Generative Component Production via Multi-Zone Laser Heating
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Solution Overview
Problem
Existing methods for generatively producing components using powder layers, such as those involving alloys like Mar M247, face issues with hot cracking due to high local temperature gradients, especially at high feed rates, and inhomogeneous temperature distributions in complex geometries.
Innovation Solution
A method involving local heating of powder layers to melting temperature with a first high-energy beam, followed by post-heating a downstream zone to a lower temperature using a second high-energy beam, and setting the component to a base temperature using a heating device, minimizing temperature gradients and allowing for increased feed rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high-energy beam is used to locally heat powder layer to melting temperature for generative production, then the component can be produced layer by layer, but high local temperature gradient causes hot cracking
Solution Approach 1:
The heating process is divided into multiple independent heating zones along the feed direction: a first heating zone that heats powder to melting temperature, and a second heating zone downstream that heats to a lower temperature. This segmentation allows independent control of temperature gradients in different regions, preventing hot cracking while maintaining generative production capability.
Solution Approach 2:
The powder layer is preheated in the second heating zone before the material is deposited and solidifies. This preliminary heating reduces the temperature gradient that would otherwise occur during rapid cooling, preventing hot cracking in the solidified component.
2Productivity
If feed rate is increased to improve productivity, then production efficiency increases, but temperature gradient becomes steeper causing hot cracking
Solution Approach 1:
By dividing the heating process into multiple zones with different temperature levels, the system can handle higher feed rates without creating excessive temperature gradients. The first zone maintains melting temperature for material deposition, while the second zone provides preliminary heating that reduces gradient steepness even at high speeds.
Solution Approach 2:
The temperature parameter is varied along the feed direction, with the first heating zone operating at melting temperature and the second zone operating at a lower temperature. This parameter change allows the system to accommodate higher feed rates while maintaining acceptable temperature gradients.
3Temperature
If induction heating is used to preheat component in powder bed, then component can be preheated, but inhomogeneous temperature distribution occurs in complex geometries
Solution Approach 1:
Instead of uniform induction heating of the entire component, the invention applies localized heating zones that follow the feed direction and component geometry. The first and second heating zones are positioned to provide targeted heating where needed, ensuring uniform temperature distribution even in complex geometries.
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
This approach effectively prevents hot cracking by maintaining a small temperature gradient and allows for higher feed rates by preheating the component to a base temperature, ensuring uniform heating and reducing inhomogeneous temperature distributions.
Implementation Method 1
a first high-energy beam (16) for locally heating a powder layer (4c) to a melting temperature for producing a molten bath (56)
Implementation Method 2
a second high-energy beam (18) for post-heating a zone (58) arranged downstream of the molten bath (56) to a post-heating temperature
Implementation Method 3
the component (2) is set globally to a base temperature (T1) by means of a heating device (10)
Data Source
AI summary
Disclosed is a method for generatively producing or for repairing at least one area of a component, wherein a zone arranged downstream of a molten bath is post-heated to a post-heating temperature and the component is set to a base temperature, and also a device for carrying out such a method.