Method for producing a flow component for flow deflection by means of a 3D printing method, flow component for flow deflection, and turbine engine having such a flow component

Abstract

The invention relates to a method (10) for producing a flow component (20) for flow deflection by means of a 3D printing method. The method comprises: printing (12) a plurality of flow-guiding elements (22) and a plurality of support structures (23), which are arranged between the flow-guiding elements (22), in a printing direction (15); printing (13) a closure element (24) which is connected to the flow-guiding elements (22) and the support structures (23), the closure element (24) comprising a structure having extensions (25) on a side (241) facing the printing direction (15), the extensions (25) being supported by the support structures (23) during printing of the closure element (24); and removing (14) the support structures (23) after printing of the closure element (24) has been completed.

Description

METHOD FOR MANUFACTURING A FLOW COMPONENT FOR FLOW REVERSING USING A 3D- PRESSURE PROCESS, FLOW COMPONENT FOR FLOW REVERSION, AND TURBO MACHINE WITH SUCH A FLOW COMPONENT TECHNICAL AREA

[0001] The invention relates to a method for manufacturing a flow deflector component using a 3D printing process. The invention further relates to a flow deflector component and a turbomachine with such a flow deflector component. TECHNICAL BACKGROUND

[0002] Additive manufacturing, also known as 3D printing, is a manufacturing technology that allows components to be built layer by layer from digital models. Unlike traditional manufacturing processes, where material is removed or shaped through milling, turning, or casting, additive manufacturing offers the advantage of being able to produce virtually any shape with high precision and without the need for complex tooling. This technology has proven particularly valuable in mechanical engineering, as it enables the production of complex and customized components at lower costs and with shorter production times. The ability to process materials precisely and selectively allows for the production of components with optimized geometries and improved functional properties that would be difficult to achieve with conventional methods.Additive manufacturing opens up new design possibilities, such as the integration of lightweight but stable structures or the production of components with internal channels or. complex geometries that cannot be achieved with conventional manufacturing techniques.

[0003] Flow control components for turbomachinery play a central role in the efficiency and performance of modern turbomachinery, such as turbochargers, gas turbines, and compressors. These components are designed to precisely direct and optimize fluid flow within the machine to ensure optimal energy utilization and improved flow characteristics. By precisely controlling the flow direction and velocity, flow control components can improve flow properties, such as reducing turbulence or minimizing losses, which directly impacts the efficiency and performance of the turbomachine.

[0004] A major problem with 3D printing lies in the physical and geometric limitations of the technology when producing overhangs—that is, parts of a structure that are suspended in mid-air without direct support. To create overhanging structures using 3D printing, they require support structures, which must be added during the printing process to ensure a stable printing environment. However, these support structures not only require additional material but also incur significant extra costs, both in terms of material usage and production time. Furthermore, removing the support structures after printing is a time-consuming and labor-intensive process, further increasing the overall cost.Furthermore, the need for support structures can limit the design of complex and innovative geometries, as the functionality of the support structures must be considered during the component design and adapted to its printability. This reduces the flexibility and potential of additive manufacturing to achieve optimal, lighter, or more functional designs.

[0005] The object of the present invention is therefore to provide a method for manufacturing a flow component, a flow component and a to provide a turbomachine with such a flow component, with which one or more of the disadvantages known from the prior art can be partially or completely overcome. BRIEF DESCRIPTION OF THE INVENTION

[0006] To solve the aforementioned problem, a method for manufacturing a flow deflection component using a 3D printing process, a flow deflection component, and a turbomachine according to the independent claims are provided. Further aspects, advantages, and features of the present invention can be found in the dependent claims, the description, and the accompanying figures.

[0007] According to a first aspect of the invention, a method for manufacturing a flow deflector component using a 3D printing process is provided. The method comprises printing several flow guide elements and several support structures arranged between the flow guide elements in a printing direction. Furthermore, the method comprises printing a terminal element connected to the flow guide elements and the support structures. The terminal element has a structure with projections on one side facing the printing direction. The projections are supported by the support structures during the printing of the terminal element. The method further comprises removing the support structures after completion of the printing of the terminal element.

[0008] The manufacturing process according to the invention offers significant advantages in terms of efficiency and cost reduction in the 3D printing process. In particular, the provision of the structure with extensions considerably minimizes the need for support structures, which significantly reduces both material consumption and manufacturing time. This leads to a substantial reduction in production costs and enables faster manufacturing of components. At the same time, post-processing effort is significantly reduced, as less support material needs to be removed, simplifying the entire process. The reduction of support structures and the associated manufacturing steps not only ensures efficient resource utilization but also opens up new design possibilities for complex components. Overall, the invention contributes to making the 3D printing process more economical and flexible, offering considerable advantages in both the production and development of components.

