Additive manufacturing of a component made from a metal matrix composite

Abstract

The embodiments relate to a method for additive manufacturing of a component made from a metal matrix composite for a vehicle. In a step of the method, a plurality of elongated filaments is provided. In another step, metallic powder is provided. In a further step, the metal matrix composite component is additively manufactured by melting the metallic powder.

Claims

1. A method for additively manufacturing of a component made from a metal matrix composite for a vehicle, the method comprising the steps of: providing metal powder as a powder bed in a manufacturing apparatus; disposing a plurality of elongated filaments on the powder bed, such that the elongated filaments are elongated along a moving direction; and melting the metal powder, with a laser beam that scans the metal powder in a scanning direction, while moving the elongated filaments along the moving direction, wherein the moving direction is transverse to the scanning direction, to form the metal matrix component.

2. The method of claim 1, wherein at least one of the elongated filaments is a metal filament, a metal-coated non-metallic filament, a semi-metallic filament or a polymer fiber.

3. The method of claim 1, wherein the metal powder is scanned by the laser beam in the scanning direction to achieve melting and to fuse at least a part of said elongated filaments with each other and thereby to selectively melt the metal powder into a desired shape.

4. The method of claim 3, wherein the powder bed is disposed within a manufacturing device; wherein the manufacturing device comprises at least one opening suitable for receiving the elongated filaments; and wherein the elongated filaments are moved along the moving direction transverse to the scanning direction, whereby a desired length of the component is formed.

5. The method of claim 4, wherein a chemically inert atmosphere is provided within the manufacturing device.

6. The method of claim 1, wherein the elongated filaments have a round or polygonal cross-section.

7. A manufacturing apparatus for additive manufacturing of components made from a metal matrix composite with elongated filaments, comprising: a powder bed comprising a metallic powder; a feed to dispose a plurality of elongated filaments on the powder bed, such that the elongated filaments are elongated along a moving direction; and a heat source comprising a movable laser beam having a scanning direction; wherein the heat source is configured to melt the metal powder with the laser beam by scanning the metallic powder in the scanning direction while the elongated filaments are moved along the moving direction, wherein the moving direction is transverse to the scanning direction, to selectively fuse the metallic powder with the elongated filaments into a desired shape.

8. The manufacturing apparatus according to claim 7, wherein the manufacturing apparatus comprises at least one opening which is suitable for receiving the elongated filaments.

9. The manufacturing apparatus according to claim 7, further comprising: a manufacturing chamber, in which the metallic powder is melted and in which there is a chemically inert atmosphere.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The various embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and:

(2) FIG. 1 shows a flow diagram of a method for additive manufacturing of a metal matrix composite component of a vehicle,

(3) FIG. 2 shows a perspective view of an example of a manufacturing apparatus,

(4) FIG. 3 shows a perspective view of another example of a manufacturing apparatus.

DETAILED DESCRIPTION

(5) The following detailed description is merely exemplary in nature and is not intended to limit the disclosed embodiments or the application and uses thereof. Furthermore, there is no intention to be bound by any theory presented in the preceding background detailed description.

(6) FIG. 1 shows a flowchart 10 of a method for additive manufacturing of a component of a metal matrix composite for a vehicle. The method comprises several steps that are described below. However, it should be noted that the method may also comprise further steps, which are not explicitly mentioned.

(7) In step 12 of the method, a plurality of elongated filaments is provided. At least one of the elongate filaments may e.g. be a metal filament, a metal-coated non-metallic filament, a semi-metallic filament or a polymer fiber. In other words, an elongated filament may at least partly be made of metal, such as tool-steel or stainless steel, aluminum or titanium. The cross-section of an elongated filament is e.g. round or polygonal. Depending on the application, the diameter may also vary, such as less than 1 centimeter or a few centimeters (e.g., 5 cm).

