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WO2025157553A1 - Procédé et dispositif de fabrication additive de pièces à fissuration à chaud réduite - Google Patents

Procédé et dispositif de fabrication additive de pièces à fissuration à chaud réduite

Info

Publication number
WO2025157553A1
WO2025157553A1 PCT/EP2024/087896 EP2024087896W WO2025157553A1 WO 2025157553 A1 WO2025157553 A1 WO 2025157553A1 EP 2024087896 W EP2024087896 W EP 2024087896W WO 2025157553 A1 WO2025157553 A1 WO 2025157553A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
radiation intensity
trajectories
building material
impact
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/EP2024/087896
Other languages
German (de)
English (en)
Inventor
Philipp Stich
Markus Birg
Johannes Romanow
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.)
EOS GmbH
Original Assignee
EOS 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 EOS GmbH filed Critical EOS GmbH
Publication of WO2025157553A1 publication Critical patent/WO2025157553A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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
    • 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
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • 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
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
    • 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
    • B22F10/30—Process control
    • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
    • 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
    • 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
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0433—Nickel- or cobalt-based alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
    • 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
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • 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
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C2200/00—Crystalline structure
    • 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 present invention relates to a method for adjusting a radiation intensity of a beam in a manufacturing process for the additive manufacturing of a component, an additive manufacturing method in which this method is carried out, a computer-aided method for generating control command data for adjusting a radiation intensity of a beam in a manufacturing process for the additive manufacturing of a component and a beam profile adjusting device for generating a beam in a manufacturing process for the additive manufacturing of a component.
  • the present invention relates in particular to additive manufacturing methods and devices in which a component is melted by irradiating layers of a starting material, which is in powder or paste form, with electromagnetic or particle radiation, in order to form a solid after cooling.
  • a component is melted by irradiating layers of a starting material, which is in powder or paste form, with electromagnetic or particle radiation, in order to form a solid after cooling.
  • processes are selective laser sintering (SLS) or selective laser melting (SLM).
  • SLS selective laser sintering
  • SLM selective laser melting
  • Selective laser melting in particular, processes metallic starting materials, and in recent years, the processes have evolved to the point where even components that must meet high requirements regarding mechanical and thermal properties can be manufactured using additive manufacturing.
  • turbine guide vanes and rotor shells are exposed to high thermal, corrosive, and oxidative stresses. Due to typically high operating temperatures, creep damage, for example, due to grain boundary sliding, can occur. This damage mechanism can generally be counteracted by a coarser grain structure. Accordingly, The aim is to produce the components with a single-crystalline microstructure or at least with a directed solidified grain structure with the orientation of the crystallites at least approximately in the future main loading direction.
  • Nickel-based alloys e.g., Hastelloy, Inconel
  • tungsten-molybdenum alloys or titanium alloys
  • Nickel-, cobalt-, and/or iron-based superalloys are particularly preferred.
  • difficulties in using nickel-based alloys as build-up materials arise from the tendency for hot cracks to form during welding (melting and solidification) of these materials.
  • a high proportion of alloying elements leads to difficulties in the processability, e.g., with regard to weldability, of the materials. This is also due to the formation of hot cracks during solidification.
  • the object is achieved by a method for adjusting a radiation intensity according to claim 1, an additive manufacturing method according to claim 8, a method for generating control command data according to claim 14, a beam profile adjustment device according to claim 15, and an additive manufacturing device according to claim 16. Further developments of the invention are specified in the dependent claims. The methods can also be further developed by the features of the devices set out below or in the dependent claims, or vice versa. The features of the devices and methods can also be used for further development among each other.
  • a method for adjusting a radiation intensity of a beam in a manufacturing process for the additive manufacturing of a component wherein in the manufacturing process components are produced by applying a build-up material layer upon layer and in each applied Layer is solidified by supplying radiation energy by a beam to those points of the layer which are assigned to the cross-section of the component in this layer, in that the beam is moved by means of a, preferably controllable, beam movement device along a plurality of trajectories in the cross-section of the component in order to melt the building material at the points which are assigned to the cross-section of the component, and wherein the radiation intensity of the beam is adjusted using a beam profile adjustment device within an impact region of the beam on the building material, is characterized in that the radiation intensity of the beam is adjusted such that its distribution in the impact region of the beam on the building material changes at least at one point by at least 1% per pm.
  • Additive manufacturing devices and methods to which the present invention relates are, in particular, those in which energy is selectively supplied to a layer of a formless building material as electromagnetic radiation or particle radiation.
  • the working plane (also referred to as the building plane) is a plane in which the upper side of the layer to which the energy is supplied lies and is also referred to here as the layer plane.
  • the radiation energy can be generated, for example, by a laser or an electron beam source, although a plurality of radiation sources and/or beams can also be used.
  • the radiation supplied to the building material heats it and thereby causes a sintering or melting process.
  • the present invention relates to laser melting devices and the associated methods.
  • the invention is preferably applied in a manufacturing process in which the build-up material (usually in powder form) consists of a material which contains a nickel-based alloy (e.g. Hastelloy, Inconel, MAR M 247), tungsten-molybdenum alloys or titanium alloys, in particular superalloys based on nickel, cobalt and/or iron, or at least contains such a material.
  • a nickel-based alloy e.g. Hastelloy, Inconel, MAR M 247
  • tungsten-molybdenum alloys or titanium alloys in particular superalloys based on nickel, cobalt and/or iron, or at least contains such a material.
