Three-dimensional deposition device and three-dimensional deposition method

• US 10,639,740 B2
• Filed: 03/20/2015
• Issued: 05/05/2020
• Est. Priority Date: 03/31/2014
• Status: Active Grant

• Current Assignee: Mitsubishi Heavy Industries, Ltd.
• Original Assignee: Mitsubishi Heavy Industries, Ltd.
• Inventors: Yoshimura, Hitoshi, Ozawa, Yoshiharu
• Primary Examiner(s): Evans, Geoffrey S
• Application Number:
  US15/300,015
• Publication Number:
  US 20170144248A1
• Time in Patent Office: 1,873 Days
• Field of Search: None
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/32 of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 10/368 Temperature or temperature gradient, e.g. temperature of the melt pool
• CPC Class Codes: B22F 10/50 Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
• CPC Class Codes: B22F 10/73 of powder
• CPC Class Codes: B22F 12/222 for motion along a direction orthogonal to the plane of a layer
• CPC Class Codes: B22F 12/224 for motion along a direction within the plane of a layer
• CPC Class Codes: B22F 12/37 Rotatable
• CPC Class Codes: B22F 12/43 pulsed; frequency modulated
• CPC Class Codes: B22F 12/44 characterised by the configuration of the radiation means
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B22F 2003/245 Making recesses, grooves etc on the surface by removing material
• CPC Class Codes: B22F 2203/03 for feed-back
• CPC Class Codes: B22F 2203/11 temperature, temperature profile
• CPC Class Codes: B22F 2207/01 Composition gradients
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B23K 26/0093 combined with mechanical machining or metal-working covered by other subclasses than B23K combined welding or cutting procedures or apparatus B23K28/02
• CPC Class Codes: B23K 26/034 Observing the temperature of the workpiece
• CPC Class Codes: B23K 26/04 Automatically aligning, aiming or focusing the laser beam, e.g. using the back-scattered light
• CPC Class Codes: B23K 26/046 : Automatically focusing the laser beam
• CPC Class Codes: B23K 26/0626 : Energy control of the laser beam B23K26/0622 takes precedence
• CPC Class Codes: B23K 26/064 : by means of optical elements, e.g. lenses, mirrors or prisms
• CPC Class Codes: B23K 26/14 : using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor B23K26/12 takes precedence
• CPC Class Codes: B23K 26/144 : the fluid stream containing particles, e.g. powder
• CPC Class Codes: B23K 26/1476 : Features inside the nozzle for feeding the fluid stream through the nozzle
• CPC Class Codes: B23K 26/342 : Build-up welding
• CPC Class Codes: B29C 64/153 : using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/188 : involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B33Y 10/00 : Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 : Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 : for controlling or regulating additive manufacturing processes
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A three-dimensional deposition device and a three-dimensional deposition method used to manufacture a three-dimensional object with high accuracy are provided. A three-dimensional deposition device for forming a three-dimensional shape by depositing a formed layer on a base unit, includes: a powder supply unit which supplies a powder material by injecting the powder material toward the base unit; a light irradiation unit which irradiates the powder material feeding from the powder supply unit toward the base unit with a light beam so that the powder material is melted and the melted powder material is solidified on the base unit to thereby form the formed layer; and a control device which controls operations of the powder supply unit and the light irradiation unit.

Claims

1. A three-dimensional deposition device for forming a three-dimensional shape by depositing a formed layer on a base unit, comprising:

a powder supplier which supplies a powder material toward the base unit;

a light irradiator which irradiates the powder material supplied from the powder supplier toward the base unit with a light beam;

a powder introducer which includes a plurality of storages storing the powder material to be supplied to the powder supplier; and

a controller which controls operations of the powder supplier, the powder introducer, and the light irradiator so that the light beam is irradiated to the powder material, and the melted powder material is solidified on the base unit,

wherein the powder introducer includes;

a first storage storing a first powder material to be supplied to the powder supplier;

a second storage storing a second powder material to be supplied to the powder supplier;

a buffer which temporarily stores at least one of the first powder material supplied from the first storage and the second powder material supplied from the second storage;

a powder switcher which controls (i) whether the first powder material is supplied to the buffer from the first storage and (ii) whether the second powder material is supplied to the buffer from the second storage;

a distributer to which at least one of the first and second powder materials is supplied from the buffer through a powder supply tube;

a branch tube which includes a plurality of tubes and connects between the distributor and the powder supplier, to which at least one of the first and second powder materials is supplied from the distributor and from which at least one of the first and second powder materials is supplied to the powder supplier.

