Modular Additive Manufacturing of Components Without Support Structures
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Solution Overview
Problem
Additive manufacturing methods, particularly selective laser melting, face challenges in reproducing complex geometries and fine surface structures due to the need for support structures, which can complicate the production of components like turbine blades with internal cavities and labyrinthine features.
Innovation Solution
A method involving modular additive manufacturing of sections using powder bed-based methods like selective laser melting, followed by laser deposition welding to connect these sections in a substance-bonding manner, allowing for the elimination of support structures and enabling efficient manufacturing of complex components with improved accessibility for surface treatment and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If support structures are used in powder bed-based additive manufacturing to enable complex geometries, then manufacturing capability is improved, but device complexity and production time increase
Solution Approach 1:
The component is divided into multiple sections that are manufactured separately without requiring support structures. Each section can be independently built and then assembled, eliminating the need for complex support frameworks while maintaining the ability to produce complex geometries.
Solution Approach 2:
The manufacturing process transitions from a single monolithic build to a multi-dimensional approach where sections are built in separate builds and then assembled in space. This dimensional shift allows complex internal geometries to be achieved without support structures that would be required in a single continuous build.
2Adaptability or versatility
If support structures are added during selective laser melting, then complex internal structures can be manufactured, but manufacturing time and resource consumption increase
Solution Approach 1:
By segmenting the component into multiple sections that are manufactured separately, the process eliminates the need for support structures during each individual build. This segmentation allows each section to be built more efficiently and quickly, then assembled to form the complete complex internal structure.
3Ease of operation
If sections are arranged to form a composite before substance-bonding connection, then accessibility for surface treatment is improved, but additional process steps are required
Solution Approach 1:
The component is segmented into multiple sections that are manufactured and arranged separately, allowing surface treatment to be applied to each section while it is accessible. This segmentation enables surface treatment operations that would be impossible or difficult on a monolithic component, despite requiring an additional arrangement step.
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 enables the production of components with complex internal geometries and enhanced cooling efficiency, reducing manufacturing time and costs while maintaining dimensional stability, and allowing for higher operating temperatures in turbomachines.
Implementation Method 1
A method for selective laser melting on the other hand is known for example for EP 1 355 760 B1
Implementation Method 2
A deposition welding method is known for example from EP 2 756 909 A1
Data Source
AI summary
A method for the additive manufacturing of a component having the following steps: additively building up multiple sub-sections for the component using a powder bed-based method, arranging the sub-sections to form a composite and additively completing the component, wherein material is deposited, by a deposition welding method, along a peripheral direction around the composite of the sub-sections in such a way that the sub-sections are integrally bonded to each other.