  • the term "beam” here does not imply that the beam diameter must be very small. Rather, the beam impact area on the build material (in the build plane or layer plane) can certainly have a larger diameter (e.g., approximately 250 pm).
  • the beam is preferably a laser-generated beam, generated, for example, using one or more single-mode lasers, e.g., a fiber laser with a power of 3 kW and a wavelength of 1070 nm.
  • the beam movement device is, for example, an XY galvanometer scanner.
  • the beam profile adjustment device is designed to adjust the distribution of the radiation intensity in a plane perpendicular to the beam direction, particularly in the area where the radiation impacts the build material.
  • a change in radiation intensity of 1% per pm expresses that the difference between the values of radiation intensity at two points in the impact area that are 1 pm apart is 1% of the maximum intensity of the beam in the impact area.
  • the beam profile adjustment device can comprise at least one micro-optical element, which can be controlled by a control device or can be controlled by a control device.
  • This can be a so-called diffractive optical element (DOE).
  • DOEs can, for example, operate reflectively or transmissively and modify the wavefront of an incident beam by locally modulating the phase and/or amplitude of the reflected or transmitted partial beams.
  • the beam profile adjustment device can also be implemented using a controllable array of liquid crystals.
  • a beam trajectory is the path a beam follows in the build plane as the beam is directed toward the build material to melt the build material at the locations corresponding to the component's cross-section. It is a sequence of locations in the build plane specified in the control data of the beam movement device. The sequence in the control data specifies the chronological order in which the beam is to be directed toward these locations by the beam movement device, i.e., these locations are to be scanned with the beam.
  • the impact area is a surface on the build material in the build plane onto which the beam impinges.
  • the impact area thus corresponds to a two-dimensional extension on the build material at the build plane.
  • an inner region and an edge region (often an edge line whose width roughly corresponds to the diameter of the beam impact area on the build material in the build plane perpendicular to the direction of beam movement) of a component cross-section.
  • the inner region and/or the edge region are solidified by moving the beam along trajectories that are usually essentially parallel to one another, which can be straight and parallel to one another or non-straight and parallel to one another.
  • a trajectory refers to a line (of zero width) specified in the control data
  • a “hatch line” or “scan line” refers to a track in the build plane with a non-zero width, which roughly corresponds to the diameter of the beam impact area on the build material in the build plane perpendicular to the beam's direction of motion.
  • the width of the scan line therefore corresponds to the width of the impact area.
  • the trajectories are spaced apart from one another, enabling a uniform, seamless energy input into the build material during a scan.
  • the radiation intensity in the impact area can be distributed radially symmetrically, for example, a donut profile, a Gaussian profile, or a so-called top-hat profile, i.e., a profile in which the radiation intensity is more or less constant but decreases toward the edge of the impact area.
  • a crescent beam profile also called a "C-shape”
  • a ramp profile a profile in the shape of an inclined plane, where, in practice, there may be a main maximum intensity along with secondary maxima, or the intensity may decrease in steps.
  • a heat conduction welding process is preferably carried out when melting the construction material.
  • the radiation intensity is adjusted such that its distribution in the area of impact of the beam on the building material decreases at at least one point towards the edge of the impact area by at least 1% per pm, preferably at least 2% per pm, more preferably at least 3% per pm, most preferably at least 4% per pm, and/or in which the radiation intensity is adjusted such that its distribution at the at least one point towards the edge of the impact area decreases by at most 5% per pm, more preferably at most 7% per pm, more preferably at most 9% per pm.
  • the inventors were able to determine that the hot cracking behavior is more favorable the steeper the radiation intensity drops toward the edge of the impact zone. This can be explained by the fact that a steep drop in radiation intensity can prevent the formation of agglomerates of powder particles at the edge of the radiation impact zone, which would otherwise lead to instabilities and hot cracking in the subsequent process.
  • the radiation intensity is adjusted such that its distribution in the impact area on the build-up material varies such that, in the event of rotation of the beam, the decrease in radiation intensity towards the edge of the impact area changes at at least one point on the layer and/or the position of the impact area changes with respect to the point on the layer.
  • the rotation can take place at any angle, whereby the axis of rotation is assumed to be the beam axis, i.e. the direction of the beam.
  • the radiation intensity in the direction of the trajectory can, for example, have a different distribution than in a direction perpendicular to it, i.e., it can be axially symmetric (with the trajectory as the axis of symmetry). This means that in the event of a rotation, different radiation intensity is supplied to certain areas of the construction material.
  • the radiation intensity is adjusted such that at least 90%, preferably at least 95%, particularly preferably at least 99%, of the total radiation power is distributed within an impact region of the beam on the building material, the diameter of which is at most 300 pm, more preferably 420 pm, even more preferably 470 pm, and/or at least 30 pm, more preferably 80 pm, even more preferably 200 pm.
  • the area of the impact area is defined in some way.
  • the area of the impact area is defined as the area in the construction plane onto which at least 90%, preferably at least 95%, particularly preferably at least 99%, of the total radiation power is incident.
  • the maximum extent of the impact area in the construction plane can be used as the diameter of the impact area.
  • the method according to the invention advantageously achieves an increase in the radiation intensity in the impact area without increasing the diameter of the impact area.
