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WO2025082667A1 - Procédé de fabrication de lingots, en particulier destiné à une utilisation dans un système viga ou un système eiga - Google Patents

Procédé de fabrication de lingots, en particulier destiné à une utilisation dans un système viga ou un système eiga Download PDF

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Publication number
WO2025082667A1
WO2025082667A1 PCT/EP2024/075328 EP2024075328W WO2025082667A1 WO 2025082667 A1 WO2025082667 A1 WO 2025082667A1 EP 2024075328 W EP2024075328 W EP 2024075328W WO 2025082667 A1 WO2025082667 A1 WO 2025082667A1
Authority
WO
WIPO (PCT)
Prior art keywords
ingot
starting material
manufacturing
ingot body
plant
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.)
Pending
Application number
PCT/EP2024/075328
Other languages
German (de)
English (en)
Inventor
Fuad OSMANLIC
Christian Lehnert
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.)
ALD Vacuum Technologies GmbH
Original Assignee
ALD Vacuum Technologies GmbH
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 ALD Vacuum Technologies GmbH filed Critical ALD Vacuum Technologies GmbH
Publication of WO2025082667A1 publication Critical patent/WO2025082667A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/70—Recycling
    • B22F10/73—Recycling of 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • 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
    • B22F5/12—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of wires
    • 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
    • B22F8/00—Manufacture of articles from scrap or waste metal particles
    • 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
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • 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
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F2009/001—Making metallic powder or suspensions thereof from scrap particles
    • 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
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0836—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid with electric or magnetic field or induction
    • 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

  • Processes for the industrial production of metal powder usually comprise one or more sub-processes in which the grain size of the individual powder grains is distributed around a statistical mean.
  • a starting metal is melted and fed in the form of a thin melt jet into a nozzle, through and/or to which an inert gas stream is simultaneously passed.
  • the melt is accelerated as it passes through the nozzle and, due to contact with the inert gas stream and/or acceleration, is atomized into small droplets, which then solidify into powder.
  • the size of an individual powder grain is determined by the respective droplet size, which in turn is sometimes randomly determined during the atomization of the melt jet.
  • Processes of this type include, for example, the so-called EIGA (Electrode Induction Melting Inert Gas Atomization) process and the so-called VIGA (Vacuum Induction Melting Inert Gas Atomization) process.
  • Metal powders are particularly frequently used in additive manufacturing processes.
  • a workpiece is typically manufactured from a powder bed by selective melting.
  • residues of the powder bed often remain after the workpiece is manufactured.
  • Workpiece blanks are also often subjected to machining during further processing, which generates chips of the workpiece material.
  • a method for producing an ingot which is particularly intended for use in a VIGA plant or an EIGA plant, is described.
  • the method comprises providing a granular ingot starting material.
  • the method further comprises producing an ingot body from the ingot starting material, wherein the production comprises melting portions of the ingot starting material, and the ingot starting material is melted to a greater extent in a region of a shell of the ingot body to be produced than in a region of a core of the ingot body to be produced.
  • This process makes it possible to produce an ingot body and, provided the ingot body already meets all the shape requirements for an ingot for a specific application, also an ingot without completely melting the material used. This reduces the energy required to produce an ingot.
  • the process also favors the use of ingot feedstock with non-uniform grain sizes. This is possible because the dimensional accuracy requirements for an ingot for common applications are lower than the dimensional accuracy of the shell of the ingot body, as can typically be achieved using known manufacturing processes for common grain sizes of the feedstock.
  • the possibility of using ingot feedstock with non-uniform grain sizes for the process favors the use of reclaimed material as the ingot feedstock. This applies in particular to reclaimed grain-related production rejects from powder production, reclaimed powder bed residues from additive manufacturing, and/or reclaimed machining chips from machining. This reduces losses from a valuable materials cycle.
