Particle size influencing layer-by-layer manufacturing method

• US 9,149,989 B2
• Filed: 10/19/2006
• Issued: 10/06/2015
• Est. Priority Date: 10/20/2005
• Status: Active Grant

• Current Assignee: Bego Medical GmbH
• Original Assignee: Bego Medical GmbH
• Inventors: Uckelmann, Ingo
• Primary Examiner(s): YI, STELLA KIM
• Application Number:
  US12/090,630
• Publication Number:
  US 20090176007A1
• Time in Patent Office: 3,274 Days
• Field of Search: 264/1.7, 264/510, 264/297.4, 264/642, 264/471, 264/473, 264/476, 264/477, 264/481, 264/482, 264/112, 264/171.1
• US Class Current: 1/1
• CPC Class Codes: A61C 13/0018 using laser
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/36 of energy beam parameters
• CPC Class Codes: B22F 10/40 Structures for supporting workpieces or articles during manufacture and removed afterwards
• CPC Class Codes: B22F 2207/13 Size gradients
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• 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 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The invention concerns a process for the layerwise production of a product comprising the steps of applying a layer of a hardenable material, wherein for example the process parameters of layer thickness and layer material are adjustable, selectively hardening predetermined regions of the applied layer on the basis of the geometrical data of the product, wherein for example the process parameters for the nature and level of the energy input are adjustable, repeating those steps until the geometry of the product has been produced in the form of hardened material, and finally removing the non-hardened material. Known processes suffer from the disadvantage that they do not afford variability in regard to the local properties of the product. The invention remedies that disadvantage insofar as at least one process parameter is altered during the production procedure in order to influence the grain size in a first region of the product in relation to a second region of the product.

Claims

1. A process for layerwise production of a metallic product comprising the steps of:

a. applying a layer of non-hardened metallic material, the material capable of being hardened, wherein process parameters of layer thickness and layer material are adjustable;

b. selectively hardening predetermined regions of the applied layer of the metallic material on the basis of the geometrical data of the product, wherein the process parameters for the nature and level of the energy input are adjustable;

c. repeating steps a) and b) until the geometry of the product has been produced in the form of hardened material; and

d. removing a remaining non-hardened metallic material from the regions that were not selectively hardened,

wherein at least one process parameter is adjusted during the production process in order to influence a crystal size of a finished product produced in a first region of the product in relation to a second region of the product as the predetermined regions of the applied layer are selectively hardened,

wherein the non-hardened metallic material is applied with a different layer thickness in the first region of the product from that in the second region of the product in order to influence the crystal size in the first region in relation to the second region of the product.

2. A process according to claim 1 wherein the at least one process parameter is adjusted in dependence on the geometrical data of the product.

3. A process according to claim 1 wherein hardening of the material is achieved by means of a laser or electron beam which is passed over the regions to be hardened and an intensity of radiation is adjusted in the first region of the product in relation to the second region of the product in order to influence the crystal size in the first region in relation to the second region of the product.

4. A process according to claim 3 wherein the intensity of the radiation is adjusted by a radiation source power and a diameter of the electron beam in the processing region wherein a focus and/or a speed of a displacement between the beam and the material to be hardened is adjusted.

5. A process according to claim 4 wherein the intensity of the radiation is increased by increasing the radiation source power and/or reducing the diameter of the beam in the processing region at a focus region and/or the speed of displacement between the beam and the material to be hardened in order to influence the crystal size in the first region of the product in relation to the second region of the product.

6. A process according to claim 3 further wherein the first region of the product-has a higher degree of heat conduction than the second region of the product,

the first region involving a greater wall thickness of the product and/or;

the first region is in contact with a plate on which the product is built up and/or;

the first region of an overhang of the product includes adjusting the at least one process parameter in relation to the second region by adjusting an intensity of radiation and/or increasing the layer thickness in the first region to influence the crystal size.

8. A process according to claim 1 wherein the at least one process parameter is adjusted to alter the crystal size or a crystal boundary surface in the first region of the product in relation to the second region of the product.

10. A process according to claim 1 wherein the at least one process parameter is adjusted in order to reduce a size of at least one flaw.

11. A process according to claim 10 wherein in the first region of the product, the layer thickness is reduced and/or an intensity of radiation or the speed of displacement is increased in order to prevent flaws in the first region, the flaws including insoluble melting impurities which occur in the molten material or during the cooling operation combining to form larger flaws.

12. A process according to claim 10 wherein in the first region of the product, the layer thickness is increased and/or the intensity of radiation or the speed of displacement is reduced in order to prevent flaws in the first region, the flaws including soluble melting impurities combining to form larger flaws.

7. A process for layerwise production of a metallic product comprising the steps of:

a. applying a layer of non-hardened metallic material, the material capable of being hardened, wherein process parameters of layer thickness and layer material are adjustable;

b. selectively hardening predetermined regions of the applied layer of the metallic material on the basis of the geometrical data of the product, wherein the process parameters for the nature and level of the energy input are adjustable;

c. repeating steps a) and b) until the geometry of the product has been produced in the form of hardened material; and

d. removing a remaining non-hardened metallic material from the regions that were not selectively hardened,

wherein at least one process parameter is adjusted during the production process in order to influence a crystal size of a finished product produced in a first region of the product in relation to a second region of the product as the predetermined regions of the applied layer are selectively hardened,

wherein the at least one process parameter is adjusted on the basis of the geometrical data of the product in the first region of the product in relation to the second region of the product in order to keep the crystal size in the first region of the product approximately constant in relation to the second region of the product.

9. A process for layerwise production of a metallic product comprising the steps of:

a. applying a layer of non-hardened metallic material, the material capable of being hardened, wherein process parameters of layer thickness and layer material are adjustable;

b. selectively hardening predetermined regions of the applied layer of the metallic material on the basis of the geometrical data of the product, wherein the process parameters for the nature and level of the energy input are adjustable;

c. repeating steps a) and b) until the geometry of the product has been produced in the form of hardened material; and

d. removing a remaining non-hardened metallic material from the regions that were not selectively hardened,

wherein the at least one process parameter is adjusted to alter the crystal size or a crystal boundary surface in the first region of the product in relation to the second region of the product, and

wherein at least one process parameter is adjusted during the production process in order to influence a crystal size of a finished product produced in a first region of the product in relation to a second region of the product as the predetermined regions of the applied layer are selectively hardened,

wherein the layer thickness is increased and/or an intensity of radiation is increased in the first region in order to increase the crystal size or the crystal boundary surface in the first region of the product in relation to the second region of the product.