  • this changes the ratio between the radiation intensity in the impact area and outside the impact area or achieves that a predominant part of the radiation intensity (as explained above, at least 90%, preferably at least 95%, particularly preferably at least 99%) is distributed in the impact area.
  • the radiation intensity is adjusted such that, starting from a point on the trajectory lying within the impact area, the distribution of the radiation intensity in the impact area of the beam on the building material has a different extent in a direction perpendicular to the trajectory than in the direction opposite to this perpendicular direction.
  • Such a distribution of radiation intensity is particularly advantageous during hatching, i.e., the sequential scanning of the build-up material along trajectories that are, at least in sections, essentially parallel to one another.
  • the impact area has a wider extension in the direction of the subsequent and/or previous trajectory, thus promoting or enabling a thermal conduction welding process.
  • a wide impact area or a wide melt pool in combination with an overlap of adjacent trajectories promotes crystal growth in the vertical direction.
  • the beam movement device is controllable and is controlled such that the distance between two adjacent trajectories which are substantially parallel to each other is less than or equal to 50% of the Beam width of the beam is preferably less than or equal to 35% of the beam width and greater than or equal to 15% of the beam width.
  • the extent of the impact area perpendicular to the trajectory is defined as the beam width.
  • the specified overlap of the impact areas of the beams used when scanning successive trajectories makes it possible to achieve a wide, flat melt pool, allowing the preferred thermal conduction welding process to occur during melting. Furthermore, the specified overlap and the radiation intensity distribution described above make it possible to achieve a wide, flat melt pool, particularly with a wider extent in the direction of the subsequent and/or previous trajectory.
  • This approach can also be used when the parallel trajectories are not straight, e.g. in the so-called "onion hatching", in which the build-up material is scanned in a spiral or concentric circles.
  • the beam movement device is controllable and is controlled such that the beam is moved along a trajectory at a speed that is greater than or equal to 1 m/s.
  • the speed at which the beam is moved along a trajectory is a value greater than or equal to 1 m/s and less than or equal to 2 m/s.
  • the additive manufacturing process according to the invention can be a selective laser melting process (SLM).
  • a beam generated by a laser operated in continuous wave mode is used to melt the build-up material along at least one of the trajectories, this beam can be moved along the trajectories at a speed greater than or equal to 1 m/s.
  • the variation of the radiation intensity in the impact area on the build-up material, the speed at which the beam is moved along the plurality of trajectories, and the distance between adjacent trajectories are selected such that after cooling of the previously melted build-up material, the proportion of large-angle grain boundaries is less than 75%, preferably less than 66%, more preferably less than 50%, most preferably less than 33%.
  • a high-angle grain boundary is defined here as a grain boundary where the orientation of adjacent crystal regions or crystallites differs by at least 15°.
  • the degree of polycrystallinity in the manufactured component is limited, since the degree of polycrystallinity increases with the proportion of high-angle grain boundaries. As the degree of polycrystallinity increases, the tendency for hot cracking also generally increases.
  • the degree of polycrystallinity can also be defined via the aspect ratio of the grains or via the extent to which the crystal regions are produced by epitaxial growth.
  • the variation of the radiation intensity in the impact area on the build-up material, the speed at which the beam is moved along the plurality of trajectories, and the distance between adjacent trajectories are selected such that, after cooling of the previously melted build-up material, the orientation of the grains relative to a perpendicular to the plane of the layer is a maximum of 15°.
  • the orientation of the grains is defined as the angle between the direction of maximum extension of a grain and the normal.
  • the normal to a layer plane usually corresponds to the direction in which the layers are stacked.
  • the crystallites (grains) in the component can be aligned in a preferred direction, which is preferably selected so that it essentially or exactly coincides with the direction in which the greatest mechanical stress occurs during later use of the component.
  • the variation of the radiation intensity in the impact area on the building material, the speed at which the beam is moved along the plurality of trajectories, and the distance between adjacent trajectories are selected such that after cooling of the previously melted building material, the maximum dimension of the grains is greater than or equal to 20 times, preferably greater than or equal to 50 times, more preferably greater than or equal to 100 times, the distance between two adjacent trajectories.
  • Grain size is defined here as the mean diameter of the grains (crystallites).
  • the specified match between grain size and trajectory spacing reflects the fact that a conduction welding process with a flat, extended weld pool is desired.
  • the variation of the radiation intensity in the impact area on the building material, the speed at which the beam is moved along the plurality of trajectories, the distance between adjacent trajectories are selected such that after cooling of the previously melted building material, the extension of the grains perpendicular to the planes of the layers is greater than or equal to 20 times, preferably greater than or equal to 50 times, more preferably greater than or equal to 100 times, the distance between two adjacent trajectories.
  • the directions of superimposed trajectories in successive layers are rotated relative to each other by an angle which is substantially 90°, preferably exactly 90°.
  • the angle between two superimposed trajectories can be determined by projecting the trajectories onto a plane parallel to both (which is parallel to the build plane or coincides with the build plane). Rotating the trajectories by 90° ensures that the crystal structure is maintained in the z-direction.