[0009] According to a second aspect of the invention, a flow deflector component is provided. The flow deflector component comprises several flow guide elements that are integrally connected to a closing element. The closing element has a structure with projections on a side facing the flow guide elements. The projections are arranged and designed to provide support for the closing element during the manufacture of the flow deflector component using the method according to the embodiments described herein.

[0010] According to a third aspect of the invention, a turbomachine, in particular a turbocharger, is provided with a flow component according to one of the embodiments described herein. BRIEF DESCRIPTION OF THE FIGURES

[0011] The invention will now be explained with reference to exemplary embodiments illustrated in the figures, from which further advantages and modifications will become apparent. These figures show: Figure 1 shows a schematic representation of a method for manufacturing a flow deflection component using a 3D printing process according to an embodiment described herein; Figure 2 shows a schematic representation of a process for manufacturing a Flow component for flow deflection using a 3D printing process according to a further embodiment described herein; Figure 3 shows a schematic representation of the state of the art Figures 4, 5 and 6 show schematic detail views of a termination element with extensions according to the embodiments described herein; Figure 7 shows a schematic perspective section view of a flow component according to the embodiments described herein; and Figures 8 and 9 are schematic perspective views of a flow component according to the embodiments described herein. DETAILED DESCRIPTION OF THE FIGURES

[0012] The following describes various embodiments, one or more examples of which are shown in each figure. Each example serves for illustrative purposes and is not to be understood as a limitation. For example, features shown or described as part of one embodiment can be used on or in combination with any other embodiment to obtain a further embodiment. It is intended that this disclosure includes such modifications and variations.

[0013] In the following description of the figures, the same reference numbers refer to the same or similar components. Generally, only the differences between the individual embodiments are described. Unless otherwise stated, the description of a part or aspect in one embodiment may also refer to a corresponding part or aspect in another embodiment.

[0014] With reference to Figure 1, a method 10 for manufacturing a flow deflector component 20 using a 3D printing process according to embodiments of the present disclosure is described. According to one embodiment, which can be combined with other embodiments described herein, the method 10 comprises printing (represented by block 12) several flow guide elements 22 and several support structures 23 arranged between the flow guide elements 22 in a printing direction 15. Furthermore, the method 10 comprises printing (represented by block 13) a termination element 24, which is connected to the flow guide elements 22 and the support structures 23. The termination element 24 has a structure with extensions 25 on a side 241 facing the printing direction 15. The extensions 25 are supported by the support structures 23 during the printing of the termination element 24.Furthermore, the procedure includes the removal (represented by block 14) of the support structures 23 after completion of the printing of the finishing element 24.

[0015] This provides a beneficial additive manufacturing process for flow-optimized components, offering improved efficiency and cost-effectiveness. Integrating the structure with extensions significantly reduces the need for support structures, leading to a substantial decrease in material usage and manufacturing time. This lowers production costs and enables faster component manufacturing. Simultaneously, post-processing effort is reduced, as less support material needs to be removed, simplifying the entire process. Minimizing support structures and their associated manufacturing steps promotes more efficient resource utilization and opens up new possibilities for designing complex components. Overall, the invention contributes to making the 3D printing process more economical and flexible, offering advantages in both production and component development.

[0016] To illustrate the advantages of the invention compared to the prior art, Figure 3 shows a schematic representation of a component 30, which was manufactured in a printing direction 15 according to a prior art 3D printing process. The component 30 comprises several flow guide elements 32 and a closing element 34, which extends transversely to the printing direction 15. In the prior art, the side 341 of the closing element 34 facing the flow guide elements 32 is flat, so that, compared to the invention, a significantly higher number of support structures 33 are required to manufacture the closing element 34 using the 3D printing process.

[0017] In the present disclosure, a "flow deflection component" can be understood to be an element or device used in a fluid-mechanical system, for example, a turbomachine, to selectively change the flow direction of a fluid medium (e.g., air, gas, or liquid). Typically, the flow deflection component is a device designed to selectively change the direction of a flow without causing significant energy or efficiency losses. Such components are typically designed to minimize flow resistance and reduce turbulence. In particular, flow deflection components have fluid-dynamically optimized shapes to ensure the most uniform possible deflection of the flow.