(8) In step 14 of the method, metal powder is provided. Again, depending on the application, in principle different metals, such as tool-steel or stainless steel, aluminum or titanium, may be used. Metal alloys, such as aluminum forging alloys, titanium alloys or magnesium alloys, may also be used. The metal powder and the elongated filaments may be made of the same metal. The volume ratio between the elongate filaments, and the metal powder may also be different depending on the component to be manufactured. In one example, the volume ratio between the elongate filaments, and the metal powder may be about at 4:1. In another example, the volume ratio between the elongate filaments, and the metal powder may be 5:1.

(9) In step 16 of the method, additive manufacturing of the metal matrix composite component is performed by melting the metal powder. The additive manufacturing can be e.g. a laser-based additive manufacturing or an electric-arc-based additive manufacturing method. In other words, additive manufacturing processes can be realized by applying and solidifying the metal in a solid state in layers on a carrier medium. The connection can be made by melting using a laser or an arc welding. The power of the heat source can be adapted to allow for a low porosity.

(10) By using the elongated filaments, a large-size component of a vehicle can be manufactured. An example is an aircraft stringer. The production time and manufacturing costs can also be reduced.

(11) The first step 12 is also referred to as step a), the second step 14 as step b), and the third step 16 as step c).

(12) FIG. 2 shows a perspective view of an example of a manufacturing apparatus 100 for additive manufacturing of a metal matrix composite component with a plurality of elongated filaments 102. The manufacturing apparatus 100 comprises a powder bed 104 and a heat source 106. The powder bed 104 provides metal powder 108. The heat source 106 is configured to melt the metal powder 108 for additive manufacturing of a component in order to selectively fuse the metal powder 108 with the elongate filaments 102 into a desired shape.

(13) The manufacturing apparatus may be closed, that is, the elongated filaments to be manufactured can be accommodated in the manufacturing apparatus during additive manufacturing and the manufactured component can only be removed after the additive manufacturing process. It is also possible that the manufacturing apparatus is open. In other words, during the additive manufacturing process further elongated filaments to be manufactured can be introduced into the manufacturing apparatus and the manufactured component can also be removed. An example of an open manufacturing apparatus is shown in FIG. 3.

(14) In the additive manufacturing, at least a portion of the elongate filaments 102 is disposed on the powder bed 104. The metal powder is scanned in a scanning direction 110 to achieve a melting and to connect at least a part of elongated filaments 102 with each other, and thereby selectively fuse the metal powder 108 into a desired shape.

(15) A laser-based additive manufacturing or an electric-arc-based additive manufacturing method may be used. In other words, the heat source 106 may be e.g. a laser or an electric arc. The metal powder may also be fused by other methods.

(16) The porosity of the solidified material depends on the size of the energy supplied. A rough classification depending on the use of a laser or an electric arc for solidifying the metal powder can be made. The power of the heat source can be adapted to allow for a low porosity.

(17) FIG. 3 shows a perspective view of another example of a manufacturing apparatus 100. The manufacturing apparatus 100 comprises at least one opening 112 that is adapted to receive the elongated filaments 102.

(18) In this manner, the elongated filaments 102 can be moved during the additive manufacturing along a moving direction 114 transverse to the scanning direction 110. Accordingly, a desired length of the component can be produced. For example, FIG. 3 shows a manufactured component 116.

(19) Furthermore, the manufacturing apparatus 100 comprises a manufacturing chamber 118. In the manufacturing chamber 118, the metal powder is melted and a chemically inert atmosphere prevails. Inert gas such as e.g. nitrogen may be introduced into the manufacturing chamber 118. The openings 112 of the manufacturing chamber 118 can be hermetically sealed. Corrosion damages may thus be avoided.

(20) The above-described embodiments can be combined in different ways. In particular, aspects of the method can be used for embodiments of the devices and use of the devices and vice versa.

(21) In addition, it shall be noted that the terms such as comprising, including or similar do not exclude further elements or steps and that the article a or an does not exclude the presence of a plurality of objects. It is further noted that features or steps, which have been described with reference to one of the above embodiments, can also be used in combination with features or steps of other above described embodiments. Reference signs in the claims shall not restrict the scope of the invention.

(22) While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the embodiment in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the embodiment as set forth in the appended claims and their legal equivalents.