  • An ingot produced by this process is also particularly suitable for melting It is advantageously used for further processing, particularly in a VIGA plant or an EIGA plant for powder production, in casting plants, and other processing plants where complete melting of the ingot material to be processed necessarily takes place before further processing. Voids and/or gas inclusions in the ingot body escape or can be removed in this way without requiring additional energy expenditure and/or additional processing effort.
  • the granular ingot starting material may be suitable for processing using an additive manufacturing process. Furthermore, the production of the ingot body may be additive manufacturing.
  • the production of the ingot body can further comprise forming the ingot starting material into a raw form of the ingot body.
  • Melting parts of the ingot starting material can comprise remelting the raw form of the ingot body to produce the shell.
  • the forming and remelting can be carried out by means of a heatable mold designed to form the ingot starting material into the raw form of the ingot body and to melt the raw form in the region of an outer side of the raw form to produce the shell while the raw form is located in the heatable mold.
  • the remelting can be carried out outside of a shaping device used to form the ingot starting material into the raw form.
  • Manufacturing the ingot body by additive manufacturing or by forming and remelting a raw form favors the use of ingot starting material with non-uniform grain sizes. This is possible because the requirements for the dimensional accuracy of an ingot for common applications are lower than the dimensional accuracy of the shell of the ingot body, as can typically be achieved using additive manufacturing processes or by forming and remelting processes for common grain sizes of the starting material. This particularly favors the use of recovered material as the ingot starting material. Losses from a recycling cycle can be avoided in particular by reduce.
  • the shell may surround the core at least partially, preferably completely.
  • the ingot starting material can be melted in the area of the shell, preferably completely.
  • the ingot starting material in the core region may remain at least partially, preferably completely, unmelted and unsintered.
  • the ingot may be intended for use in a VIGA system and/or a crucible melting system.
  • the ingot starting material can be at least partially, preferably completely, sintered in the core region during manufacturing.
  • the ingot can be intended for use in an EIGA system.
  • Partially sintered can mean that the ingot starting material is partially sintered in the relevant areas.
  • Melting can be carried out at least partially by means of an electron beam and under vacuum. Additionally or alternatively, melting can be carried out at least partially by means of a laser beam and under a protective gas atmosphere.
  • Melting can be carried out at a melting rate between 200.0 cm 3 /h and 1500.0 cm 3 /h, preferably between 300.0 cm 3 /h and 1100.0 cm 3 /h. This allows for economically viable recycling of production rejects into new ingot bodies.
  • the ingot body can be manufactured using additive manufacturing, which takes place layer by layer.
  • the thickness of each of several manufacturing layers can be in the range between 0.02 and 5.0 millimeters, preferably between 0.2 and 0.8 millimeters, and more preferably between 0.3 and 0.5 millimeters.
  • the ingot body may have at least one cylindrical, in particular a generally cylindrical, section.
  • the ingot body may be manufactured by additive manufacturing, which takes place in a region of the cylindrical section such that a layering direction runs parallel to a cylinder axis of the cylindrical section.
  • the ingot body may have at least one rotationally symmetrical section.
  • the ingot body may be manufactured by additive manufacturing, which takes place in a region of the rotationally symmetrical section such that a layering direction runs parallel to a rotation axis of the rotationally symmetrical section.
  • the shape of the ingot body can correspond to any intended geometry, in particular an intended freeform.
  • the ingot body can be manufactured by additive manufacturing, which occurs in such a way that a layering direction is not predetermined by the shape of the ingot body.
  • the cross-section of the ingot body can be circular, rectangular, square, triangular, and/or polygonal.
  • the ingot body may have a length in the range between 10.0 and 150.0 centimeters, preferably between 20.0 and 100.0 centimeters, preferably between 30.0 and 90.0 centimeters.
  • the ingot body may have an average diameter in the range between 30.0 and 300.0 millimeters, preferably between 40 and 250 millimeters, preferably between 50.0 and 200.0 millimeters.
