Laser Additive Manufacturing With Ultrasonic Densification
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Solution Overview
Problem
Additive manufacturing of components, such as turbomachine parts, often results in material properties that are inferior to those of cast and forged parts, particularly in terms of strength, toughness, and surface hardness, which do not meet the high demands of components like gas turbine guide vanes or moving blades.
Innovation Solution
The method involves selectively layering material with an underlying layer or carrier, using a laser to bond the material thermally or chemically, and generating structure-borne sound waves through pulsed laser application to induce internal stresses and improve material properties, while also allowing for post-processing to refine the component's surface and edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If additive manufacturing is used to produce components, then complex shapes and smaller batch sizes can be manufactured, but material properties such as strength, toughness, and surface hardness are inferior to cast and forged parts
Solution Approach 1:
The patent applies ultrasonic vibration through a piezoelectric transducer to the deposited material layer during the additive manufacturing process. This mechanical vibration densifies the material structure, reduces porosity, and improves bonding between layers, thereby enhancing strength and toughness while maintaining the ability to create complex shapes
Solution Approach 2:
The patent implements continuous ultrasonic vibration during the entire material deposition and bonding process. This continuous application of mechanical energy ensures consistent material densification and bonding quality throughout the component build, preventing weak points that would otherwise occur with intermittent processing
2Ease of manufacture
If laser sintering or welding is used to connect material particles, then layers can be selectively bonded, but material properties remain between cast and forged parts
Solution Approach 1:
The patent combines laser heating with ultrasonic vibration in a single integrated process. The laser provides thermal energy for material melting and bonding, while the ultrasonic vibration simultaneously densifies the material and enhances interlayer bonding. This merging of thermal and mechanical energy sources creates superior material properties compared to using either method alone
3Manufacturing precision
If mechanical compression of loose material is applied before laser sintering, then material density may improve, but pressurization equipment becomes problematic
Solution Approach 1:
The patent replaces the need for external mechanical pressurization equipment by generating ultrasonic vibrations directly within the material layer through a piezoelectric transducer. This substitution of external mechanical compression with internal ultrasonic densification achieves similar or superior density improvement without requiring complex pressurization systems
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 the material properties, particularly strength and grain size, of the manufactured components, enabling the production of high-performance parts like gas turbine components with complex shapes, meeting the stringent requirements of turbomachine components.
Implementation Method 1
The material is selectively connected by a controlled laser beam, in that the laser beam exposes the desired layer cross-section and heats the material to such an extent that its particles combine with each other
Implementation Method 2
A pulsed application makes it possible, in particular, to generate structure-borne sound waves, preferably ultrasonic waves, directly in the material
Implementation Method 3
Additionally or alternatively, material can also be sublimated by the additional laser impingement before, during and/or after the connection. The pressure surge generated by the expansion of the sublimated material can in particular induce the structure-borne sound waves
Implementation Method 4
The material is selectively connected by a controlled laser beam, in that the laser beam exposes the desired layer cross-section and heats the material to such an extent that its particles combine with each other
Data Source
Figure 1
AI summary
The invention relates to a method for the generative production of a component (3), in particular of a turbo-engine component, wherein material (4) is bonded layer-wise selectively to a layer or to a substrate (6) disposed therebeneath, wherein before, during and/or after the bonding a laser (1A; 1B; 2) additionally acts on the material (4).