Additive Manufacturing of Thin Angled Component Structures
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Solution Overview
Problem
Existing additive manufacturing methods struggle to produce thin, angled, or thin-walled component structures with improved contour and surface quality, particularly in the hot gas path of gas turbines where complex geometries are required.
Innovation Solution
An adaptive irradiation strategy is employed in powder bed-based additive manufacturing, where irradiation parameters such as line energy and scanning speed are adjusted layer-by-layer to control the melt pool width and shift the irradiation path to form angled edges, allowing for the production of thin, angled, or thin-walled geometries with enhanced contour fidelity and reduced stair-step effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional exposure strategies with fixed irradiation parameters are used, then the manufacturing process is simple, but the contour fidelity and surface quality of thin, angled component structures deteriorate
Solution Approach 1:
The patent applies dynamics by transitioning from fixed irradiation parameters to dynamic, layer-by-layer adjusted parameters. The line energy and scanning speed are continuously adapted based on the specific geometric requirements of each layer, enabling precise control of melt pool width and angled edge formation while maintaining manufacturing precision for thin, angled structures
Solution Approach 2:
The patent implements parameter changes by systematically varying irradiation parameters (line energy, scanning speed) across different layers. This allows the melt pool width to be controlled and the irradiation path to be shifted, achieving improved contour fidelity and surface quality for challenging geometries without requiring complex additional equipment
2Manufacturing precision
If standard hatching or single track exposure is used, then the process is straightforward, but the minimal structure width is limited to 120-200 μm
Solution Approach 1:
The patent applies preliminary action by pre-calculating and planning the layer-by-layer irradiation strategy before manufacturing begins. The CAD/CAM process determines the specific parameters for each layer in advance, allowing the system to achieve minimal structure widths below 100 μm through predetermined adaptive exposure patterns rather than reactive adjustments
Solution Approach 2:
The patent implements segmentation by dividing the component into multiple layers, each with optimized irradiation parameters. This layer-by-layer approach allows different regions of the component to receive tailored energy input, enabling the production of thin-walled structures with wall thicknesses under 100 μm that would be impossible with uniform exposure strategies
3Strength
If higher irradiation power is used to improve melting, then the contour fidelity of thin structures deteriorates due to excessive melt pool width
Solution Approach 1:
The patent applies local quality by providing different irradiation conditions to different regions of the component. Thin structures receive lower line energy and higher scanning speed to maintain narrow melt pools and sharp contours, while thicker regions receive higher energy input for complete melting. This spatially varying parameter strategy resolves the contradiction between adequate melting and contour fidelity
4Adaptability or versatility
If conventional manufacturing methods are used for gas turbine components, then production costs and throughput time are high, but shaping freedom is limited
Solution Approach 1:
The patent implements parameter changes through adaptive irradiation strategies that automatically adjust processing parameters based on the component geometry. This enables additive manufacturing to produce complex gas turbine components with intricate cooling channels and thin-walled structures that would be impossible with conventional methods, while reducing production time through optimized layer-by-layer manufacturing parameters
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 thin, angled, or thin-walled component structures with improved contour fidelity and surface quality, reducing the stair-step effect and achieving structures that cannot be replicated by conventional additive manufacturing methods.
Implementation Method 1
additive manufacturing, in particular powder bed-based additive manufacturing, of a thin, angled or thin-walled component structure
Implementation Method 2
additive manufacturing methods, colloquially also referred to as 3-D printing, for example comprise selective laser melting (SLM) or laser sintering (SLS) as powder bed method
Implementation Method 3
adjusting irradiation parameters from a first layer in the manufacture of the component to a following (second) layer... to control the melt pool width of an irradiation or exposure path
Data Source
AI summary
A method for the additive manufacturing of a thin, angled component structure. The method includes adjusting irradiation parameters from a first layer to a following layer in the construction direction, wherein a line energy and/or a scanning speed is changed for the irradiation of the following layer in order to change a melt pool width of an irradiation path for the following layer, and shifting an irradiation path for the following layer from the first layer in such a way that an angled edge is formed on a side of the component structure being formed opposite a movement direction. A correspondingly manufactured component and a computer program product are provided.