  • the production of the ingot body can be additive manufacturing, wherein the method comprises simultaneously producing a plurality of ingot bodies from the ingot starting material in a production zone of a system for producing the plurality of ingot bodies.
  • a distance between adjacent ingot bodies of the ingot bodies to be produced can be in the range between 0.5 and 5.0 millimeters, preferably between 1.0 and 5.0 millimeters.
  • the plurality of ingot bodies can be in the range between 2 and 200, preferably between 10 and 100.
  • a ratio between an average thickness of the shell of the ingot body to an average diameter of the core of the ingot body can be in the range between 0.05 and 1, preferably between 0.08 and 0.5, preferably between 0.1 and 0.2.
  • a ratio between an average diameter of the core of the ingot body to an average diameter of the ingot body may be in the range between 1/3 and 10/11, preferably between 1/2 and 6/7, preferably between 5/7 and 5/6.
  • a ratio between a total volume of the core to a total volume of the ingot body may be between 0.2 and 0.9, preferably between 0.5 and 0.85, preferably between 0.65 and 0.8.
  • a transition zone of the ingot body extending between the core and the shell may have an average thickness such that a ratio between the average thickness of the transition zone and an average diameter of the ingot body is less than 0.5, preferably less than 0.1, preferably less than 0.05.
  • the shell can enclose the core gas-tight.
  • Providing the ingot starting material may comprise recovering powder bed residues of at least one powder bed of one or more additive manufacturing devices, and providing the recovered powder bed residues at least as parts of the ingot starting material.
  • providing the ingot starting material may comprise recovering grain-related production rejects from one or more powder production devices, and providing the recovered production rejects at least as parts of the ingot starting material.
  • providing the ingot starting material may comprise recovering machining chips from one or more machining devices, and providing the recovered machining chips as at least parts of the ingot starting material.
  • manufacturing the ingot body may include forming at least one of one or more retaining notches and/or a melting tip as components of a shape of the ingot body.
  • an ingot particularly for use in a VIGA plant or an EIGA plant, is described.
  • the ingot is produced using a method of the type presented here.
  • a programmable system for producing an ingot which is intended in particular for use in a VIGA system or an EIGA system, is described.
  • the system is designed to produce an ingot body from a granular ingot starting material, preferably by means of additive manufacturing.
  • the system is further programmed to process the ingot starting material in to melt a larger proportion in an area of a shell of the ingot body to be manufactured than in an area of a core of the ingot body to be manufactured.
  • a programmable system for producing an ingot which is intended in particular for use in a VIGA system or an EIGA system, is described.
  • the system is designed to carry out a method of the type described above.
  • Fig. 1 shows an ingot body according to an example
  • Fig. 2 shows a method for producing an ingot according to an example
  • Fig. 3 shows an ingot according to an example
  • Fig. 4 shows a method for producing an ingot according to another example
  • Fig. 5 shows a plant for producing an ingot according to an example.
  • Fig. 1 schematically shows an example of an ingot body 100.
  • the ingot body 100 comprises a shell 110 and a core 120 surrounded by the shell 110.
  • the ingot body 110 is made of a granular ingot starting material, for example, metal powder and/or metal chips.
  • the granular ingot starting material is melted (and solidified) to a greater extent in the region of the shell 110 than in the region of the core 120.
  • the melting of the ingot starting material in the region of the shell 110 occurs, for example, by completely melting the ingot starting material in the region of the shell 110.
  • the granular ingot starting material is only partially melted, for example, partially melted and/or sintered, or has remained completely unmelted.
  • the ingot body 100 has a higher material density and greater strength in the region of the shell 110 than in the region of the core 120. Voids present between individual grains of the granular ingot starting material are at least largely displaced from the region of the shell 110.
  • the ingot starting material remains in the region of the core 120.
  • several of the initial voids merge into larger voids, for example, by partially fusing the grains of the ingot starting material in the region of the core 120, such as by melting or sintering the ingot starting material in the region of the core 120.
