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EP3253513A1 - Procédé de fabrication d'un élément structural en un superalliage avec un procédé de fabrication additif basé sur un lit de poudre et élément structural en un superalliage - Google Patents

Procédé de fabrication d'un élément structural en un superalliage avec un procédé de fabrication additif basé sur un lit de poudre et élément structural en un superalliage

Info

Publication number
EP3253513A1
EP3253513A1 EP16711992.4A EP16711992A EP3253513A1 EP 3253513 A1 EP3253513 A1 EP 3253513A1 EP 16711992 A EP16711992 A EP 16711992A EP 3253513 A1 EP3253513 A1 EP 3253513A1
Authority
EP
European Patent Office
Prior art keywords
component
superalloy
particles
powder
powder bed
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP16711992.4A
Other languages
German (de)
English (en)
Inventor
Frank Heinrichsdorff
Ralph Reiche
Daniel Reznik
Oliver Stier
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Siemens AG
Siemens Corp
Original Assignee
Siemens AG
Siemens Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Siemens AG, Siemens Corp filed Critical Siemens AG
Publication of EP3253513A1 publication Critical patent/EP3253513A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/16—Metallic particles coated with a non-metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/10—Auxiliary heating means
    • B22F12/13—Auxiliary heating means to preheat the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/04—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to a method for producing a component from a superalloy with a powder bed-based additive manufacturing method.
  • the component is layer by layer in a powder bed by melting the powder bed forming particles with an energy beam such. B. an electron beam or a laser beam.
  • the powder bed is preheated to a temperature below the melting temperature of the particles before and while the particles are melted.
  • the invention relates to a component made of a superalloy, which may have been produced, for example, by the said method.
  • a method of the type described above is known for example from EP 1 355 760 Bl.
  • the selective laser melting method discussed in this document is intended to be suitable for processing refractory materials.
  • pre-heating of the material powder to a temperature of at least 500 ° C. be preceded by melting of the powder.
  • this temperature must still be clearly below the melting point of the material of the powder.
  • the coating of the particles has the advantage that they can be preheated to a higher temperature without having to to cook adjacent particles. This is explained by the fact that ceramic materials can be heated to higher temperatures without caking of the particles.
  • the use according to the invention of a powder which is enveloped merely with a ceramic layer therefore has the advantage that the core of the particles has the material properties which are required on account of the material selection.
  • the ceramic layer acts, so to speak, as a masking of these particles, which behave with regard to the problem of caking by powder preheating, such as ceramic particles.
  • constituents of the layer located on the particles can be incorporated into the constituent component, this proportion is extremely low, since the layer on the particles is a very thin layer.
  • the layer may, for example, have a thickness of at least 1 nm and at most 20 nm. This is advantageously sufficient already so that caking on adjacent particles is effectively prevented. With advantageously selected particle sizes of at least 10 ⁇ m and at most 50 ⁇ m, preferably an average particle size of 25 ⁇ m to 30 ⁇ m, it is then ensured that the proportion of the ceramic with respect to the entire particle material turns out to be very small. Assuming, for example, particles with a diameter of 30 ⁇ m, which are provided with a coating of 3 nm, the volume fraction of the ceramic is only 0.06% (3 ⁇ 3 nm / 15 ⁇ m). Thus, the impurities in the alloy that result from melting the powder by incorporating the material of the cladding into the component can be minimized. Incidentally, it has been shown that the very thin
  • Ceramic layer from the powder flakes off when it is heated to melting This is due to the fact that the metallic alloy forming the core of the particles expands more strongly during heating than the ceramic layers. It is advantageous that the ceramic layers prevent caking of adjacent particles, even if these are due to the Heating the particles from the core of the Particles peel off. In the areas in which the particles touch, the residual layers remain even after a release of the core surface between the respective particles and thus prevent caking.
