Method for additive production, component, and apparatus for additive production

Abstract

A method for additive production of a component, which includes the additive construction of the component on a component platform having an opening, wherein, during the first part of the additive construction of the component an auxiliary structure is produced additively around the opening of the component platform. The method further includes the introduction of a device through the opening into a cavity defined by the auxiliary structure, wherein, during a second part of the additive construction, following the first part of the additive construction, properties of the component to be produced are influenced and/or measured by the device. A component is produced by the method and an apparatus for the additive production of the component, includes the component platform having the opening and the closure.

Claims

1. A method for the additive production of a component, comprising: additively constructing a component on a component platform having an opening, wherein during a first part of the additive construction of the component an auxiliary structure is additively produced beside the component on the component platform and fully surrounding the opening of the component platform so that the auxiliary structure is a separate structure from the component, wherein the opening at the beginning of the additive construction of the component is closed by a closure, wherein the component platform during the first part of the additive construction of the component is lowered relative to the closure, and the closure is removed after the first part of the additive construction, and during a second part of the additive construction, subsequent to the first part of the additive construction, when a cavity defined by the auxiliary structure and the component is complete: introducing a device through the opening into a cavity defined by the auxiliary structure after the component has been built on the auxiliary structure and is directly above the cavity, and influencing and/or detecting properties of the component to be produced by the device.

2. The method as claimed in claim 1, wherein the component to be produced is heated or cooled by the device during the second part of the additive construction.

3. The method as claimed in claim 1, wherein the temperature of a portion that is to be produced in a manner spaced apart from the component platform is measured and/or set by heating or cooling by the device.

4. The method as claimed in claim 1, wherein the component during the additive construction is provided with a projecture, and wherein the projecture defines the cavity.

5. The method as claimed in claim 1, wherein the component to be produced is additively constructed in such a manner that said component has an aspect ratio of at least 2:1.

6. The method as claimed in claim 1, wherein the method is a powder-bed-based production method or a method for selective laser melting.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIGS. 1 to 7 show in each case a simplified schematic sectional view of an apparatus for the additive production of a component.

(2) FIGS. 1 to 6 describe in particular various method steps of a method for the additive production of a component according to a first embodiment.

(3) FIG. 7 indicates a part of a method for the additive production of a component according to an embodiment that is an alternative to that of FIGS. 5 and 6.

DETAILED DESCRIPTION OF INVENTION

(4) FIG. 1 schematically shows at least a part of an apparatus 200 for the additive production of a component 100 (cf. FIGS. 2 to 7). The component 100 is in particular a component having a complex structure or contour, or an elongate and/or curved component.

(5) The apparatus 200 is in particular an apparatus or a system for an additive, for example powder-bed-based production method such as a method for selective laser melting (SLM) and/or electron beam melting (EBM).

(6) The apparatus 200 comprises a component platform 1. The component platform 1 can be a substrate on which a workpiece or a component is constructed layer-by-layer in the context of the additive production. The component platform in commonplace respective apparatuses is usually and advantageously capable of being lowered relative to further components of the apparatus, for example to an exposure or laser apparatus. The component platform 1 has an opening 2. The opening 2 in an exemplary manner is disposed centrally in the component platform 1. When viewed in the plan view of the component platform 1, the opening can have a multiplicity of shapes, for example be configured so as to be square or rectangular, however advantageously circular.

(7) A closure 3 is disposed in the opening 2. The closure 3 is advantageously configured for closing the opening 2 in a tight fit or in a powder-tight manner. The closure 3 comprises, for example, a piston (not explicitly identified). The closure 3 furthermore comprises a piston rod 4 by way of which the closure 3 can be disposed advantageously vertically or along a construction direction (cf. direction D). The closure can furthermore be a piston, a plug, a closure piston, or a slide.

(8) Furthermore, powder 6 is shown on the closure 3 and on the component platform 1 in FIG. 1. The powder is advantageously a metal powder which in the context of an SLM method is sourced for the construction of components. The powder herein is usually distributed tier-by-tier or layer-by-layer at a specified layer thickness on the component platform by way of a slide or a spreading blade. For example, a continuous powder layer which can be constructed or produced in a first solidification step is illustrated on the component platform 1 in FIG. 1. Alternatively to the illustration in FIG. 1, the closure can be disposed along the construction direction in such a manner that the component platform 1 and the closure 3 form a flat basic area for the production of a component.