  • a computer-aided method for generating control command data for adjusting a radiation intensity of a beam in a manufacturing process for the additive manufacturing of a component, wherein components are produced in the manufacturing process by applying a build-up material layer upon layer and solidifying it in each applied layer by supplying radiation energy by a beam to those locations of the layer that are associated with the cross-section of the component in this layer, by moving the beam by means of a preferably controllable beam movement device along a plurality of trajectories in the cross-section of the component in order to melt the build-up material at the locations that are associated with the cross-section of the component, wherein the radiation intensity of the beam is determined using a
  • Beam profile adjustment device is adjusted within an impact area of the beam on the build field, and wherein the control command data are used to control the beam profile adjustment device, characterized in that the control command data are generated such that a distribution of the radiation intensity in the impact area of the beam on the build material changes at least at one point by at least 1% per pm and/or that at least 90%, preferably 95%, particularly preferably 99%, of the total radiation power is distributed within an impact area of the beam on the build material, the diameter of which is at most 300 pm, more preferably 420 pm, even more preferably 470 pm and/or at least 30 pm, more preferably 80 pm, even more preferably 200 pm.
  • model data contains a geometric description of the cross-sections of the component to be manufactured, which are assigned to the layers during layer-by-layer production, in particular a three-dimensional CAD model.
  • CAD model CAD model
  • other geometric description options are also available, e.g., a description using a set of parameters and a design specification.
  • the control command data for setting a radiation intensity are generally part of a control data set, which is considered to be the entirety of all control data specified for controlling the manufacturing process in an additive manufacturing device.
  • the control data related to an individual layer is usually referred to as a layer data set.
  • a layer data set contains a data model of locations of an object cross-section or object partial cross-section that are to be solidified in a layer by means of one or more beams during the manufacturing process.
  • an object cross-section or object partial cross-section can be included, in particular the chronological order in which an object cross-section or object partial cross-section
  • the corresponding locations are to be solidified by specifying scan lines or trajectories along which the beam is to be moved, a temporal sequence of scanning a plurality of scan lines or trajectories, or, for example, the layer thickness or irradiation parameter values, such as the diameter or the travel speed of a beam impinging on the build-up material, etc.
  • the control command data for adjusting a radiation intensity comprises data for controlling an array of liquid crystals.
  • Arrays of liquid crystals are divided into regions, usually into square columns or square regions (“pixels”).
  • the refractive index can be modulated by an electrical signal.
  • the beam is expanded and collimated.
  • the beam hits several, for example all, regions of the array, and different beam components pass through different regions (columns or pixels) of the array.
  • the beam is then refocused and directed, as described above, onto the build area to solidify the build material.
  • electrically modulating the refractive index of the regions of the array different beam components of the beam experience different refractive indices.
  • the control command data for adjusting a radiation intensity comprises data for controlling an array of liquid crystals, and that the adjustment of the radiation intensity depends on the data for controlling the array of liquid crystals.
  • the data for controlling the array of liquid crystals is then a special case of control command data for adjusting the radiation intensity and consequently a component of a control data set that comprises the entirety of all control data specified for controlling the manufacturing process in an additive manufacturing device.
  • the data for controlling the array of liquid crystals can be generated together with the remaining control command data, or part of the control command data can be in the form of data for Control of the liquid crystal array can be generated.
  • the data for controlling the liquid crystal array can be generated in a separate step, and the control command data can be subsequently supplemented with the data for controlling the liquid crystal array.
  • a preferred variant of the computer-aided method according to the invention for generating control command data for adjusting a radiation intensity of a beam in the manufacturing process for the additive manufacturing of a component, wherein the radiation intensity of the beam is adjusted using a beam profile adjustment device within an impact area of the beam on the construction field and the control command data serve to control the beam profile adjustment device, is characterized in that the control command data comprise data for controlling an array of liquid crystals, wherein the adjustment of the radiation intensity depends on the data for controlling the array of liquid crystals.
  • a further preferred variant of the computer-aided method according to the invention for generating control command data for adjusting a radiation intensity of a beam in the manufacturing process for the additive manufacturing of a component is characterized in that the control command data and/or the data for controlling the array of liquid crystals are generated in such a way that a distribution of the radiation intensity in the area of impact of the beam on the building material changes at least at one point by at least 1% per pm and/or that at least 90%, preferably 95%, particularly preferably 99%, of the total radiation intensity is distributed within an area of impact of the beam on the building material, the diameter of which is at most 300 pm, more preferably 420 pm, even more preferably 470 pm and/or at least 30 pm, more preferably 80 pm, even more preferably 200 pm.
  • a beam profile adjustment device for generating a beam in a manufacturing process for the additive manufacturing of a component, wherein in the manufacturing process components are produced by applying a build-up material layer upon layer and in each applied layer by means of Supply of radiation energy to those points of the layer which are assigned to the cross-section of the component in this layer, is solidified, wherein the beam profile adjustment device is designed to adjust the distribution of a radiation intensity within an impact region of the beam, is characterized in that the beam profile adjustment device generates the beam such that the radiation intensity in the impact region of the beam on the building material changes at least one point by at least 1% per pm and/or that at least 90%, preferably 95%, particularly preferably 99%, of the total radiation power is distributed within an impact region of the beam on the building material, the diameter of which is at most 300 pm, more preferably 420 pm, even more preferably 470 pm and/or at least 30 pm, more preferably 80 pm, even more preferably 200 pm.
  • the beam profiling device comprises a multiple light splitter (e.g., a beam splitter or a diffractive element) by which the radiant power can be distributed among light guides, e.g., optical fibers.
  • light guides can also be part of the beam profiling device.
