Component having a component body

Abstract

The present invention relates to a component which has a component body made of a metal material and a sensor, wherein the component body is constructed additively from the metal material as a one-piece part per se, wherein the sensor is surrounded by the component body and is thus integrated into the component body, and wherein the component body is hardened at least in regions and has a Rockwell hardness of at least 40 HRC.

Description

[0001] COMPONENT WITH A COMPONENT BODY

[0002] DESCRIPTION

[0003] Technical field

[0004] The present invention relates to a component with a component body made of a metal material.

[0005] State of the art

[0006] As detailed below, the component can serve, for example, as a fastening or clamping element, i.e., for force-fit and / or form-fit holding or gripping another component or workpiece. It could, for example, be a plunger or bolt onto which a clamping force is applied in the application.

[0007] A preferred application environment can include axial turbomachinery, particularly aircraft engines. Both in the manufacture of their components and parts, and in their application, high demands may be placed on the load-bearing capacity and dimensional accuracy of the components. This can also apply to the tools used in their manufacture.

[0008] Description of the invention

[0009] The present invention is based on the technical problem of providing an advantageous component which can be used, for example, to fasten and / or clamp another component or workpiece.

[0010] This is achieved according to the invention with the component according to claim 1. Its component body is additively manufactured from a metal material, and a sensor is enclosed and thus integrated within the component body. In other words, the component body, as a single, integral part, can enclose the sensor; the sensor is therefore embedded within the component body. Furthermore, the component body is at least partially hardened, meaning it has a Rockwell hardness of at least 40 HRC in at least one area.

[0011] The integrated sensor allows for the measurement of physical parameters, such as mechanical force / deformation or temperature profiles, wherever stress or strain occurs in the application. The partially hardened component body can make certain applications possible in the first place, for example, when the component is subjected to specific mechanical stresses during operation. This can include not only static (virtually stationary) but also dynamic (e.g., oscillating) stresses. Another advantage is that components can be replicated without structural modifications or design changes, i.e., with an unchanged external shape, while still integrating the sensor technology.

[0012] Hardening can also be advantageous for the measurement itself, for example, because it can reduce wear compared to a non-hardened component. Since the sensor's environment can change as the component wears, a partially hardened component can provide more stable conditions for the sensor. This can, for example, increase measurement accuracy or reduce measurement errors, such as wear-related sensor drift.

[0013] Further preferred embodiments are found in the dependent claims and the entire disclosure, whereby the description of features does not always explicitly distinguish between device, process, and use aspects; in any case, the disclosure is implicitly to be read with regard to all claim categories. For example, if a component manufactured in a particular way is described, this also refers to a corresponding manufacturing process, and vice versa. Likewise, advantages described with regard to a specific application also refer to a corresponding use of the component. The component body is additively built up from the metal material, for example, based on a data model of the component body by selectively solidifying the previously formless or shapeless metal material (see below for details). The resulting component body is a single, in-piece part, i.e., it is, for example,It cannot be separated non-destructively. The metal material can be present as a continuous material within the component body, apart from interfaces between layers resulting from additive manufacturing.

[0014] The integrated sensor can be completely enclosed by the component body, for example, in such a way that the sensor cannot be removed from the component body. In other words, the sensor can be positively locked within the component body, even independently of any additional material-bonded embedding, see below for details. Preferably, the component body can completely enclose the sensor, e.g., except for an opening for the sensor's wiring.

[0015] Generally, in the context of this disclosure, "a" and "an" are to be read as indefinite articles unless explicitly stated otherwise, and thus implicitly also as "at least one" or "at least one." For example, several sensors can be integrated into the component body, such as those of the same sensor type or different sensors (e.g., for mechanical stress or strain, or temperature). Alternatively, however, only exactly one sensor can be integrated into the component body.

[0016] The hardness is specified here according to Rockwell scale C (HRC). Further lower limits for the at least partial hardening of the component body may be, for example, at least 45 HRC, 50 HRC or 55 HRC, and possible upper limits, for example, at a maximum of 70 HRC or 65 HRC.