2. The three-dimensional deposition device according to claim 1,

wherein when the powder material introduced from the powder introducer to the powder supplier is switched from the first powder material to the second powder material, the controller instructs the powder introducer to:

form the formed layer by the first powder material,

thereafter start a supply of the second powder material to the powder supplier while supplying the first powder material to the powder supplier, and

thereafter change a supply ratio by increasing a supply amount of the second powder material to the powder supplier while decreasing a supply amount of the first powder material to the powder supplier.

3. The three-dimensional deposition device according to claim 1, further comprising:

a machining device which includes a tool and performs a machining operation on the formed layer by the tool.

4. The three-dimensional deposition device according to claim 1,

wherein the powder supplier is concentrically disposed on an outer periphery of the light irradiator so that a powder passage causing the powder material to flow therethrough is formed between an inner tube surrounding a path of the light beam of the light irradiator and an outer tube covering the inner tube.

5. The three-dimensional deposition device according to claim 4, further comprising:

a shield gas supplier which is disposed on an outer periphery of the powder supplier concentrically with the outer periphery of the light irradiator while surrounding an outer periphery of a powder material supplying area from outside the powder passage and supplying a shield gas toward the base unit.

6. The three-dimensional deposition device according to claim 1, further comprising:

a focal position adjuster which adjusts a focal position of the light beam emitted from the light irradiator.

7. The three-dimensional deposition device according to claim 6,

wherein the focal position adjuster is mechanism that moves a position of the light irradiator.

8. The three-dimensional deposition device according to claim 6,

wherein the focal position adjuster is a mechanism that moves a focal distance or a focal position by adjusting a light concentrating optical system of the light irradiator.

9. The three-dimensional deposition device according to claim 1, further comprising:

a temperature detector which detects and obtains a temperature of a surface of the formed layer,

wherein the controller controls intensity of the light beam output from the light irradiator based on a measurement result obtained by the temperature detector.

10. The three-dimensional deposition device according to claim 9,

wherein the controller specifies a temperature detection position based on at least one of the temperature of the surface of the formed layer obtained by the temperature detector and properties of the base unit and the formed layer.

11. The three-dimensional deposition device according to claim 1, further comprising:

a plasma emission detector which detects and obtains a plasma emission state of a surface of the formed layer,

wherein the controller controls the intensity of the light beam output from the light irradiator based on a measurement result obtained by the plasma emission detector.

12. The three-dimensional deposition device according to claim 1, further comprising:

a reflected light detector which detects and obtains a state of a reflected light from a surface of the formed layer,

wherein the controller controls the intensity of the light beam output from the light irradiator based on a measurement result obtained by the reflected light detector.

13. The three-dimensional deposition device according to claim 1, further comprising:

a mover which relatively moves a position of the light irradiator and the powder supplier with respect to a position of the base unit,

wherein the controller determines a path through which the position of the light irradiator and the powder supplier pass with respect to the position of the base unit by the mover.

14. The three-dimensional deposition device according to claim 13, further comprising:

a shape measurer which measures a surface shape of the formed layer,

wherein the controller controls operations of the powder supplier, the light irradiator, and the mover based on a measurement result obtained by the shape measurer.

15. The three-dimensional deposition device according to claim 1,

wherein the light irradiator is able to adjust a profile of the light beam.

16. The three-dimensional deposition device according to claim 1,

wherein the light irradiator is able to switch a mode of emitting the light beam in the form of pulse waves and a mode of emitting the light beam in the form of continuous waves.

17. The three-dimensional deposition device according to claim 1, further comprising:

a powder collector which collects the powder material supplied from the powder supplier and not melted by the light beam.

18. The three-dimensional deposition device according to claim 17, further comprising:

a separator which separates the powder material collected by the powder collector in accordance with the property of the powder material.

19. The three-dimensional deposition device according to claim 1, further comprising:

a powder identifier which identifies the powder material stored in at least one of the first and second storages and introduces the identified powder material into the powder supplier,

wherein the controller controls the introduction of the powder material from the powder introducer to the powder supplier based on an identification result of the powder identifier.

20. The three-dimensional deposition device according to claim 19,

wherein when the controller determines that the powder material stored in at least one of the first and second storages is not appropriate, the controller instructs to stop a supply of the powder material from the powder introducer to the powder supplier.

21. The three-dimensional deposition device according to claim 20,

wherein the controller transmits information indicating the powder material is inappropriate or information of an inappropriate powder material to an external data server.

22. The three-dimensional deposition device according to claim 19,

wherein when the controller determines that the powder material stores in at least one of the first and second storages is appropriate, the controller introduces the powder material from the powder introducer to the powder supplier and determines a formed layer forming condition based on the identification result of the powder identifier.

23. The three-dimensional deposition device according to claim 22,

wherein when the controller instructs the powder introducer to supply different types of powder material in a mixed state, the controller determines the formed layer forming condition based on a content of an instruction of supplying injecting different types of powder material in a mixed state.