  • the ceramic contains metals, which also represents an alloying constituent of the superalloy. These metals advantageously interfere with the alloy composition much less than non-alloyed metals, since these only insignificantly shift the alloying proportions in the alloy of the manufactured component.
  • non-alloy alloy components can have a greater share in the fact that the property profile of the material of the component changes.
  • the alloy content of that alloying constituent of the superalloy in the core of the particles, which, as mentioned, is also contained in the ceramic is reduced in comparison to the desired alloy composition of the superalloy.
  • the reduction is carried out according to the invention to an extent that this alloying component based on the entire particle (including the layer) reaches or exceeds the alloy content of the target alloy composition of the superalloy. In other words, a compensation of a possible change in the alloy composition is counteracted here by the fact that this is already taken into account in the production of the component.
  • the material of the layer is then incorporated in the melting of the particles in the material of the forming component and there replaces the missing alloy content in the particles, which was deliberately omitted taking into account this effect.
  • Prerequisite for this measure is a sufficient diffusibility of the alloy component in question, said diffusivity by the on Reason the preheating reduced cooling rate of the component is given.
  • the ceramic is oxidic or nitridic. Oxygen and nitrogen as an alloying component in superalloys can be advantageously taken to some extent without the alloy changing its property profile too much.
  • a nickel-base superalloy is used as the superalloy. From these superalloys, for example, the blades of gas turbines can be produced.
  • the powder is advantageously preheated in this material to a temperature of at least 800 ° C and at most 1000 ° C.
  • the device which enters the heat for the purpose of preheating in the powder bed, that the cooling is cooled after the manufacture of the component at a rate of at most 1 ° C per second.
  • ⁇ ⁇ precipitates of intermetallic phases to form in the nickel-base superalloy component that characterize the typical microstructure of the nickel-base superalloy.
  • Solidus temperature is 1150 ° C. To ensure a slow cooling from this temperature level, the temperature of the powder bed must be slightly lower. A temperature level between 900 ° C and at most 1000 ° C has proven to be advantageous.
  • oxidic or nitridic ceramics are used as a layer on the particles (advantageous are aluminum oxide, titanium). tanoxide, silicon oxide, zirconium oxide, yttrium oxide and aluminum nitride), then a structure is formed in the component which contains oxygen or nitrogen or both alloying components.
  • a component advantageously solves the problem stated at the outset that this can be produced by selective laser melting, the powders described being used.
  • the proportion of oxygen or the proportion of nitrogen does not exceed 0.3% by volume, preferably 0.1% by volume.
  • the layer on the particles can have a sufficient thickness in order to develop its effect.
  • the resulting proportion of nitrogen or oxygen is nevertheless so low that this does not adversely affect the alloy of the component.
  • the proportion of oxygen or the proportion of nitrogen is at least 0.03 vol%, so that the ceramic layer on the particles can have a sufficient thickness.
  • FIG. 1 shows a laser melting system in which an embodiment of the method according to the invention is carried out, cut,
  • FIG. 5 shows a detail of an embodiment of the component according to the invention, which has been prepared according to the figures 2 to 4.
  • FIG. 1 schematically shows a system 11 for laser melting.
  • This has a process chamber 12, in which a powder bed 13 can be produced.
  • a distribution device in the form of a doctor blade 14 is moved over a powder supply 15 and then over the powder bed 13, whereby a thin layer of powder in the powder bed 13 is formed.
  • a laser 16 then generates a laser beam 17, which is moved by means of an optical deflection device with mirror 18 over the surface of the powder bed 13. The powder is melted at the point of impact of the laser beam 17, whereby a component 19 is formed.
  • the powder bed 13 is produced on a building platform 20, which can be lowered incrementally by one respective powder layer thickness via an actuator 21 in a cup-shaped housing 22.