[0017] In general, the component body can have a coating applied to the metal material that has a corresponding hardness (> 40 HRC). Such a layer can be applied, for example, as a PVD / CVD coating (e.g., at 100 °C to 250 °C) and be relatively hard and resistant, but may pose a challenge, for example, regarding the accessibility of hidden edges or undercuts. Alternatively, a hard metal could be applied to the metal material, e.g., by brazing (e.g., with local heat input), but this can have limited accuracy and thus require rework. Preferably, however, the metal material itself, from which the component body is additively built, is hardened, at least in certain areas.

[0018] According to a preferred embodiment, the metal material of the entire component body is hardened, meaning the entire metal material has a Rockwell hardness > 40 HRC (see above regarding further lower / upper limits). This can be achieved, for example, by heat treatment following additive manufacturing, generally by nitriding and case hardening at a high temperature of several hundred degrees Celsius, e.g., above 500 degrees Celsius. Induction and flame hardening are also possible in principle (although potentially complex from a manufacturing perspective). Preferably, however, the heat treatment is carried out at low temperatures; see below for details.

[0019] According to an alternative preferred embodiment, the metal material of the component body is only hardened in certain areas. Thus, it has a higher Rockwell hardness in a hardened area than in an unhardened area, for example, a hardness < 40 HRC in the unhardened area, and in particular < 35 HRC.

[0020] Preferably, the metal material is hardened in the area of ​​a functional surface of the component; for example, contact surfaces, bearing surfaces, and / or guide surfaces of the component can be hardened, while the areas in between can remain unhardened. Generally, this area-specific hardening can be achieved, for example, by a corresponding local heat treatment, such as local heat application with a laser, see below for details.

[0021] In general, an integrated sensor is a measuring device for determining a physical quantity. This could be, for example, a temperature sensor, such as a PTLOO or thermocouple, for temperature measurement. A fiber Bragg grating (FBG)-based sensor can also be integrated, as can an accelerometer or piezoelectric element. In general terms, the sensor can detect the physical quantity optically, electro-optically, or electronically. Preferably, the sensor can be a strain gauge, meaning that a mechanical force or stress is measured, for example, via deformation. In a preferred embodiment, the sensor is designed as a foil strain gauge, meaning it has, for example, a plastic carrier film. While a foil strain gauge can be widespread, proven, and therefore reliable and economically attractive, it can, for example,The plastic film may have limited temperature resistance (other temperature-sensitive components may include, for example, an adhesive and / or soft solder).

[0022] In general, the integration of a foil strain gauge into a component body additively manufactured from metal material can be of interest regardless of whether the component is at least partially hardened. Disclosure should therefore also include a component that comprises a component body made of metal material and a sensor, wherein the component body is additively manufactured from the metal material as a single, integral part, and wherein the sensor is enclosed by and thus integrated into the component body, and wherein the sensor is a foil strain gauge.

[0023] A combination with a component body or metal material that is at least partially hardened is preferred. Despite the limited high-temperature strength of the foil strain gauge (see above), the methods described here allow integration into a partially or even fully hardened component body, for example, due to local heat input or cryogenic treatment. Furthermore, one or more cooling channels can be incorporated into the component body, either during additive manufacturing or subsequently. A coolant can be supplied through these channels, allowing, for example, the area around the sensor to be cooled even if the entire component body is heated for hardening.

[0024] As mentioned at the beginning, the component can be used, for example, as a fastening element, such as in a machine, particularly a turbomachine or aircraft engine. As a fastening element, it can create a permanent, form-fit and / or force-fit connection between other components, for example, by being designed as a bolt, clamp, or hook. The integrated sensor can be used, for example, for assembly control and / or for monitoring during operation, e.g., also as a basis for needs-based repair or maintenance (changes in the sensor signal over time).

[0025] Another advantageous application lies in the area of ​​grippers or gripping systems, which are used, for example, to temporarily pick up workpieces or goods in production or logistics. The integrated sensors can, for instance, indicate correct gripping and / or prevent excessive force and thus damage to the workpiece / goods.