  • the higher strength of the ingot body 100 in the region of the shell 110 gives the ingot body 110 increased mechanical stability. This facilitates safe handling, for example, transport, of the ingot body 100. Furthermore, the shell 110 prevents the less firmly bonded material in the region of the core 120 from detaching from the ingot body 100.
  • the shell 110 encloses the core 120.
  • the shell 110 thereby also reduces gas exchange between cavities within the core 120 and the environment of the ingot body 100.
  • the shell 110 thus effectively reduces a surface of the ingot body 100 at which a chemical interaction between the ingot body 100 and the environment takes place.
  • the chemical stability of the ingot body 100 is therefore also promoted by the shell 110.
  • the ingot body 100 can be manufactured with less energy than would be the case if the entire ingot starting material were completely melted.
  • the remaining cavities in the region of the core 120 are also harmless for many uses of an ingot. This applies, for example, to uses in which the ingot is first completely melted before the molten ingot material is processed, such as in a casting system with one or more crucible melting devices, in a VIGA system for powder production, etc. During the melting of the ingot body 100, the cavities are automatically displaced by the forming melt before the melt is processed. In typical applications, no additional energy and/or process expenditure is required for this.
  • a total energy expenditure both for the production of an ingot corresponding to, or starting from (see below), the ingot body 100 as well as a melting further processing of the ingot is thus reduced compared to the energy required for the production and further processing of an ingot if the entire ingot material is completely melted both during the production of the ingot and during its further processing.
  • the ingot body 100 For intended uses of an ingot for which the ingot body 100 already meets all requirements, in particular all shape requirements, for an ingot after its production, the ingot body 100 already represents a finished ingot. In contrast, for intended uses that place further requirements on an ingot, in particular on one or more shape features of the ingot, the ingot body 100 is intended, for example, for post-processing in order to complete an ingot that meets the requirements starting from the ingot body 100.
  • the ingot body 100 is manufactured layer by layer using an additive manufacturing process.
  • a layering direction S1 corresponds, for example, to the axis of the ingot body 100.
  • the axis corresponds, for example, to at least one of a longitudinal axis, a (geometric) rotation axis, or a cylinder axis of at least a portion of the ingot body 100.
  • a longitudinal axis of the ingot body 100 is defined, for example, as an axis along a greatest extent of the ingot body 100.
  • a cylinder axis of at least a portion of the ingot body 100 is defined, for example, according to a general cylinder, i.e., as an axis along which the ingot body 100 has a constant cross-sectional profile.
  • the melting of parts of the ingot starting material is carried out at least partially using an electron beam and under vacuum. This ensures that no ambient air enters the core 120 during the production of the ingot body 100, or that air initially present in the cavities of the ingot starting material is removed before the ingot body 100 is manufactured, for example, by evacuating the manufacturing chamber. The chemical purity and chemical stability of the ingot body 100 can thus be improved.
  • the melting of portions of the ingot starting material to produce the ingot body 100 takes place under a protective gas atmosphere. This allows air initially present in the cavities of the ingot starting material to be displaced and replaced by the protective gas before the ingot body 100 is produced and/or prevents the penetration of ambient air into the core 120 during production.
  • the thickness of each of several manufacturing layers is, for example, between 0.02 and 5.0 mm, preferably between 0.2 and 0.8 mm, and more preferably between 0.3 and 0.5 mm. In this way, with known additive manufacturing systems, rapid production of the ingot body 100 with typical dimensions for intended applications is achievable. At the same time, a manufacturing quality of the ingot body 100 required for typical applications is achievable.
  • the ingot body 100 is manufactured by forming the ingot starting material into a green form of the ingot body 100, for example, by compression molding, and by subsequently remelting the green form of the ingot body 100 to form the shell 110. During the remelting of the green form, the green form is melted in the region of its outer surface, with the melt adhering to the remainder of the green form. The adhering melt is then allowed to solidify, forming the shell 110 around the core 120.