  • the light guides can be attached to the beam profiling device. The fact that the light guides are attached to the beam profiling device does not mean that they necessarily have to be in the immediate vicinity of the beam profiling device or that they necessarily have to be mechanically connected to the beam profiling device. It is sufficient that the beam emanating from the beam profiling device can be coupled into the additional light guides.
  • multiple beams are coupled into a plurality of optical fibers, i.e., without the use of a multiple light splitter.
  • the light guides are considered part of the beam profiling device.
  • the beam profile can be adjusted by superimposing multiple beams, which originate either from multiple independent laser sources or from a single laser source.
  • a beam already exhibits a specific beam profile before coupling into a fiber optic cable.
  • the beam profile is inevitably altered during propagation in the fiber optic cable.
  • the change in the beam profile during propagation in a fiber optic cable can be predicted, for example, by simulation.
  • the properties of a light guide can then be selected such that the change in the beam profile due to propagation in the light guide contributes to the generation of a desired beam profile.
  • a beam profile is adjusted before coupling into a light guide, and the properties of a light guide are selected such that the combination of the adjustment of the beam profile and the change in the beam profile due to propagation in the light guide produces a desired beam profile.
  • An additive manufacturing device for producing a three-dimensional object with an application device for applying a building material layer upon layer and an energy input device for supplying radiation energy by means of a beam to those locations of a layer which are assigned to the cross-section of the object in this layer, which has: a beam profile device for adjusting a radiation intensity of the beam and a beam movement device for moving the beam along a plurality of trajectories, wherein the building material is melted at the locations which are assigned to the cross-section of the component in the layer along the trajectories, is characterized in that the beam profile device adjusts the radiation intensity of the beam such that the radiation intensity in the area of impact of the beam on the building material changes at least at one location by at least 1% per pm.
  • a further variant of a method for adjusting a radiation intensity of a beam and for moving the beam in a manufacturing process for the additive manufacturing of a component wherein in the manufacturing process components are produced by applying a building material layer upon layer and solidifying it in each applied layer by supplying radiation energy through the beam to those points of the layer that are assigned to the cross-section of the object in this layer, by moving the beam by means of a, preferably controllable, beam movement device is moved along a plurality of trajectories in the cross-section of the object in order to melt the building material at the locations which are assigned to the cross-section of the component, wherein the radiation intensity of the beam is adjusted using a beam profile adjustment device, is characterized in that the radiation intensity of the beam is adjusted such that its distribution in the area of impact of the beam on the building material changes at least at one location by at least 1% per pm and that at least 90%, preferably 95%, particularly preferably 99%, of the total radiation intensity is distributed within an area of impact of the beam on the building material, the diameter of which
  • a method for introducing radiation energy by a beam in a manufacturing process for the additive manufacturing of a component comprises: adjusting a radiation intensity of the beam using a beam profile adjustment device within an impact area of the beam on the build-up material and moving the beam by means of a preferably controllable beam movement device along a plurality of trajectories in the cross-section of the component, wherein the build-up material is melted at locations that are associated with the cross-section of the component.
  • the method is characterized in that that the radiation intensity is adjusted such that its distribution in the area of impact of the beam on the building material changes at least at one point by at least 1% per pm and that at least 90%, preferably 95%, particularly preferably 99%, of the total radiation intensity is distributed within an area of impact of the beam on the building material whose diameter is at most 470 pm, more preferably 420 pm, even more preferably 300 pm and/or at least 30 pm, more preferably 80 pm, even more preferably 200 pm.
  • the method is characterized in that the beam is moved such that the distance between adjacent trajectories which run substantially parallel to one another is less than 50% of the beam width of the beam, preferably less than or equal to 35% of the beam width, particularly preferably greater than or equal to 15% of the beam width, and the energy input device is controlled such that the beam is moved along a trajectory at a speed which is greater than or equal to 1 m/s.
  • An energy input device for inputting radiation energy by means of a beam in a manufacturing process for the additive manufacturing of a component, wherein components are produced in the manufacturing process by applying a build-up material layer upon layer and solidifying it in each applied layer by supplying radiation energy to those locations of the layer that are associated with the cross-section of the component in this layer, comprises: a beam profile adjustment device that is designed to adjust a radiation intensity of the beam and a, preferably controllable, beam movement device for moving the beam along a plurality of trajectories in the cross-section of the component, wherein the build-up material is melted at the locations that are associated with the cross-section of the component.
  • the energy input device is characterized in that the beam profile adjustment device adjusts the radiation intensity of the beam in such a way that its distribution in the area of impact of the beam on the building material changes at least at one point by at least 1% per pm and that at least 90%, preferably 95%, particularly preferably 99%, of the total radiation intensity is distributed within an impact area of the beam on the building material, the diameter of which is at most 470 pm, more preferably 420 pm, even more preferably 300 pm and/or at least 30 pm, more preferably 80 pm, even more preferably 200 pm.
  • the beam movement device is controlled such that the distance between adjacent trajectories which run substantially parallel to one another is less than 50% of the beam width of the beam, preferably less than or equal to 50% of the beam width, particularly preferably greater than or equal to 15% of the beam width, and the energy input device is controlled such that the beam is moved along a trajectory at a speed which is greater than or equal to 1 m/s.
  • Fig. 1 shows a schematic, partially sectioned view of an exemplary device for additively manufacturing a three-dimensional object according to the invention.