[0026] According to a preferred embodiment, the component is designed as a clamping element for a tool fixture, namely for clamping a workpiece. The component can be temporarily clamped in the tool fixture, for example, for material removal machining. The workpiece can be, for example, a blade for a stator or rotor of a turbomachine, which is machined following a shaping process (e.g., by casting). Regardless of the specific workpiece, a sensor integrated into the clamping element can measure, for example, a mechanical force or stress, and thus a clamping force applied by the clamping element can be set and / or monitored. Compared to torque-controlled force application, this can allow for more direct process control with fewer measurement errors. As a result, deviations in material removal, e.g.,Machining, processing of the individual workpiece and / or from workpiece to workpiece can be reduced.

[0027] The clamping element with the integrated sensor can be a contact element of the tool fixture, wherein typically one or more plungers are guided in the tool fixture so as to be displaceable relative to the contact element. The plunger(s) can press the clamped workpiece against the contact element, which can have a contour that is partially complementary to the workpiece. A sensor can be integrated into both the contact element and the plunger(s), meaning each can be a component in the present sense. In a preferred embodiment, at least one plunger with an integrated sensor is provided, wherein the component body forms a head and a guide part of the plunger. The guide part of the plunger can be guided in a corresponding receptacle of the tool fixture, e.g., so as to be linearly displaceable towards the workpiece or the contact element. The head is designed to contact the workpiece, thus pressing, for example,In the clamped state, the workpiece is pressed against the support element. The functional surfaces discussed above, where the component body is at least hardened, can be, for example, sliding guide surfaces on the guide part within the fixture and / or a contact surface on the head of the plunger designed to rest against the workpiece. The shape of the plunger's contact surface can be adapted to a contour of the workpiece, as detailed below.

[0028] A preferred embodiment relates to a tool device for clamping a workpiece, comprising a clamping element and a plunger that is displaceable relative to the clamping element. The clamping element and / or the plunger is designed as a component with an integrated sensor (see the preceding remarks). Preferably, the tool device can have several plungers, at least some of which are then designed as components with an integrated sensor.

[0029] A preferred embodiment relates to a manufacturing process for a component, wherein i) the component body is additively built up from the metal material and the sensor is enclosed by the component body; ii) the component body is hardened at least in certain areas.

[0030] The additive manufacturing process in step i) can be performed layer by layer. After the first part of the component body has been built, the additive manufacturing process can be interrupted and the sensor inserted before the second part of the component body is built, and in particular, before the second part is completed. After the sensor is inserted into the first part, it can be further bonded, i.e., embedded in a material-bonded manner. This can be done, for example, by welding or bonding. As mentioned at the beginning, exactly one sensor or several sensors can be integrated into the component body; therefore, the manufacturing process can be interrupted multiple times, and a sensor inserted each time, and / or several sensors can be inserted simultaneously.

[0031] The additive manufacturing of the component body can be carried out, for example, using a powder bed process, in which the metal material in powder form is applied sequentially layer by layer. In each layer, a predetermined area, based on the component body's data model, is selectively solidified, for example, by melting using a beam source, preferably a laser source. This is also known as selective laser melting (SLM).

[0032] As mentioned at the outset, in a preferred embodiment, the metal material itself, from which the component body was previously constructed, is hardened in step ii). Before hardening, the component body can be post-processed by material removal; for example, its surface can be smoothed and / or the contour of a contact surface can be adjusted (see above).

[0033] According to a preferred embodiment, hardening takes place during a cryogenic treatment, meaning that the component body is cooled to at least 0 °C in step ii) (where 0 °C is an upper limit that the temperature should reach or fall below during the cryogenic treatment). In other words, the temperature to which the component is cooled during the cryogenic treatment is at most 0 °C; other possible upper limits could be, for example, -20 °C, -40 °C, -50 °C, -70 °C, -80 °C, or -90 °C (possible lower limits could be, for example, -200 °C, -150 °C, or -100 °C). In a preferred embodiment, the metal material can be a martensitic steel, e.g., X15TN. During the additive manufacturing of such materials, a temperature gradient can occur during cooling that is sufficient for the subsequent cryogenic treatment to transform retained austenite into a martensitic microstructure.The increase in hardness during low-temperature treatment can result from this structural transformation from austenite to martensite, whereby, for example, a complete transformation to martensite can also be achieved in the aforementioned temperature range.

