Additive Composite Layering With Dense-Porous Phases for Crack Relief
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Solution Overview
Problem
Existing additive manufacturing methods struggle to produce high-strength, precipitation-hardened nickel- or cobalt-based superalloys with sufficient reproducibility and process reliability, often resulting in high intrinsic stresses and cracking issues.
Innovation Solution
A method of layer-by-layer additive manufacture that alternates between producing a dense first material phase and a porous second material phase, using selective irradiation techniques such as selective laser sintering or electron beam melting, to reduce intrinsic stresses and improve crack propagation characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If selective laser melting or electron beam melting is used to produce high-strength precipitation-hardened superalloys, then mechanical strength and durability are improved, but intrinsic stresses and cracking issues worsen
Solution Approach 1:
The build process is segmented into alternating layers of dense material (produced by selective laser melting) and porous material (produced by electron beam melting with lower energy input). This segmentation allows the structure to accommodate thermal stresses differently in each layer, preventing crack propagation while maintaining overall mechanical strength.
Solution Approach 2:
Different regions of the component have different material densities - dense regions provide mechanical strength while porous regions act as stress relief zones. The porous layers are strategically positioned to reduce intrinsic stresses without compromising the overall structural integrity of the component.
2Strength
If complete melting is used to produce dense material structure, then mechanical strength is improved, but production speed and energy efficiency worsen
Solution Approach 1:
The manufacturing process alternates periodically between complete melting (for dense layers) and partial melting/sintering (for porous layers). This periodic action allows the system to achieve necessary material density in critical layers while maintaining higher production speed in non-critical layers, optimizing the balance between strength and productivity.
Solution Approach 2:
The energy input parameters are dynamically changed between layers - high energy input for dense layers requiring complete melting, and reduced energy input for porous layers using sintering or partial melting. This parameter optimization reduces overall production time while maintaining necessary material properties.
3Reliability
If alternating dense and porous material phases are produced, then intrinsic stresses and crack propagation are reduced, but manufacturing complexity increases
Solution Approach 1:
The additive manufacturing system is configured to perform multiple functions using the same equipment - both selective laser melting and electron beam melting are utilized in sequence to produce different material phases. This multi-functionality approach avoids the need for separate manufacturing processes while achieving the desired alternating dense-porous structure.
Solution Approach 2:
The alternating production of dense and porous layers is performed in a continuous additive manufacturing process without interruption or removal of the component between steps. This continuous action maintains production efficiency while achieving the complex alternating material structure that improves crack resistance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves reduced intrinsic stresses and improved crack propagation characteristics, leading to enhanced mechanical and thermomechanical properties, increased durability, and reduced weight of the composite material, particularly suitable for high-strength components like turbine blades.
Implementation Method 1
selective irradiation techniques such as selective laser sintering
Implementation Method 2
selective irradiation techniques such as selective laser sintering or electron beam melting
Implementation Method 3
selective irradiation of a base material for production of a first, dense material phase
Implementation Method 4
electron beam melting
Data Source
AI summary
A method for the layer-by-layer additive manufacturing of a composite material having the selective irradiation of a base material to produce a first, dense material phase and to produce a second, porous material phase, wherein the production of the first material phase and the production of the second material phase take place alternately. A correspondingly produced composite material and to a component has the composite material.