[0018] 3D printing can be understood as a process that creates three-dimensional objects directly from a digital model by building up material layer by layer. A model of the component to be manufactured is created in CAD software and divided into individual layers, which a printer applies sequentially. This technique belongs to the additive manufacturing processes, in which material is added instead of being removed by cutting or milling, as in subtractive processes. This layer-by-layer construction enables 3D printing to... the production of complex geometries, individual components and rapid prototypes, while minimizing material losses.

[0019] Typically, the 3D printing process for manufacturing a flow component according to the embodiments described herein is a metal 3D printing process in which the component is produced by layer-by-layer application and fusing of metallic material. The starting material, for example, metal powder or metal wire, is processed using energy sources such as lasers, electron beams, or plasma to bond the layers together.

[0020] For example, the 3D printing process according to the embodiments described herein can be a selective laser melting (SLM) process, in which a laser selectively melts metal powder to produce components with high density and strength. Alternatively, the 3D printing process according to the embodiments described herein can be a direct metal laser sintering (DMLS) process. The main difference between DMLS and SLM is that DMLS only sinters (partially melts) the metal powder, while SLM melts it completely. As a result, SLM produces components with higher density and strength, while DMLS is more energy-efficient and may be better suited for complex alloys. The choice of process depends on the specific requirements of the component and the cost.The key difference between Direct Metal Laser Sintering (DMLS) and Selective Laser Melting (SLM) lies in the fact that in the DMLS process, the metal powder is merely sintered, with the particles being heated to just below their melting point and thus bonded together. In contrast, the SLM process involves the complete melting of the metal powder, resulting in a homogeneous and virtually pore-free material structure. This complete fusion leads to components with higher density and strength. DMLS, however, is characterized by higher energy efficiency. This enables the processing of complex material alloys that are less suitable for complete melting. The selection of the appropriate process depends on the mechanical and structural requirements of the component as well as the economic conditions.

[0021] Another alternative 3D printing method according to the embodiments described herein is electron beam melting (EBM), in which an electron beam is used instead of a laser, making the method particularly suitable for heat-resistant materials such as titanium. Another alternative 3D printing method for metal is binder jetting, in which a metal powder is held together by a liquid binder and then hardened in a sintering furnace. A further possible 3D printing method is direct energy deposition (DED), in which the metal material, in the form of wire or powder, is applied directly to a component surface and simultaneously fused. This method is particularly flexible and is also suitable for repairing existing metal parts.

[0022] Another possible 3D printing method according to the embodiments described herein is the Laser Powder Bed Fusion (LPBF) process. The LPBF process typically begins with the uniform application of a thin layer of metal powder onto a build platform. A high-power laser then melts the powder precisely along the contours of a 3D CAD model. The powder is completely melted, creating a dense and solid layer. This process is repeated layer by layer: After a layer is fused, the build platform lowers, and a new layer of powder is applied. Layer by layer, the component grows until the desired shape is complete. Once printing is finished, the component is cleaned of excess powder and removed from the build platform. Depending on requirements, additional post-processing steps such as heat treatment or surface finishing can be performed.LPBF is characterized by its high precision and material efficiency. because unprocessed powder can be recycled.

[0023] In this disclosure, the “printing direction” refers to the orientation in which the material is applied during the 3D printing process, particularly during the layer-by-layer construction of the component. In other words, the printing direction indicates the direction in which the individual layers are stacked on top of each other. It should be noted that the printing direction typically influences material utilization, the surface finish of the parts, and properties such as strength and stiffness, since materials can exhibit different mechanical properties in different directions. Typically, the printing direction is chosen to maximize the component's strength in the critical load directions.

[0024] In the present disclosure, "flow-guiding elements" can be understood to mean parts of a flow component described herein that are configured for the targeted deflection and control of the flow pattern. In particular, the flow-guiding elements are typically shaped and designed to influence the direction and / or velocity of the flow in order to achieve a desired flow configuration.

[0025] In the present disclosure, "support structures" can be understood to mean temporary structures used during the 3D printing process to stabilize a subsequent part extending transversely to the printing direction, in particular the end element according to the embodiments described herein. In other words, the support structures refer to special, temporarily provided structures to support overhangs, complex geometries, or areas that would not be stable without support during printing.

[0026] In the present disclosure, a “closing element” can be understood as a structural element that serves to complete a component, In particular, the end element is used to complete, close, or stabilize the flow component described herein in a specific direction, especially in the pressure direction. Typically, the end element forms an outer boundary or surface of the component. It is a part that is connected to other components of the system to create the overall structure.