[0034] According to an alternative preferred embodiment, which allows in particular the production / obtaining of a component body with selectively hardened metal material, the component body is locally heat-treated in step ii) by irradiation, preferably with a laser beam. This allows for selective temperature application, whereby, for example, the part of the component body in which the sensor is arranged is heated less intensely. This also allows, for example, the integration of a temperature-critical sensor, such as a foil strain gauge (see above). In a preferred embodiment, the metal material has a carbon content of at least 0.2 wt%, more preferably at least 0.3 wt%, and can, for example, be a chromium and / or molybdenum alloy, such as 42CrMo4.

[0035] One potential application for the component with integrated sensor is in turbomachinery, such as gas turbines or aircraft engines. The component can be used, for example, to mount another component, but it can also be used independently of a mounting function within the turbomachine, e.g., as a component located in its gas channel, such as a stator or rotor, or a part thereof, e.g., a guide vane or impeller. The component, or rather its sensor, can be used to collect usage data during the turbomachine's operation.

[0036] A preferred embodiment relates to the use of a component with an integrated sensor for fastening another component (e.g., in a turbomachine, but also independently of this application) and / or for clamping a workpiece and / or for gripping; see above for further details. During mechanical fastening and / or clamping, measurements are also taken with the sensor, at least intermittently. In a preferred embodiment, the measurement data acquired with the sensor are used in a control loop; for example, the clamping of the workpiece in the tooling fixture and / or the machining of the workpiece are adjusted or controlled based on the sensor measurement. The same applies when gripping a workpiece / item with a gripper or gripping system.

[0037] Brief description of the drawings

[0038] The invention will now be explained in more detail using an exemplary embodiment, whereby the individual features within the scope of the dependent claims may also be essential to the invention in other combinations, and no distinction will be made in detail between the different claim categories.

[0039] In detail, it shows

[0040] Figure 1a shows a component with an integrated sensor in a schematic side view;

[0041] Figure 1b shows the component according to Figure 1a in a schematic top view;

[0042] Figure 2 shows a schematic oblique view of the component according to Figures 1a,b;

[0043] Figure 3 shows a tool device with a clamped workpiece;

[0044] Figure 4 shows a turbomachine, specifically a turbofan engine, in a schematic longitudinal section;

[0045] Figure 5 shows an intermediate step in the production of a component with an integrated sensor;

[0046] Figure 6 shows some process steps in a flowchart.

[0047] Preferred embodiment of the invention

[0048] Figure 1a shows a component 1 comprising a component body 2 and a sensor 3. The component body 2 is additively manufactured from a metal material 20, with the sensor 3 enclosed within the component body 2. Reference is made to Figure 1b, which shows a top view of the component 1, while Figure 1a shows a side view. The comparison clearly illustrates how the component body 2, or rather its metal material 20, encloses the sensor 3. The sensor 3, located within the component body 2, is shown as a dashed line in Figures 1a and 1b. This also applies to a channel 21 through which a cable leads from the sensor 3 to the outside (not shown).

[0049] In the example shown, the sensor 3 is a strain gauge 30, specifically a foil strain gauge 31, which can be used to determine deformation and thus mechanical stress. The component 1 is a clamping element 10, which can be used to clamp a workpiece in a tooling fixture (see Figure 3 for details). The integrated strain gauge 30 allows forces or stresses occurring in the clamping element 10 to be determined.

[0050] Figure 2 illustrates component 1, or clamping element 10, in an oblique view. In this case, it is a plunger 11 comprising a guide part 11.1 and a head 11.2. The plunger 11 is guided by the guide part 11.1 in a cam (not shown) in such a way that the head 11.2 is pressed against the workpiece to clamp it (see Figure 3).