  • Fig. 2 shows schematically the course of the radiation intensity along a section through the center of the incident surface of a beam with radially symmetric radiation intensity and donut shape of the intensity profile.
  • Fig. 3 shows schematically the course of the radiation intensity along a section through the center of the incident surface of a beam with radially symmetric radiation intensity and Gaussian shape of the intensity profile.
  • Fig. 4 shows schematically the course of the radiation intensity along a section through the center of the incident surface of a beam with radially symmetric radiation intensity and tophat shape of the intensity profile.
  • Fig. 5 schematically shows two trajectories along which the beam is moved when scanning the build material.
  • Fig. 6 shows a three-dimensional representation of a donut-shaped intensity distribution.
  • Fig. 7 shows a three-dimensional representation of a 'tophat' intensity distribution.
  • Fig. 8 shows a common procedure for scanning ("hatching") the build-up material with electromagnetic radiation
  • Fig. 9 shows a three-dimensional representation of a ramp-shaped intensity distribution (ramp distribution).
  • the laser sintering or laser melting device 1 For constructing an object 2, the laser sintering or laser melting device 1 contains a process chamber or build chamber 3 with a chamber wall 4. Arranged within the process chamber 3 is a build container 5 open at the top and with a container wall 6. A work plane 7 is defined by the upper opening of the build container 5, with the area of the work plane 7 located within the opening, which can be used to construct the object 2, being referred to as the build field 8.
  • a support 10 movable in a vertical direction V, to which a base plate 11 is attached, which closes off the container 5 at the bottom and thus forms its base.
  • the base plate 11 can be a plate formed separately from the support 10 and fastened to the support 10, or it can be formed integrally with the support 10.
  • a build platform 12 can be attached to the base plate 11 as a build base, on which the object 2 is built. However, the object 2 can also be built on the base plate 11 itself, which then serves as the build base.
  • the object 2 to be formed in the container 5 on the build platform 12 is shown below the work plane 7 in an intermediate state with several solidified layers, surrounded by unsolidified build material 13.
  • the laser melting device 1 further includes a reservoir 14 for a build material 15, in this example a powder that can be solidified by electromagnetic radiation, and a coater 16 movable in a horizontal direction H for applying the build material 15 within the build field 8.
  • a heating device e.g., a radiant heater 17, can be arranged in the process chamber 3.
  • An infrared radiator for example, can be provided as the radiant heater 17.
  • the exemplary additive manufacturing device 1 further includes an energy input device 20 with a laser 21 that generates a laser beam 22, which is focused onto the working plane 7 via a beam profile adjustment device 26 and an XY galvanometer scanner 23 as a beam movement device and optionally a focusing device 24 via a coupling window 25 that is attached to the top of the process chamber 3 in the chamber wall 4.
  • an energy input device can comprise, for example, one or more gas or solid-state lasers or any other type of laser, such as laser diodes, in particular VCSELs (Vertical Cavity Surface Emitting Lasers) or VECSELs (Vertical External Cavity Surface Emitting Lasers), or a row of these lasers.
  • VCSELs Vertical Cavity Surface Emitting Lasers
  • VECSELs Very External Cavity Surface Emitting Lasers
  • the laser melting device 1 further includes a control device 29, via which the individual components of the device 1 are controlled in a coordinated manner to carry out the construction process.
  • the control device can also be mounted partially or entirely outside the additive manufacturing device.
  • the control device can include a CPU whose operation is controlled by a computer program (software).
  • the computer program can be stored separately from the additive manufacturing device in a storage device. from where it can be transferred (e.g. via a network) into the additive
  • control device 29 lowers the carrier 10 layer by layer, controls the coater 16 to apply a new powder layer, and controls the energy input device 20 to solidify the respective layer at the locations corresponding to the respective object by means of the laser by scanning these locations with the laser beam.
  • a manufacturing process takes place in such a way that the control device 29 processes a control data set.
  • the control data set tells the energy input device at which point on the working plane 7 the radiation is to be directed at each point in time during the scanning process of the build-up material with the laser beam.
  • metallic construction material is preferably used, in particular one which consists mainly, preferably more than 90%, of a nickel-based alloy, e.g. Inconel or MAR M 247 or CM 247 LC, and which is melted by introducing the radiation energy.
  • a nickel-based alloy e.g. Inconel or MAR M 247 or CM 247 LC
  • Fig. 8 shows a common procedure for scanning the build-up material with electromagnetic radiation.
  • an object cross-section 50 is divided into an inner region or core region 52 and a contour region 51, whereby the contour region 51 is usually assigned different parameters for the energy input into the
  • the inner region 52 is typically solidified by dividing it into subregions 53, which typically have an approximately rectangular or square shape and are therefore also referred to as "strips" or "squares.”
  • the inner region 52 is then scanned with the laser beam, subregion by subregion.
  • the laser beam is moved along parallel paths (hatch lines) 54 across the build material, resulting in a hatch-like movement pattern when scanning each partial area 53 with the laser beam.
  • This process is also referred to as "hatching" in technical jargon.
  • the direction of movement of the laser beam is illustrated by arrows. It can be seen that the directions of movement for adjacent hatch lines 54 are opposite to each other.
  • Fig. 5 illustrates in detail the situation for two adjacent hatch lines 54 (also referred to as trajectories).
  • the trajectories illustrate the sequence of points on the build material layer that are scanned one after the other, in other words, the positions that are specified to the energy input device in the control data set for an energy input in chronological succession.