(9) The space above the component platform 1 advantageously describes a production space (not explicitly identified).

(10) FIG. 2, additionally to FIG. 1, shows a laser 50 or a respective laser device, by way of which powder is initially used in a punctiform and layer-by-layer manner on the component platform 1 and/or the closure 3, and subsequently can be solidified for the respective component to be produced. In order for the latter to be produced, the laser 50 or the laser beam in the respective illustration is aligned or focused toward an auxiliary structure 101. The auxiliary structure 101 is advantageously additively constructed around the opening 2.

(11) A component 100 (cf. right-hand periphery of FIG. 2) is produced successively layer-by-layer, simultaneously with the auxiliary structure 101, advantageously by the same method. Accordingly, the auxiliary structure 101 and the component 100 are advantageously made from the same material. The material can be, for example, the basic material of a nickel-based or cobalt-based super alloy for the production of components in the hot gas path of a gas turbine.

(12) A situation in which both the first layer of the auxiliary structure 101 as well as the first layer of the component 100 have already been exposed and solidified by the laser beam is described in particular in FIG. 2.

(13) The reference sign 100 in a synonymous manner advantageously describes the component to be produced as well as the component 100 produced or partially produced.

(14) As opposed to FIG. 2, FIG. 3 shows a situation in which the component platform 1 has been lowered relative to the closure 3, for example by the layer thickness of an individual tier. Accordingly, the apparatus 200 comprises an arrester mechanism on account of which the closure 3 is not conjointly lowered. The lowering is indicated by the two arrows identified as A on the sides of the component platform 1. It can be likewise seen that in relation to the situation in FIG. 2 a further powder tier is or has been applied in the context of a conventional SLM method, for example. On account of the fact that the closure 3 has not been lowered conjointly with the component platform 1, excess powder which can project in relation to the powder disposed on the component platform can accumulate on the closure 3, as is indicated.

(15) While reference presently is made only to an SLM method, the inventive concept can likewise be applied to further methods, for example EBM.

(16) FIG. 4 indicates that in relation to the illustration in FIG. 3, a further powder tier has been up applied and/or spread smooth, for example by means of the spreading blade described or a coating apparatus, said powder tier subsequently being able to be exposed and solidified by way of the laser 50 (cf. FIG. 2).

(17) In order for the individually designed component 100 to be constructed, the method steps described by means of FIGS. 2 to 4 can in particular be repeated successively.

(18) The additive construction of the component 100 as well as of the auxiliary structure 101 in the illustration of FIG. 5 has already progressed far or already been completed. It can be seen in particular that the component 100 has a portion 100a and/or a projecture 110 which on an upper side protrudes beyond the auxiliary structure 101 or terminates said auxiliary structure 101.

(19) On account of the closure 3 not having been conjointly lowered relative to the component platform 1 in each individual construction step (in which in each case one tier of material in pulverulent form has been applied and solidified), a cavity 20 has formed at least under the piston of the closure.

(20) The region 100a mentioned, or the projecture 110, respectively, accordingly defines the cavity 20 at least on an upper side. The cavity 20 is furthermore defined or delimited by the auxiliary structure 101, for example on the lateral or shell faces.

(21) It can furthermore be seen in FIG. 5 that regions in the production space in which no material has been solidified, for example, are filled with powder 6.

(22) As further method steps of the described method for additive production, it is indicated by the arrow B in FIG. 5 that the closure 3, advantageously after completely defining the cavity 20, has been removed from the cavity 20, or from the opening 2, respectively. This is advantageously performed so as to include the powder remaining on the piston of the closure 3.

(23) The time period up to which the cavity 20 has been defined or completed, for example since the beginning of the construction by the auxiliary structure 101 and the portion 100a of the component 100, advantageously describes a first part of the additive construction of the component 100.

(24) The temporal point as from which the cavity 20 is completed, for example by the auxiliary structure 101 and the portion 100a of the component 100, and in which the component 100 continues to be constructed without the construction of the auxiliary structure 101, advantageously describes a second part of the additive construction of the component 100.