[0051] In Figure 2, the functional surfaces 12 of component 1 or plunger 11 are marked with hatching. These are, firstly, guide surfaces 12.1, along which the guide part 11.1 slides in the guide. Secondly, a contact surface 12.2 is formed on the head 11.2, which presses against the workpiece when clamped.

[0052] The component body 2 is hardened at least in certain areas; in this case, the metal material 20 has a Rockwell hardness of at least 55 HRC, at least in the area of ​​the functional surfaces 12. The hardening can be limited to the functional surfaces 12, or alternatively, the entire metal material 20 can be hardened. Figure 3 shows a tooling device 40, which has clamping elements 10 equipped with sensors 3 as described above for clamping a workpiece 50. In this case, the workpiece 50 is a blade 51 for an aircraft engine, as illustrated in Figure 4. The workpiece 50, or blade 51, is shown in section in Figure 3, i.e., in profile.

[0053] A clamping element 10 of the tool device 40 serves as a contact element 41 against which the blade 51, in the example shown, is pressed with its suction side. The other clamping elements 10, which are positioned relative to the contact element 41 and are movable, are plungers 11, as described above. Additional plungers may be provided offset from the plane of the drawing, which press the workpiece 50 or blade 51 against the contact element 41.

[0054] As shown in Figure 3, the clamping elements 10 can be equipped with sensors 3 as described above, i.e., one or more of the plungers 11 and / or the support element 41. For the lower plunger 11 in Figure 3, a computer unit 60 schematically illustrates how sensor data 61 are read out. This data can be used, for example, in a control loop 70, i.e., to generate control data 71. As shown, the control data 71 can relate to the adjustment of the clamping and / or, alternatively, to the control of a machining tool (not shown).

[0055] Figure 4 shows a schematic longitudinal section of a turbomachine 100, in this example a turbofan engine 110. The turbomachine 100 is functionally divided into a compressor 101, a combustion chamber 102, and a turbine 103. In the compressor 101, intake air is compressed. In the combustion chamber 102, fuel, e.g., kerosene, is added and this mixture is burned. The resulting hot gas is expanded in the downstream turbine 103, thereby driving its rotors 103.1 and thus also the rotors 101.1 of the compressor 101. Furthermore, both the compressor 101 and the turbine 103 have stators 101.2 and 103.2, respectively. Both the rotors 101.1, 103.1 and the stators 101.2, 103.2 each have a plurality of circumferentially arranged blades, one such blade being shown in section in Figure 3. Figure 5 illustrates an intermediate step in the manufacture of the component with integrated sensor 3.The component body is built up from the metal material 20 using a known powder bed process 80, in which the metal material 20 is applied layer by layer in the form of a powder 25 and selectively solidified with a laser beam 81. The component body, or the part thereof produced at any given time, is arranged on a platform 82, which is lowered after the solidification of each layer and before the application of the subsequent layer.

[0056] Figure 5 shows an intermediate step, as this process is temporarily interrupted. A first part 2.1 of the component body 2 has been built up so far, in which an upwardly open cavity 85 is formed. The powder 25 is removed from this cavity, and then the sensor 3 is inserted. After the sensor 3 is possibly filled with, for example, adhesive (not shown), the additive manufacturing process continues, i.e., the component body 2 is closed around the sensor. The representation in Figure 5 is schematic; the component body 2 can also be built up in a different orientation, e.g., upright (rotated 90°) or rotated 180°, for optimization purposes such as considering overhangs.

[0057] Figure 6 summarizes some process steps in a flowchart. A sensor modification 200 can include the additive manufacturing 201 of a first part of the component body. The sensor is then inserted into the first part of the component body 202, before a second / remaining part of the component body is additively manufactured 203. Subsequently, the component body or metal material is hardened 210, e.g., by cooling 211 to approximately -90 °C. The metal material can be a martensitic steel. Alternatively, hardening 210 can be achieved by local heat treatment 212 with a laser, e.g., of a carbon steel. REFERENCE SYMBOL LIST