  • heaters 23 are provided in the form of electrical resistance heaters, which can preheat the emerging component 19 and the particles of the powder bed 13.
  • FIG. 2 shows an edge of the component 19 to be produced, which could be produced, for example, in a system according to FIG.
  • This component is located in the powder bed 13, whose edges are indicated by a dot-dash line.
  • 13 selected particles 25 are shown from the powder bed, which consist of the material of a nickel-based alloy.
  • the manufactured component can, for. B. be a turbine blade.
  • the particles each consist of a core 26, which consists of the actual material of the component 19, in the present case a nickel-based alloy.
  • the core 26 of the particles 19 is surrounded by a layer 27 which completely envelopes the core and consists of alumina. This allows a preheating of the powder bed to up to 1000 ° C without adjacent particles 25 caked together.
  • FIG. 3 shows how a part of the powder bed 13 is melted by means of the laser beam 17, namely that part which lies on the edge of the component 19.
  • the cores 26 of the particles 25 melt.
  • the cores 26, which are made of a metallic material expand.
  • the layer 27 partially bursts from the cores 26, resulting from it layer fragments 28 remain in the molten material and dissolve there (alloy formation).
  • part of the layer fragments 28 is blasted so far that they remain outside of the molten bath 29 formed by the laser beam 17.
  • FIG. 4 shows how the laser 17 is moved over the powder bed 13, wherein the molten bath, as shown in FIG. 4, travels from left to right. In this case, a position of the component 19 to be produced corresponding to the layer thickness d of the powder bed is formed. If the laser beam 17 continues to migrate, the material solidifies with simultaneous formation of the component volume. The heating indicated in FIG. 1 causes the cooling rate of the material of the component 19 being produced to be less than 1 ° C. per second.
  • the finished component can be seen. This is shown schematically as a microsection.
  • the material from which the component 19 is made is a nickel-base superalloy. Due to the controlled cooling speed It has been possible to achieve a high proportion of so-called ⁇ ⁇ precipitates 30 from intermetallic phases. These are embedded in a matrix 31 of the component. In this way, a component structure can be achieved by means of the selective laser melt according to the invention, as could hitherto only be produced by casting, for example, turbine blades according to the prior art.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Physics & Mathematics (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Composite Materials (AREA)
  • Structural Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un élément structural par fusion au laser, par exemple. L'élément structural (19) est ici fabriqué dans un lit de poudre (13). La poudre est mise en fusion par un rayon laser (17). Si l'élément structural (19) doit être fabriqué dans un superalliage à base de nickel, par exemple, la structure avec dépôts γ', typique de cet alliage, ne peut alors être générée que si, conformément à l'invention, le taux de refroidissement du matériau solidifié et se refroidissant (immédiatement après le bain de fusion généré par le rayon laser (17)) est maintenu à moins de 1 °C par seconde. Pour ce faire, selon l'invention, le lit de poudre est préchauffé au moyen de dispositifs chauffants (23). Selon l'invention, un préchauffage de la poudre jusqu'à des plages de températures d'environ 1000 °C n'est possible que si la poudre en superalliage à base de nickel est recouverte d'une mince couche d'oxyde d'aluminium, par exemple. Cela permet d'empêcher une cuisson des particules dans le lit de poudre qui ne participent pas à la formation de l'élément structural (19). La poudre peut ainsi avantageusement être enlevée facilement et réutilisée plusieurs fois après avoir terminé le processus de fabrication.
EP16711992.4A 2015-03-24 2016-03-10 Procédé de fabrication d'un élément structural en un superalliage avec un procédé de fabrication additif basé sur un lit de poudre et élément structural en un superalliage Withdrawn EP3253513A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102015205316.4A DE102015205316A1 (de) 2015-03-24 2015-03-24 Verfahren zum Erzeugen eines Bauteiles aus einer Superlegierung mit einem pulverbettbasierten additiven Herstellungsverfahren und Bauteil aus einer Superlegierung
PCT/EP2016/055146 WO2016150720A1 (fr) 2015-03-24 2016-03-10 Procédé de fabrication d'un élément structural en un superalliage avec un procédé de fabrication additif basé sur un lit de poudre et élément structural en un superalliage