(25) It is indicated in FIG. 6 that the closure 3 has been removed from the cavity 20, and the cavity 20 is likewise free of powder. It is indicated by the arrow C that a device 10 has been introduced into the completely hollow cavity. By way of the method described to this point, it can be advantageously achieved that a side, a region or surface of the component 100, in particular by way of the additive construction of the auxiliary structure 101, is now rendered accessible, for example for influencing or detecting properties of the component 100.

(26) When reference is presently made to the component, a portion 100a of the component 100 that is spaced apart from the component platform 1, and/or the projecture 110 or the projecting portion, can likewise be referenced, and vice versa.

(27) The device 10 can be, for example, a device for measuring vibrations and accordingly comprise a piezoelectric sensor, for example.

(28) Alternatively or additionally, the device 10 can be a temperature measuring device and accordingly comprise a thermal element or a Pyro meter for measuring the temperature of the projecture 110. Additionally, the device 10 can comprise a heating device and/or a cooling device. The device 10 can furthermore comprise a temperature regulator such that the component 100 can be maintained at a predetermined temperature, for example. This can be particularly advantageous for the configuration of a particularly advantageous microstructure of the component 100 or of the respective portion of the latter.

(29) Alternatively or additionally, the device can initiate further effects.

(30) A heating resistor 11 by way of which the projecture 110 of the component 100 can be heated or warmed, for example, is shown in the device 10 in FIG. 6. As has already been indicated above, rapid cooling and thus configuration of imperfections or fissures in the material of the component can be prevented or limited by such heating. The device 10 can furthermore comprise an endoscope 12 in order for said device 10 to be introduced into the cavity 20 in a space-saving manner.

(31) According to the illustration in FIG. 6, the component 100 is advantageously not yet fully constructed and/or produced.

(32) As soon as the cavity in the progress of the construction has been fully closed or been continuously configured, properties of the component 100 can be influenced or detected by the device 10 so as to favor the desired component or the structure of the latter.

(33) FIG. 7 schematically shows a design embodiment of the method and/or of the component that is an alternative to the description to date, in a manner analogous to the state of the method indicated in FIG. 6. As opposed to the illustration from FIG. 6, the cavity 20 according to this design embodiment is entirely defined or delimited by the auxiliary structure 101.

(34) In other words, this design embodiment of the method is an upper side of the auxiliary structure 101 that has been constructed in only an auxiliary manner.

(35) As an alternative to the powder-bed-based method, an additive production method which, for example, utilizes a liquid initial material instead of a pulverulent initial material, can be used for the present invention.

(36) This design embodiment is in particular expedient for the additive production of components which on account of the desired geometrical parameters or of the purpose of said components do not have any substantial projectures. The illustrated device 10 can be designed or chosen according to the description pertaining to FIG. 6. In spite of this, a temperature measurement or heating of the component, for example, is not as effective as compared to the design embodiment from FIG. 6, since the device 10 is in contact with the component 100 only indirectly and not in a direct physical manner. Nevertheless, better access to a portion of the component that is currently to be processed is likewise enabled by the described method, on account of which the production method is simplified, for example, and/or the microstructure of the component can be improved. This design embodiment is furthermore advantageously expedient in the case of components which have a high aspect ratio, for example an aspect ratio of 2:1 or more, since the inventive advantage of the method, or of the described apparatus 200, respectively, has a greater effect as the spacing from the component platform increases.

(37) A further embodiment of the method and/or of the component, not explicitly identified in the figures, relates to a component to be produced which at least in part or entirely is formed by the auxiliary structure. According to this design embodiment, the component that is to be additively constructed, that is to say by virtue of the predefined form of said component, can per se have a hollow structure or a cavity. On account of the respective design embodiment of the apparatus and/or of the component platform, this hollow geometry or cavity can then specifically be utilized for influencing or detecting, for example, properties of the component by means of the device, as has been described above.

(38) The invention by way of the description by means of the exemplary embodiments is not limited to the latter, but comprises each new feature and any combination of features. This includes in particular any combination of features in the patent claims, even when said feature or said combination is not explicitly specified in the patent claims or the exemplary embodiments.