Single Crystal Component Manufacturing via Layered Powder Deposition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing components from single crystal or directionally solidified materials are expensive and limited in geometry, particularly for complex shapes, and often result in inhomogeneous grain orientations.
Innovation Solution
A method involving the superimposition of a powder layer onto a substrate with a single crystal or directionally solidified material, followed by energy application to transform the layer while maintaining the substrate's grain orientation, using a low focus beam for in situ heat treatment and correction, allowing layer-by-layer growth into a predefined shape without exceeding the melting temperature of the materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional casting techniques are used to manufacture single crystal components, then the grain orientation can be maintained, but the geometry is limited and production is expensive
Solution Approach 1:
The manufacturing process is divided into discrete layers that are deposited and transformed sequentially. Each powder layer is transformed into a substrate layer independently, allowing complex geometries to be built up layer by layer while maintaining grain orientation control through the substrate's influence
Solution Approach 2:
The physical condition of the powder material is altered by applying energy to transform it into a substrate layer. By controlling the transformation parameters and maintaining process temperature below the melting point, the grain orientation of the substrate is preserved while enabling complex geometries
2Stability of the object's composition
If conventional casting techniques are used to manufacture single crystal components, then the grain orientation can be maintained, but the manufacturing cost is high
Solution Approach 1:
The method uses powder material that can be deposited and transformed layer by layer, replacing expensive single crystal casting processes. The powder layers serve as temporary material that is transformed in situ, reducing overall manufacturing costs while maintaining grain orientation
Solution Approach 2:
The conventional mechanical casting process is replaced with a deposition and energy transformation process. By using energy to transform powder layers directly on the substrate, the expensive and complex casting equipment is replaced with more cost-effective deposition and energy application systems
3Adaptability or versatility
If laser sintering is used to manufacture components, then complex geometries can be achieved, but inhomogeneous grain orientation occurs
Solution Approach 1:
The grain orientation of each transformed substrate layer is detected in situ using a detection device. Based on this feedback, the process parameters can be adjusted to correct any deviations in grain orientation, ensuring homogeneous orientation throughout the component while maintaining complex geometry capability
Solution Approach 2:
By controlling the process temperature to remain below the melting temperature of the materials and adjusting the energy application parameters, the grain orientation is maintained throughout the layer-by-layer construction process, preventing the inhomogeneity that occurs in conventional laser sintering
4Productivity
If the process temperature exceeds the melting temperature during manufacturing, then the transformation is faster, but the grain orientation is lost
Solution Approach 1:
The process temperature is optimized to remain below the melting temperature of the materials while still enabling effective transformation of the powder layers. This parameter control ensures that the substrate's grain orientation is preserved during the transformation process, maintaining both productivity and grain orientation stability
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 method enables the cost-effective production of components with homogeneous grain orientation and complex geometries, reducing production costs and limitations compared to conventional casting techniques, while maintaining the beneficial properties of single crystal or directionally solidified materials.
Implementation Method 1
transforming the powder layer into a substrate layer with a new surface of the substrate by altering at least a physical condition of the first material of the powder by applying energy to the powder layer
Implementation Method 2
applying energy is by a low focus beam used to execute an in situ heat treatment process that is an ageing or an annealing process
Implementation Method 3
the material of the substrate layer adopts the same grain orientation as the grain orientation of the substrate during the transforming process
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a method for manufacturing a component (10) of a single crystal or a directionally solidified material, said component (10) being manufactured having a predefined shape (12), comprising at least the following steps: superimposing at least a powder layer (14) of a powder of a first material onto at least a surface (16) of a substrate (18) out of a second, single crystal or directionally solidified, material; transforming the powder layer (14) into a substrate layer (20) with a new surface (22) of the substrate (18) by altering at least a physical condition of the first material of the powder by applying energy to the powder layer (14); wherein said substrate layer (20) is becoming a part of the substrate (18); wherein the second, single crystal or directionally solidified, material of the substrate (18) has a grain orientation (24) and the material of the substrate layer (20) has a grain orientation (26); wherein the material of the substrate layer (20) adopts the same grain orientation (24) as the grain orientation (26) of the substrate (18) during the transforming process and wherein the steps are repeated till the component (10) has grown layer by layer into the predefined shape (12) while a process temperature (Tp) is maintained below a melting temperature (Tm) of at least the first material and the component (10) has been manufactured thereby.