24. The three-dimensional deposition device according to claim 22,

wherein the formed layer forming condition includes at least one of a shape of each formed layer, a type of powder material, a powder supplying speed, a powder supplying pressure, a laser beam irradiation condition, a temperature of a molten body, a solid body cooling temperature, and a base unit moving speed.

25. The three-dimensional deposition device according to claim 22,

wherein the controller is connected to an external device via a communication line and is able to change the formed layer forming condition based on an instruction input from the external device.

26. The three-dimensional deposition device according to claim 1,

wherein the branch tube includes a mixer which stirs the powder material inside the plurality of tubes.

27. The three-dimensional deposition device according to claim 26,

wherein the mixer includes a mechanism that homogenize the powder material flowing through the plurality of tubes.

28. The three-dimensional deposition device according to claim 27,

wherein the mixer includes a stirring plate twisted about an axial direction of the branch tube along a flow direction of the branch tube.

29. The three-dimensional deposition device according to claim 26,

wherein the powder supplier includes a flow straightener which is disposed in a downstream of the mixer in view of a flow of the powder material and straightens the flow of the powder material supplied from the branch tube.

30. The three-dimensional deposition device according to claim 1,

wherein the stirring plate includes a first range and a second range, and

the stirring plate disposed in a first range and the stirring plate disposed in a second range are twisted in opposite directions.

31. The three-dimensional deposition device according to claim 1,

wherein the powder switcher includes a first valve disposed between the first storage and the buffer and a second valve disposed between the second storage and the buffer.

32. The three-dimensional deposition device according to claim 1,

wherein the powder introducer includes a carrying gas supplier which supplies a carrying gas for carrying the powder material temporarily stored in the buffer to the powder supply tube.

33. The three-dimensional deposition device according to claim 1,

wherein the powder introducer includes a third storage storing a third powder material to be supplied to the powder supplier and the buffer temporarily stores at least one of the first powder material supplied from the first storage, the second powder material supplied from the second storage, and the third powder material supplied from the third storage.

34. The three-dimensional deposition device according to claim 33,

wherein when the powder material introduced from the powder introducer to the powder supplier is switched from the first powder material to the second powder material, the controller instructs the powder introducer to:

form the formed layer by the first powder material,

thereafter form the formed layer by the third powder material which is an intermediate powder material having high affinity with both the first powder material and the second powder material, and

thereafter form the formed layer by the second powder material.

35. A three-dimensional deposition method of forming a three-dimensional object by depositing a formed layer on a base unit, comprising:

supplying, by a power supplier, a powder material towards the base unit;

irradiating, by a light irradiator, the supplied powder material with a light beam in a space between the base unit and the powder supplier to melt the powder material in the space,

dropping the melted powder material from the space to the base unit, solidifying the melted powder material on the base unit to form a formed layer on the base unit, and depositing the formed layer;

providing a powder introducer including, a plurality of storages storing the powder material to be supplied to the powder supplier; and

controlling operations of the powder supplier, the powder introducer, and the light irradiator so that the light beam is irradiated to the powder material, and the melted powder material is solidified on the base unit;

wherein the step of controlling an operation of the powder introducer includes,

storing, in a first storage, a first powder material to be supplied to the powder supplier,

storing, in a second storage, a second powder material to be supplied to the powder supplier,

temporarily storing, in a buffer, at least one of the stored first powder material and the stored second powder material,

controlling, by a powder switcher, (i) whether the first powder material is supplied to the buffer, and (ii) whether the second powder material is supplied to the buffer,

supplying, by a distributer, at least one of the first and second powder materials from the buffer through a powder supply tube, and

providing a branch tube including a plurality of tubes connecting between the distributer and the powder supplier, to which at least one of the first and second powder materials is supplied from the distributor and from which at least one of the first and second powder materials is supplied to the powder supplier.

36. The three-dimensional deposition method according to claim 35,

wherein a position of the formed layer is detected and a focal position of the light beam is adjusted in response to the position of the formed layer.

37. The three-dimensional deposition method according to claim 35,

wherein a temperature of a surface of the formed layer is detected and intensity of the output light beam is controlled based on a temperature measurement result of the surface of the formed layer.

38. The three-dimensional deposition method according to claim 35,

wherein a plasma emission state of the surface of the formed layer is detected and the intensity of the output light beam is controlled in response to a plasma emission measurement result of the formed layer.

39. The three-dimensional deposition method according to claim 35,

wherein reflected light of the surface of the formed layer is detected and the intensity of the output light beam is controlled in response to a reflected light measurement result of the formed layer.

40. The three-dimensional deposition method according to claim 35,

wherein a mode of emitting the light beam in the form of pulse waves and a mode of emitting the light beam in the form of continuous waves are switched in response to the formed layer to be formed.