[0027] In the present disclosure, a “structure with extensions” can be understood as a geometry or design of a component in which additional, protruding elements (extensions) are provided on a certain surface, in particular on a side of the end element facing the flow-guiding elements described herein. As described in the present disclosure, the extensions can have different characteristics, in particular shapes.

[0028] According to one embodiment, which can be combined with other embodiments described herein, the end element is a ring element. Typically, the extensions 25 extend from an outer radius Ra of the end element 24 to an inner radius Ri of the end element 24. In particular, the vertices 26 of the extensions extend from the outer radius Ra of the end element 24 to the inner radius Ri of the end element 24. The term vertex of the extensions typically refers to the outermost point or highest elevation of an extension structure. In the present context, especially for components manufactured by means of 3D printing, the vertex describes the outermost region of an extension geometry, which typically has the greatest distance from the origin of the extensions.

[0029] As illustrated by example in Figure 7, the contour of the extensions 25 can be adapted to a flow pattern specified by the flow-guiding elements 22.

[0030] According to one embodiment, which is comparable to others described herein The embodiments can be combined, the extensions 25 each have The flat side surfaces 251 form at least partially planar faces. These planar faces form a vertical angle α, as illustrated by way of example in Figures 4, 5, and 6. Typically, the vertical angle α is selected from a range αl < ..., where αl is the lower limit of the angle range and αl is the upper limit of the angle range. The lower limit can be αl = 25° or αl = 30°. The upper limit can be αl = 140° or αl = 120°.

[0031] According to one embodiment, which can be combined with other embodiments described herein, the extensions 25 each have vertices 26 that are rounded, flattened, or pointed. Typically, the extensions 25, and in particular the vertices 26 of the extensions 25, are arranged at uniform intervals in the circumferential direction. According to one example, the extensions 25 can form a corrugated structure.

[0032] According to one embodiment, which can be combined with other embodiments described herein, the method may further include printing a base element 21. Typically, the flow guide elements 22 and the support structures 23 extend from and are connected to the base element 21, as illustrated by way of example in Figure 9.

[0033] According to a broad aspect of the present disclosure, a flow control element 20 is provided for flow deflection. The flow control element 20 comprises several flow guide elements 22, which are integrally connected to a termination element 24. The termination element 24 has a structure with extensions 25 on a side 241 facing the flow guide elements 22. In particular, the flow control element 20 is provided by a method 10 according to one of the embodiments described herein.

[0034] The end element 24 of the flow component 20 can be a ring element, as shown by way of example in Figures 8 and 9. Typically, the extensions 25 extend from the outer radius Ra of the end element 24 to the inner radius Ri of the end element 24. For the sake of simplicity, the extensions 25 are not explicitly shown in Figures 8 and 9. It is understood that the side 241 of the end element 24 facing the flow guide elements typically includes extensions 25 according to the embodiments described herein. As already described in connection with the manufacturing process, the contour of the extensions 25 can be adapted to a flow pattern defined by the flow guide elements 22.

[0035] Typically, the extensions 25 each have at least partially flat side surfaces 251, wherein the flat side surfaces 251 form a vertical angle α. Typically, the vertical angle α is selected from a range α < α < α2 described herein. The vertices 26 of the extensions 25 can be rounded, flattened, or pointed. Furthermore, the extensions 25, in particular the vertices 26 of the extensions 25, can be arranged at uniform intervals in the circumferential direction. According to one example, the extensions 25 can form a corrugated structure.

[0036] According to one embodiment, which can be combined with other embodiments described herein, the flow component 20 comprises a base element 21, as shown by way of example in Figure 9. The flow guide elements 22 and the support structures 23 typically extend from the base element 21 and can be connected to the base element. The flow component 20 is typically a single piece and is manufactured by a method 10 according to the embodiments described herein.

[0037] The flow component 20 can, for example, be a nozzle ring or a diffuser, particularly for a turbomachine. Figure 8 shows an example of a nozzle ring open at one end, while Figure 9 shows a closed nozzle ring. It is understood that the invention is not limited to the flow components described here, such as nozzle rings or diffusers. The invention is not limited to a specific type of flow control device, but is fundamentally applicable to all possible flow deflection components. Furthermore, it should be noted that the invention also encompasses a turbomachine, in particular a turbocharger, which includes a flow deflection component according to the embodiments described herein.