Publications (1)

Publication Number Publication Date
EP3253513A1 true EP3253513A1 (fr) 2017-12-13

Family

ID=55637332

Family Applications (1)

Application Number Title Priority Date Filing Date
EP16711992.4A Withdrawn EP3253513A1 (fr) 2015-03-24 2016-03-10 Procédé de fabrication d'un élément structural en un superalliage avec un procédé de fabrication additif basé sur un lit de poudre et élément structural en un superalliage

Country Status (5)

Country Link
US (1) US11389868B2 (fr)
EP (1) EP3253513A1 (fr)
CN (1) CN107427915B (fr)
DE (1) DE102015205316A1 (fr)
WO (1) WO2016150720A1 (fr)

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Publication number Priority date Publication date Assignee Title
DE102015205316A1 (de) 2015-03-24 2016-09-29 Siemens Aktiengesellschaft Verfahren zum Erzeugen eines Bauteiles aus einer Superlegierung mit einem pulverbettbasierten additiven Herstellungsverfahren und Bauteil aus einer Superlegierung
DE102016216859A1 (de) * 2016-09-06 2018-03-08 Siemens Aktiengesellschaft Verfahren zum Erzeugen eines Bauteils mit einem pulverbettbasierten additiven Fertigungsverfahren und Pulver zur Verwendung in einem solchen Verfahren
CN110545940B (zh) 2017-04-13 2022-07-29 西门子能源全球有限公司 制造工件的方法、建立校正参数的方法和存储介质
DE102017208645A1 (de) * 2017-05-22 2018-11-22 Siemens Aktiengesellschaft Messsondenkopf
US20200114426A1 (en) * 2017-06-30 2020-04-16 Siemens Aktiengesellschaft An Additive Manufacturing Method for Precipitation-Hardened Superalloy Powdered Material
US20200331198A1 (en) * 2017-10-31 2020-10-22 Ihi Corporation Additive manufacturing device and additive manufacturing method
DE102018220225A1 (de) * 2018-11-26 2020-05-28 Robert Bosch Gmbh Verfahren zur Herstellung eines Bauteils und Fertigungsvorrichtung
WO2021041110A1 (fr) * 2019-08-23 2021-03-04 Silfex, Inc. Impression 3d de silicium entièrement dense et exempt de fissures avec fusion/frittage laser sélective à des températures élevées
EP3789135A1 (fr) * 2019-09-03 2021-03-10 Siemens Energy Global GmbH & Co. KG Matériau en poudre
US11554550B2 (en) * 2019-12-02 2023-01-17 The Boeing Company Methods for forming strengthened additive manufacturing materials and strengthened filaments for use
EP3892403A1 (fr) * 2020-04-08 2021-10-13 Heraeus Additive Manufacturing GmbH Fabrication additive de métaux réfractaires à niveau de contamination réduit
KR20230008804A (ko) * 2020-05-07 2023-01-16 램 리써치 코포레이션 실리콘 컴포넌트들의 애디티브 제작 (additive manufacturing)
CN111689764B (zh) * 2020-07-06 2022-05-31 南京理工大学 一种低成本激光选区熔化用陶瓷粉末制备及其离焦成形方法

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US4769087A (en) * 1986-06-02 1988-09-06 United Technologies Corporation Nickel base superalloy articles and method for making
GB9426257D0 (en) * 1994-12-24 1995-03-01 Rolls Royce Plc Thermal barrier coating for a superalloy article and method of application
DE10104732C1 (de) 2001-02-02 2002-06-27 Fraunhofer Ges Forschung Verfahren und Vorrichtung zum selektiven Laser-Schmelzen von metallischen Werkstoffen
EP1464723B1 (fr) * 2003-04-04 2018-02-21 Siemens Energy, Inc. Revêtement barrière thermique avec caractéristiques nanométriques
US20090047439A1 (en) * 2007-08-16 2009-02-19 Withers James C Method and apparatus for manufacturing porous articles
FR2998496B1 (fr) * 2012-11-27 2021-01-29 Association Pour La Rech Et Le Developpement De Methodes Et Processus Industriels Armines Procede de fabrication additive d'une piece par fusion selective ou frittage selectif de lits de poudre a compacite optimisee par faisceau de haute energie
FR3008014B1 (fr) 2013-07-04 2023-06-09 Association Pour La Rech Et Le Developpement De Methodes Et Processus Industriels Armines Procede de fabrication additve de pieces par fusion ou frittage de particules de poudre(s) au moyen d un faisceau de haute energie avec des poudres adaptees au couple procede/materiau vise
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DE102015205316A1 (de) 2015-03-24 2016-09-29 Siemens Aktiengesellschaft Verfahren zum Erzeugen eines Bauteiles aus einer Superlegierung mit einem pulverbettbasierten additiven Herstellungsverfahren und Bauteil aus einer Superlegierung

Also Published As

Publication number Publication date
CN107427915B (zh) 2019-09-13
US20180104741A1 (en) 2018-04-19
WO2016150720A1 (fr) 2016-09-29
DE102015205316A1 (de) 2016-09-29
CN107427915A (zh) 2017-12-01
US11389868B2 (en) 2022-07-19

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