  • the impact area of the laser beam on the surface of the build material has an extent other than zero, which is illustrated in Fig. 5 by a circular area 100.
  • the edge of the impact area is defined such that 99% of the radiation power of the laser beam impinges on the area lying within the edge.
  • the scanning laser beam can be assigned a beam width b corresponding to the extent of the impact area perpendicular to the trajectory.
  • the trajectories are spaced apart by an amount d, which is also taken into account in the control data.
  • a distance d between the trajectories is chosen that is less than 50% of the beam width b of the beam, in this case 40%.
  • the radiation power impinging on the build-up material in the impact area is not distributed homogeneously within the impact area. Rather, the radiation intensity fluctuates, as explained below using Figures 2 to 4.
  • the radiation intensity has a Gaussian distribution with a maximum of the radiation intensity in the center.
  • a so-called donut distribution i.e., a local minimum in the center surrounded by a region of higher radiation intensity
  • a so-called "top hat” distribution i.e., an approximately constant radiation intensity that decreases towards the edge.
  • the exact form of the distribution is determined by the beam profile adjustment device 26.
  • the beam shaping device can have at least one micro-optical element controllable by the control device.
  • the beam profile adjustment device can be a diffractive optical element (DOE).
  • DOE diffractive optical element
  • a diffractive optical element modifies the wavefront of an incident beam by locally modulating the phase and/or amplitude of the reflected or transmitted partial beams and can operate reflectively or transmissively.
  • a beam combining device disclosed in WO 2020/099172 A1 can be used to adjust an intensity distribution (e.g., Gaussian, donut, or tophat).
  • the intensity distribution can also be generated by superimposing multiple laser beams, either from multiple independent laser sources or from a single laser source, with the beams being split into partial beams using a beam splitter, for example.
  • a possible approach here is that proposed by nLIGHT, Vancouver, WA 98665 USA, which uses a multiple optical fiber, allowing the distribution of the radiant power to be varied among the individual fibers.
  • the intensity distribution can be adjusted by liquid crystals (e.g. arranged in columns or pixels).
  • a distribution of the radiation intensity within the impact area is defined in the control data, for example by defining a corresponding control of the beam profile adjustment device in the control data, for example also depending on the position of the build-up material layer to be scanned.
  • the distribution of the radiation intensity at the edge of the impact area should be adjusted so that it has a gradient of at least 1% per pm, preferably at least 2% per pm, more preferably at least 3% per pm, and most preferably at least 4% per pm.
  • the definition of the gradient at the edge is schematically illustrated in Figures 2 to 4.
  • a beam diameter (extension of the impact area) of no more than 470 pm, preferably 420 pm, even more preferably 300 pm, and/or at least 30 pm, preferably 80 pm, even more preferably 200 pm should be used.
  • the distance d between the trajectories should then be adjusted to the beam diameter b according to the specifications mentioned above.
  • the donut-shaped intensity distribution shown in Fig. 6 (in kW/cm 2 ) can be assigned a diameter b of the impact area on the build material of 250 pm, with the intensity decreasing by 3 to 4% per pm at least at one point in the impact area, particularly towards the edge of the impact area.
  • a diameter b of the impact area on the build material of 250 pm
  • the intensity decreasing by 3 to 4% per pm at least at one point in the impact area, particularly towards the edge of the impact area.
  • the total power in the beam fluctuated between 350 W and 500 W, with the scanning speed along the trajectories being between 1000 and 2000 mm/s (with a layer thickness between 0.085 and 0.09 mm) and the distance d between two adjacent hatch lines being between 75 pm and 95 pm (the distance between two adjacent trajectories is correspondingly between 30% and 38% of the impact area). Furthermore, the trajectories in the construction plane were rotated by 90° from layer to layer. With the parameters mentioned, a build rate of up to 3.8 mm3 /s was achieved. The inventors observed that the crack density can be influenced, particularly reduced, by parameter combinations within the above-mentioned ranges.
  • a micrograph of the manufactured component can be analyzed using image analysis software (e.g. ImageJ), whereby the total length of the individual cracks is determined by adding up all branches and finally the total length (sum) of all cracks is set in relation to the total area of the micrograph.
  • image analysis software e.g. ImageJ
  • the top-hat-shaped intensity distribution shown in Fig. 7 (in kW/cm 2 ) can also be assigned a diameter b of the impact area on the build-up material of 250 pm, with the intensity decreasing at least at one point in the impact area, particularly towards the edge of the impact area, by 1.5 to 2% per pm.
  • a diameter b of the impact area on the build-up material 250 pm
  • the intensity decreasing at least at one point in the impact area, particularly towards the edge of the impact area, by 1.5 to 2% per pm cubes with an edge length of 10 mm were again manufactured from CM247LC powder using an SLM process.
  • the total power in the beam is between 350 W and 433 W, with the
  • the scanning speed along the trajectories was between 1875 and 2167 mm/s (at a layer thickness between 0.075 and 0.09 mm), and the distance d between two adjacent hatch lines was between 65 and 90 pm. Furthermore, the trajectories were rotated by 90° in the build plane from layer to layer.