  • the ingot body 100 is manufactured, for example, by means of a heatable molding press, which heats the outer surface of the raw mold after or during the molding of the ingot starting material into the raw mold, so that the raw mold melts in the region of the shell 110.
  • a heatable molding press which heats the outer surface of the raw mold after or during the molding of the ingot starting material into the raw mold, so that the raw mold melts in the region of the shell 110.
  • the remelting of the outer surface of the raw mold takes place outside of a molding device that was used to form the raw mold.
  • the ingot starting material is sintered in the region of the core 120.
  • the material is bound in the core 120. This prevents material from the core 120 from breaking outward in an uncontrolled manner through the shell 110 under the influence of gravity when the shell 110 is melted at the bottom of the ingot body 100 during the EIGA process.
  • the use of an ingot in an EIGA system usually involves suspending the ingot in the system. This typically requires retaining notches on the ingot, i.e., contours used to attach and/or clamp the ingot in the system.
  • the ingot body 100 shown schematically in Fig. 1, for example, does not yet represent a finished ingot for such applications.
  • Post-processing of the ingot body 100 to the finished ingot for such an application comprises, for example, in a further process step the introduction or attachment of corresponding contours to the ingot body 100, for example by a machining process.
  • the production of the ingot body 100 already comprises the formation of corresponding contour features.
  • the ingot body 100 already represents a finished ingot for corresponding applications.
  • the ingot body 100 is intended for use as a finished ingot in a further processing plant, in which the ingot body 100 is completely melted before further processing of the molten ingot material.
  • the ingot starting material in the region of the core 120 is at least largely unmelted and unsintered, for example, still in the initial state of the ingot starting material. In the applications mentioned, melting or sintering of the material in the core 120 is unnecessary, since uncontrolled escape of core material during melting is harmless. The energy required to produce the ingot body 100 can thus be minimized.
  • the ingot body 100 has a length in the range between 10 cm and 150 cm, preferably between 20 cm and 100 cm, and preferably between 30 cm and 90 cm. Additive manufacturing devices that enable such dimensions along a layering direction are known.
  • a ratio between an average thickness of the shell 110 and an average diameter of the core 120 is between 0.05 and 1, preferably between 0.08 and 0.5, more preferably between 0.1 and 0.2. Furthermore, in some examples, a ratio between an average diameter of the core 120 and an average diameter of the ingot body 100 is between 1/3 and 10/11, preferably between 1/2 and 6/7, more preferably between 5/7 and 5/6.
  • a small thickness of the shell 110 promotes energy savings during production of the ingot body 100, since a proportion of the ingot starting material that is melted is lower.
  • a large thickness of the shell 110 promotes stability of the ingot body 100 in mechanical and/or chemical terms.
  • a ratio between a thickness of the shell 110 and a diameter of the ingot body 100 can be variably selected, for example, when producing the ingot body 100.
  • a transition zone 130 is usually formed in the ingot body 100 between the shell 110 and the core of the ingot body 120.
  • a proportion to which the ingot starting material is melted in the transition zone 130 lies between the proportion of molten material in the area of the shell 110 and the proportion of molten material in the Area of the core 120.
  • a thickness of the transition zone typically varies depending on several manufacturing parameters, for example, the selected ingot starting material, the selected dimensions of the ingot body 100, a process control during the manufacture of the ingot body 100, etc.
  • the transition zone 130 has an average thickness dimensioned such that a ratio between the average thickness of the transition zone 130 and an average diameter of the ingot body 100 is less than 0.5, preferably less than 0.1, preferably less than 0.05.
  • the average sizes correspond, for example, to an averaging of the respective size in the same cross-sectional plane and/or an averaging of the respective size across multiple cross-sectional planes of the ingot body 100.
