formation of the dendritic region (501 ) in the molten pool (5) and transmits the data it detects to the control unit (11 ).

9. Additive manufacturing system (1 ) according to Claim 8, characterised by a control unit (11 ) that operates the pump (9), the tank (A) and the mixing unit (10) in accordance with the data it receives from the sensor (1101 ), enabling the fluid temperature, particle (7) amount and transmission speed to be applied variably.

10. Additive manufacturing system (1 ) according to any of the previous claims, characterised by fluid channels (601 ) that are parallel to each other in their directions within the rod (6) and are spaced apart or in a spiral form on the rod wall, providing effective cooling of the rod (6).

11. Additive manufacturing system (1 ) according to any of the previous claims, characterised by a heater (H) with an electron beam or laser beam, and a body (2) that allows the production of parts with complex geometry and internal channels for aircraft.

12. Additive manufacturing system (1 ) according to any of the previous claims, characterised by particles (7) in nano or micro sizes.

Images