[0038] As can be seen from the embodiments described herein, the invention optimizes the 3D printing process by significantly reducing support structures, resulting in lower material usage and faster manufacturing. This not only lowers production costs but also shortens manufacturing time and reduces post-processing effort, as less support material needs to be removed. Overall, the invention contributes to increased efficiency, cost reduction, and greater production flexibility. REFERENCE MARK LIST 10 methods for manufacturing a flow component Step 11: Printing a basic element 12. Process step: Printing multiple flow guide elements and support structures 13th process step: Printing a finishing element Step 14: Removing the support structures 15 Print direction 20 Flow component 21 Basic element 22 flow guide elements 23 supporting structures 24 Final element 241 Side of the end element facing the flow guide elements 242 Side of the end element facing away from the flow guide elements 25 extensions 251 at least partially flat side surfaces 26 vertices of the processes 30 components according to the state of the art 32 flow guide elements 33 support structures 34 Closing element 341 Side of the end element facing the flow guide elements Ra outer radius of the end element Ri inner radius of the end element a vertex angle of the extensions

Claims

REQUIREMENTS 1. Method (10) for manufacturing a flow component (20) for flow deflection using a 3D printing process, comprising: - Printing (12) of several flow guide elements (22) and several support structures (23) arranged between the flow guide elements (22) in a pressure direction (15); - Printing (13) of a closing element (24) connected to the flow guide elements (22) and the support structures (23), wherein the closing element (24) has a structure with extensions (25) on a side (241) facing the pressure direction (15), wherein the extensions (25) are supported by the support structures (23) during the printing of the closing element (24); and - Removal (14) of the support structures (23) after completion of printing the finishing element (24).

2. Method (10) according to claim 1, wherein the end element (24) is a ring element, and wherein the extensions (25), in particular the apex (26) of the extensions, extend from an outer radius (Ra) of the end element (24) to an inner radius (Ri) of the end element (24).

3. Method (10) according to claim 1 or 2, wherein a contour of the extensions (25) is adapted to a flow pattern specified by the flow guide elements (22).

4. Method (10) according to one of claims 1 to 3, wherein the extensions (25) each have at least partially flat side surfaces (251), wherein the flat side surfaces (251) form a vertical angle α, and wherein the vertical angle α is selected from a range αl < ..., wherein αl = 25°, in particular wherein αl = 30°, wherein αl = 140°, in particular wherein αl = 120°.

5. Method (10) according to any one of claims 1 to 4, wherein the extensions (25) each have vertices (26) which are rounded, flattened or pointed, in particular wherein the extensions (25), in particular the vertices (26) of the extensions (25), are arranged uniformly spaced apart in the circumferential direction.

6. Method according to any one of claims 1 to 5, wherein the extensions (25) form a corrugated structure.

7. Method according to any one of claims 1 to 6, further comprising printing a base element (21), wherein the flow guide elements (22) and the support structures (23) extend from the base element (21) and are connected to the base element.

8. Flow component (20) for flow deflection, comprising several flow guide elements (22) which are integrally connected to a closing element (24), wherein the closing element (24) has a structure with extensions (25) on a side (241) facing the flow guide elements, wherein the extensions are arranged and designed to provide support for the closing element (24) during the manufacture of the flow component (20) by means of the method according to one of claims 1 to 7.

9. Flow component (20) according to claim 8, wherein the end element (24) is a ring element, and wherein the extensions (25) extend from an outer radius (Ra) of the end element (24) to an inner radius (Ri) of the end element (24).

10. Flow component (20) according to claim 8 or 9, wherein a contour of the extensions (25) is adapted to a flow pattern specified by the flow guide elements (22).

11. Flow component (20) according to one of claims 8 to 10, wherein the extensions (25) each have at least partially flat side surfaces (251), wherein the flat side surfaces (251) form a vertex angle α, and wherein the vertex angle α is selected from a range αl < ..., wherein αl = 25°, in particular αl = 30°, wherein αl = 140°, in particular αl = 120°.

12. Flow component (20) according to one of claims 8 to 11, wherein the extensions (25) each have vertices (26) which are rounded, flattened or pointed, in particular wherein the extensions (25), in particular the The vertices (26) of the extensions (25) are arranged at uniform intervals in the circumferential direction.

13. Flow component (20) according to one of claims 8 to 12, wherein the extensions (25) form a corrugated structure.

14. Flow component (20) according to one of claims 8 to 13, wherein the flow component (20) is a nozzle ring or a diffuser, in particular for a turbomachine, in particular wherein the flow component (20) comprises a base element (21), wherein the flow guide elements (22) and the support structures (23) extend from the base element (21) and are connected to the base element, in particular wherein the flow component is a single piece.

15. Turbomachine, in particular turbocharger, with a flow component (20) according to one of claims 8 to 14. 18 / 19

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