  • the ingot starting material for producing the ingot body 100 comprises, in some examples, powder bed residues from a powder bed of one or more additive manufacturing devices. Furthermore, in some examples, the ingot starting material comprises production rejects from one or more powder production devices and/or machining chips from one or more workpiece machining devices. These materials are often recyclable materials that are waste from conventional processes. The ingot body 100 and the process used to produce it, as described herein, promote the reuse of these materials. Losses from the recycling cycle can thereby be reduced.
  • Fig. 2 shows a flowchart of a method 200 for producing an ingot. This is, for example, an ingot corresponding to, or starting from, the ingot body 100 in Fig. 1.
  • the method 200 includes providing a granular ingot starting material, step 210.
  • the method 200 also includes manufacturing an ingot body from the ingot starting material, step 220.
  • Manufacturing includes melting portions of the ingot starting material. The ingot starting material is melted to a greater extent in a region of a shell of the ingot body to be manufactured than in a region of a core of the ingot body to be manufactured.
  • Fig. 3 shows schematically and exemplarily an ingot 300 according to a further example.
  • the ingot 300 comprises an ingot body 305 with a shell 310 and a body 320 surrounded by the shell 310.
  • the ingot body 300 has a transition zone 330 extending between the shell 310 and the core 320.
  • the ingot body 305 is manufactured using an additive process.
  • a layering direction S3 extends along a longitudinal axis of the ingot body 305. This can also be, for example, a rotational axis and/or cylinder axis of the ingot body 305.
  • a retaining notch 350 is formed in the ingot body 305 in the region of the upper side.
  • the retaining notch 350 serves, for example, to attach the ingot 300 to a further processing system, for example, to suspend the ingot 300 in an EIGA system.
  • the ingot body 305 has a melting tip 340 on its underside.
  • the melting tip 340 facilitates the use of the ingot 300 in an EIGA system.
  • the ingot In the EIGA process, the ingot is typically melted at its lower end. Due to near-surface heating, thermodynamic effects, and gravity, a tip forms on the underside of the ingot, partly from resolidifying melt. EIGA systems are therefore typically designed to melt a pointed ingot end for the most efficient operation.
  • the formation of the melting tip 340 on the ingot body 305 is therefore advantageous in enabling efficient processing of the ingot 300 in an EIGA system right from the start.
  • the ingot body 305 after its production by means of the method described above, already meets all requirements, in particular all shape requirements, of an intended use for an ingot, the ingot body 305, after its production, already represents the finished ingot 300, as described in connection with Fig. 1.
  • the ingot 300 is finished by post-processing the ingot body 305 after its production, for example by grinding a surface of the manufactured ingot body 305 and/or by re-cutting the retaining notch 350, etc.
  • Fig. 4 shows a flowchart of a method 400 for producing an ingot according to another example.
  • method 400 includes providing a granular ingot
  • step 410 a subsequent production of an ingot body from the ingot starting material, step 430.
  • step 430 a subsequent production of an ingot body from the ingot starting material
  • the method 400 comprises recovering powder bed residues of at least one powder bed of one or more devices for additive manufacturing, step 412, and providing the recovered powder bed residues at least as parts of the ingot starting material, step 414.
  • the method 400 also comprises recovering grain-related production rejects of one or more devices for powder production, step 416, and providing the recovered production rejects at least as parts of the ingot starting material, step 418.
  • the method 400 comprises recovering machining chips of one or more devices for machining one or more workpieces, step 420, and providing the recovered machining chips at least as parts of the ingot starting material, step 422.
  • the steps 412-422 represent substeps of providing granular Ingot starting material, step 410.
  • the steps 412-422 are implemented or can be implemented in pairs in combination and/or alternatively to one another for providing granular ingot starting material.
  • the method 400 also includes reworking the ingot body produced in step 430 to form a finished ingot, step 440.
  • step 440 can also be implemented optionally, for example if an intended use places requirements on an ingot, in particular shape requirements, which are not fully met by the ingot body produced in step 430 using the method described above, as described by way of example in connection with Fig. 3.
  • Step 440 includes, for example, reworking a retaining notch of the ingot body, for example by recutting a thread in the retaining notch, and/or smoothing the surface of the ingot body, for example by grinding.