[0058] Component 1

[0059] Component body 2, first part 2.1

[0060] Sensor 3

[0061] Clamping element 10

[0062] Pestle 11

[0063] Guide section 11.1

[0064] Head 11.2

[0065] 12 functional areas

[0066] Guide surfaces 12.1

[0067] Contact area 12.2

[0068] Metal material 20

[0069] Channel 21

[0070] Powder 25

[0071] Strain gauges 30

[0072] Foil DMS 31

[0073] Tool fixture 40

[0074] Plant element 41

[0075] workpiece 50

[0076] 51 shovel blade

[0077] Computer unit 60

[0078] Sensor data 61

[0079] Control loop 70

[0080] Tax data 71

[0081] Powder bed fusion 80

[0082] Laser beam 81

[0083] Platform 82

[0084] Cavity 85

[0085] Turbomachine 100

[0086] Compressor 101 Rotors 101.1

[0087] Stators 101.2

[0088] Combustion chamber 102

[0089] Turbine 103 Rotors 103.1

[0090] Stators 103.2

[0091] Mantel stromtri eb werk 110

[0092] Conversion 200 additive manufacturing 201 first part of the component body inserted 202 second / remaining part of the component body is additively manufactured 203

[0093] Hardness 210

[0094] From cooling en 211 local heat treatment 212

Claims

REQUIREMENTS 1. Component (1) comprising: a component body (2) made of a metal material (20); a sensor (3); wherein the component body (2) is additively manufactured as a single, in-piece part from the metal material (20), wherein the sensor (3) is enclosed by the component body (2) and thus integrated into the component body (2), and wherein the component body (2) is at least partially hardened and has a Rockwell hardness of at least 40 HRC.

2. Component (1) according to claim 1, in which the entire metal material (20) of the component body (2) is hardened.

3. Component (1) according to claim 1, in which the metal material (20) of the component body (2) is only hardened in certain areas.

4. Component (1) according to one of the preceding claims, wherein the sensor (3) is a strain gauge (30), in particular a foil strain gauge (31).

5. Component (1) according to one of the preceding claims, which is designed as a clamping element (10) for a tool device (40) and is designed to clamp a workpiece (50) in the tool device (40).

6. Component (1) according to claim 5, wherein the clamping element (10) is a plunger (11) and the component body (2) forms a head (11.2) and a guide part (11.1) of the plunger (11), wherein the head (11.2) is designed to rest against the workpiece (50) and the guide part (11.1) is designed to guide in the tool device (40).

7. Tool device (40) designed for clamping a workpiece (50) comprising a support element (1); a plunger (11); wherein the plunger (11) is guided displaceably in the tool device (40) relative to the support element (41), and wherein the support element (41) and / or the plunger (11) is a component (1) according to claim 5 or 6.

8. Method for manufacturing a component (1) according to one of claims 1 to 6 or a tool device (40) according to claim 7, wherein i) the component body (2) is additively built up from the metal material (20) (201, 203) and the sensor (3) is enclosed by the component body (2) (200); ii) the component body (2) is hardened at least in certain areas (210).

9. Method according to claim 8, wherein in step ii) the metal material (20) is hardened at least in certain areas.

10. Method according to claim 9, wherein the entire metal material (20) of the component body (2) is hardened by cooling the assembled component body (2) to at least 0 °C in step ii) (211).

11. Method according to claim 10, wherein the metal material (20) is a martensitic steel.

12. Method according to claim 9, wherein the metal material (20) of the component body (2) is locally heat-treated with a laser in step ii) (212).

13. Method according to claim 12, wherein the metal material (20) has a carbon content of at least 0.2 wt.%.

14. Use of a component (1) according to one of claims 1 to 6 for fastening another component (1), in particular in a turbomachine (100), or as a component (1) of a turbomachine (100), in particular as a component arranged in a gas channel of the turbomachine (100), or for clamping a workpiece (50), in particular in a tool device (40) according to claim 7, or for gripping a workpiece (50) or goods with a gripper, wherein sensor data (61) are recorded at least temporarily with the sensor (3).

15. Use according to claim 14, wherein the sensor data (61) are used in a control loop (70).

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