  • the ramp distribution (ramp-shaped distribution) of the intensity (in kW/cm 2 ) shown in Fig. 9 can be assigned a diameter b of the impact area on the build material of 300 pm in the main extension direction and 80 pm in the direction perpendicular to the main direction, with the intensity decreasing by 2.5 to 3.5% per pm at least at one point in the impact area, in particular towards an edge of the impact area.
  • the total power in the beam varied between 195 W and 350 W, with the scanning speed along the trajectories ranging between 2500 mm/s and 3500 mm/s (at a layer thickness between 0.075 and 0.09 mm), and the distance d between two adjacent hatch lines ranging between 40 and 70 pm. Furthermore, the trajectories were rotated by 90° in the build plane from layer to layer. Such a ramp-shaped intensity distribution exhibits a change in radiation intensity of up to 1.95%/pm.
  • the crack density is related to the crystal structure of the component.
  • the lower the crack density the larger and more strongly oriented the grains (crystals) are.
  • the influence of the process parameters (radiation intensity, change in radiation intensity within the impact area, diameter of the impact area or width of the scan line, Scan speed, hatch distance) on the texture properties of the component resulting from the manufacturing process.
  • Texture properties include the proportion of large-angle grain boundaries (angle of orientation between adjacent crystal regions), grain orientation relative to a plane perpendicular to the layer, maximum grain dimensions (e.g., relative to the hatch distance between adjacent trajectories), and grain extension (e.g., relative to the hatch distance between adjacent trajectories) in the direction perpendicular to the layer or the build direction of the component.
  • the inventors have observed that the maximum dimension of the grains and the extension of the grains in the direction perpendicular to the plane of the layer increase along with the change in the radiation intensity in the impact area (i.e., the greater the change in the radiation intensity in the impact area (in particular, the steeper the radiation intensity decreases towards the edge of the impact area), the greater the maximum dimension of the grains and the greater the extension of the grains in a plane perpendicular to the layer).
  • a greater extension of the grains in a plane perpendicular to the layer also means that the proportion of large-angle grain boundaries is smaller: the more the grains are oriented perpendicular to the layer, the smaller the angle between neighboring grains and the smaller the proportion of grain angle boundaries that deviate from this small angle.
  • the fact that the grains are greatly extended perpendicular to the layer also means that they are oriented essentially perpendicular to the layer.
  • the direction in which the grains have the maximum dimension has an angle with respect to a perpendicular to the layer that is at most is 15°.
  • the mentioned properties of the grains or their texture also depend on the hatch distance and the diameter of the impact area or the beam width.
  • the radiation intensity and the scanning speed in combination with the other parameters should be in certain intervals in order to achieve the desired properties of the grains in combination with the change in the radiation intensity according to the invention.
  • the proportion of high-angle grain boundaries is less than 33% means that the orientation angle of the grains relative to the perpendicular to the layer is essentially a maximum of 15°. As explained above, a larger angle of the grains relative to the perpendicular to the layer decreases the angle between the different grains, thus reducing the proportion of high-angle grain boundaries in the material.
  • the maximum dimension of the grains is typically larger than the extension of the grains perpendicular to the layer, because the maximum extension of a grain lies in a direction other than the direction perpendicular to the layer.
  • the extensions of the grains perpendicular to the layer differ The larger the grains' dimensions in the direction perpendicular to the layer, the smaller the maximum dimension of the grains.
  • the maximum dimension (the maximum diameter) of the grains (crystallites in the manufactured object) and the grain dimensions perpendicular to the layer (relative to the orientation of the component during the manufacturing process) are in the same range (see Table 5), even if the maximum dimension of the grains is generally slightly larger than their dimensions perpendicular to the layer.
  • Radiation intensity between 40 and 450 W.
  • Diameter of the impact area between 30 and 400 pm
  • Scanning speed between 1000 mm/s and 3500 mm/s
  • a smaller value can be selected for the minimum change in radiation intensity towards the edge of the impact area, e.g. a value between 1.5%/pm and 2%/pm, if more than 75% of the radiation power is distributed over half the area of the impact area, such as in a top hat profile.

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Abstract

L'invention concerne un procédé de réglage de l'intensité de rayonnement d'un faisceau dans un procédé de fabrication pour la fabrication additive d'un composant. Au cours du procédé de fabrication, des composants sont produits par le fait qu'un matériau de construction est déposé couche par couche, et que le matériau de construction est solidifié dans chaque couche déposée par l'apport d'énergie de rayonnement, au moyen d'un faisceau, aux points de la couche qui sont associés à la section transversale du composant dans ladite couche, par le fait que le faisceau est déplacé le long d'une pluralité de trajectoires dans la section transversale du composant au moyen d'un dispositif de déplacement de faisceau, de préférence un dispositif de déplacement de faisceau apte à être commandé, afin de faire fondre le matériau de construction au niveau des points qui sont associés à la section transversale du composant, l'intensité de rayonnement du faisceau étant réglée au sein d'une région d'incidence du faisceau sur le matériau de construction à l'aide d'un dispositif de réglage de profil de faisceau. Le procédé est caractérisé en ce que l'intensité de rayonnement du faisceau est réglée d'une manière telle que la distribution de l'intensité de rayonnement dans la région d'incidence du faisceau sur le matériau de construction varie d'au moins 1 % par µm au niveau d'au moins un point.
PCT/EP2024/087896 2024-01-24 2024-12-20 Procédé et dispositif de fabrication additive de pièces à fissuration à chaud réduite Pending WO2025157553A1 (fr)

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