Additive Manufacturing Inductive Heating Surface Quality
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Solution Overview
Problem
Existing additive manufacturing methods for metallic components, such as those used in turbomachines, face challenges in achieving improved surface quality due to the partial obstruction of induction coils, which limits access for energy beams and increases technical effort in coordinating coil and beam movements.
Innovation Solution
The method involves applying metallic materials in layers, local fusion or sintering using a high-energy beam, and additional inductive heating above the solidus temperature to improve surface quality, allowing for accessible and efficient fusion of previously inaccessible areas with minimal additional equipment, using existing induction devices for both preheating and forming component layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If induction coils are used for preheating powder layers during additive manufacturing, then crack formation is prevented, but the coils partially cover and obstruct the powder layers, making contour areas inaccessible to energy beams
Solution Approach 1:
The heating process is segmented into two distinct stages: first, induction coil preheating of the entire powder layer to prevent cracks, and second, selective energy beam exposure of accessible areas. This segmentation allows each method to perform its optimal function without interference.
Solution Approach 2:
The induction coils perform preliminary heating of the powder layers before the energy beam exposure. This preliminary action raises the temperature of the entire layer, particularly protecting contour areas that would otherwise be inaccessible, while preventing crack formation during subsequent processing.
2Area of stationary object
If induction coils are moved linearly to access different areas, then coverage is improved, but coil speed is limited and coordination with laser beam becomes complex
Solution Approach 1:
The invention extracts the heating function from the movement system. Instead of requiring coordinated movement of induction coils and laser beams, the induction coils remain stationary and provide continuous field heating, while only the energy beam moves selectively to expose specific areas. This eliminates the complexity of coordinating two moving systems.
Solution Approach 2:
The stationary induction coil system provides universal heating coverage for the entire build area, serving all contour regions simultaneously without requiring physical movement or coordination with the selective energy beam system.
3Manufacturing precision
If high-energy beam is used for selective melting, then precise component formation is achieved, but contour areas remain inaccessible due to coil obstruction
Solution Approach 1:
The induction coils perform preliminary heating of the entire powder layer, including contour areas that the energy beam cannot reach. This ensures that all areas, including inaccessible contour regions, receive the necessary thermal treatment before selective melting begins.
Solution Approach 2:
The processing is segmented into a universal preheating stage using induction coils for all areas, followed by a selective energy beam stage for precise component formation in accessible areas. This segmentation ensures both complete coverage and manufacturing precision.
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 enhances surface quality by preventing cracks and allowing for precise control of heating penetration, reducing surface roughness and equipment outlay, while enabling the safe fusion of previously inaccessible powder layer areas with reduced technical effort.
Implementation Method 1
energy is supplied to the component material in the area of the build-up and joining zone by means of at least one high-energy beam, for example an electron beam or laser beam
Implementation Method 2
layered and local fusion and/or sintering of the material by supplying energy by means of at least one high-energy beam
Implementation Method 3
local fusing and/or sintering of the material by means of inductive heating at a temperature or in a temperature range that is above the solidus temperature of the metallic material used
Data Source
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AI summary
The invention relates to a method for producing at least one metallic component area of a component (30), in particular a component of a turbomachine, comprising at least the following steps: a) layer-by-layer application of at least one metallic material (22) onto at least one build platform (12); b) layer-by-layer and local melting and/or sintering of the material (22) by supplying energy by means of at least one high-energy beam (16) in the area of a build-up and joining zone (40) to form at least one partial area of at least one component layer of the component area and/or the component (30); c) layer-by-layer lowering of the build platform (12) by a predefined layer thickness; and d) repetition of steps a) to c) until the component area and/or the component (30) is completed.In this process, before, during, and/or after the layer-by-layer and local melting and/or sintering according to process step b), at least one further sub-area of the component layer is formed by locally melting and/or sintering the material (22) by means of inductive heating at a temperature or in a temperature range that is above the solidus temperature of the metallic material (22) used. The invention further relates to a system for producing at least one component area of a component (30).