  • Fig. 5 schematically shows an exemplary system 500 for producing an ingot, as described above.
  • the system 500 comprises a controllable production arrangement 510 and a programmable control unit 520 operatively connected to the production arrangement 510.
  • the system 500 is designed to produce one or more ingot bodies by additive manufacturing from a granular ingot starting material by means of the production arrangement 510.
  • the control unit 520 is programmed to control the manufacturing arrangement 510 such that, during the manufacturing of the one or more ingot bodies, the ingot starting material is melted to a greater extent in a region of a shell to be manufactured of each of the one or more ingot bodies than in a region of a core to be manufactured of each of the one or more ingot bodies.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne un procédé (200 ; 400) de fabrication d'un lingot (100 ; 305) qui est en particulier fourni pour une utilisation dans un système VIGA ou un système EIGA, le procédé comprenant la fourniture (210 ; 410 – 422) d'un matériau de départ de lingot granulaire. Le procédé (200 ; 400) comprend en outre la production (220 ; 430) d'un corps de lingot (100 ; 305) à partir du matériau de départ de lingot, la production (220 ; 430) comprenant la fonte de parties du matériau de départ de lingot, et le matériau de départ de lingot étant fondu davantage dans une région d'une coque (110 ; 310) du corps de lingot (100 ; 305) à produire que dans une région d'un noyau (120 ; 320) du corps de lingot (100 ; 305) à produire.
PCT/EP2024/075328 2023-10-19 2024-09-11 Procédé de fabrication de lingots, en particulier destiné à une utilisation dans un système viga ou un système eiga Pending WO2025082667A1 (fr)

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DE102023128784.2A DE102023128784A1 (de) 2023-10-19 2023-10-19 Verfahren zum Herstellen von Ingots, insbesondere zur Verwendung in einer VIGA-Anlage oder einer EIGA-Anlage
DE102023128784.2 2023-10-19

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WO2025082667A1 true WO2025082667A1 (fr) 2025-04-24

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Citations (3)

* Cited by examiner, † Cited by third party
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US20180133804A1 (en) * 2016-11-11 2018-05-17 United Technologies Corporation Additive manufacturing process with metal chips produced by machining processes as feedstock
US20180299359A1 (en) * 2017-04-18 2018-10-18 General Electric Company Additive manufacturing test feature including powder sampling capsule
CN114515831A (zh) * 2022-03-16 2022-05-20 桂林金格电工电子材料科技有限公司 一种利用铜铬边料制备铜铬触头自耗电极的方法

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DE10165115B3 (de) 2000-03-15 2017-10-12 Realizer Gmbh Verfahren und Vorrichtung zur Herstellung eines Formkörpers
DE102005027311B3 (de) 2005-06-13 2006-11-02 Trumpf Werkzeugmaschinen Gmbh + Co. Kg Verfahren zur Herstellung eines dreidimensionalen Formkörpers
DE102011089336A1 (de) 2011-12-21 2013-06-27 Mtu Aero Engines Gmbh Generatives Herstellungsverfahren mit angepasster Bestrahlung
DE102016206105A1 (de) 2016-04-12 2017-10-12 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Vorprodukt für die Herstellung dreidimensionaler Werkstücke, die mittels heißisostatischem Pressen herstellbar sind, und ein Herstellungsverfahren

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Publication number Priority date Publication date Assignee Title
US20180133804A1 (en) * 2016-11-11 2018-05-17 United Technologies Corporation Additive manufacturing process with metal chips produced by machining processes as feedstock
US20180299359A1 (en) * 2017-04-18 2018-10-18 General Electric Company Additive manufacturing test feature including powder sampling capsule
CN114515831A (zh) * 2022-03-16 2022-05-20 桂林金格电工电子材料科技有限公司 一种利用铜铬边料制备铜铬触头自耗电极的方法

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