U.S. patent application number 14/366130 was filed with the patent office on 2014-12-11 for machine and process for powder-based additive manufacturing.
The applicant listed for this patent is COMPAGNIE GENERALE DES ETABLISSEMENTS MICHELIN, Michelin Recherche et Technique S.A.. Invention is credited to Frederic Pialot, Gilles Walrand, Pierre Wiel.
Application Number | 20140363585 14/366130 |
Document ID | / |
Family ID | 47520955 |
Filed Date | 2014-12-11 |
United States Patent
Application |
20140363585 |
Kind Code |
A1 |
Pialot; Frederic ; et
al. |
December 11, 2014 |
MACHINE AND PROCESS FOR POWDER-BASED ADDITIVE MANUFACTURING
Abstract
A machine, which is usable for additive manufacturing by
sintering or melting of powder using an energy beam acting on a
powder layer in a working zone, includes a device for producing a
layer of the powder. The device includes a storage apparatus for
storing the powder, a distributor for distributing the powder, a
feeder for transferring the powder from the storage apparatus to
the distributor, and a dose controller for controlling a quantity
of the powder transferred from the storage apparatus to the
distributor. The distributor travels over the working zone in order
to distribute the powder in a layer having a final thickness
adapted to the additive manufacturing. The storage apparatus is
located above the working zone such that the feeder utilizes
gravity. The feeder and the dose controller are movable with the
distributor.
Inventors: |
Pialot; Frederic;
(Clermont-Ferrand, FR) ; Walrand; Gilles;
(Clermont-Ferrand, FR) ; Wiel; Pierre;
(Clermont-Ferrand, FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
COMPAGNIE GENERALE DES ETABLISSEMENTS MICHELIN
Michelin Recherche et Technique S.A. |
CLERMONT-FERRAND
GRANGES-PACCOT |
|
FR
CH |
|
|
Family ID: |
47520955 |
Appl. No.: |
14/366130 |
Filed: |
December 19, 2012 |
PCT Filed: |
December 19, 2012 |
PCT NO: |
PCT/EP2012/076225 |
371 Date: |
June 17, 2014 |
Current U.S.
Class: |
427/551 ;
118/641; 419/1; 425/78; 427/554 |
Current CPC
Class: |
B22F 2003/1056 20130101;
B05D 3/14 20130101; B33Y 30/00 20141201; B29C 64/153 20170801; B23K
35/0244 20130101; B29C 64/329 20170801; Y02P 10/25 20151101; B29C
64/218 20170801; B05D 3/007 20130101; B29C 64/343 20170801; B22F
7/02 20130101; B29C 64/205 20170801; B29C 64/255 20170801; B22F
3/105 20130101; B22F 3/1055 20130101; B05C 19/04 20130101 |
Class at
Publication: |
427/551 ;
118/641; 427/554; 419/1; 425/78 |
International
Class: |
B22F 7/02 20060101
B22F007/02; B22F 3/105 20060101 B22F003/105; B05D 3/14 20060101
B05D003/14; B05C 19/04 20060101 B05C019/04; B05D 3/00 20060101
B05D003/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 20, 2011 |
FR |
1162067 |
Claims
1-10. (canceled)
11: A machine for additive manufacturing by sintering or melting
powder using an energy beam acting on a powder layer in a working
zone, the machine comprising a device for producing a layer of the
powder, wherein the device includes: a storage apparatus, which
stores the powder, a distributor, which distributes the powder in a
layer having a final thickness adapted to the additive
manufacturing, the distributor being movable to travel over the
working zone, a feeder, which transfers the powder from the storage
apparatus to the distributor, and a dose controller, which controls
a quantity of the powder transferred from the storage apparatus to
the distributor, wherein the storage apparatus is located above the
working zone, wherein the feeder utilizes gravity, and wherein the
feeder and the dose controller are movable with the
distributor.
12: The machine according to claim 11, wherein the storage
apparatus includes a hopper, which is movable with the feeder, the
dose controller, and the distributor.
13: The machine according to claim 11, wherein the dose controller
includes a rotating dosing cylinder provided with at least one
cavity, each cavity defining a dose of the powder during a dosing
operation.
14: The machine according to claim 13, wherein the at least one
cavity is or are formed of at least one groove, each groove
defining the dose of the powder during the dosing operation.
15: The machine according to claim 11, wherein the dose controller
includes a sliding trapdoor.
16: The machine according to claim 11, wherein the distributor
includes a scraper.
17: The machine according to claim 11, wherein the distributor
includes a distribution cylinder.
18: The machine according to claim 17, wherein a height of the
distribution cylinder is adjustable according to an angular
position of the distribution cylinder.
19: The machine according to claim 11, wherein the distributor and
the dose controller utilize a common cylinder.
20: The machine according to claim 13, wherein the distributor and
the dose controller utilize a common cylinder.
21: The machine according to claim 17, wherein the distributor and
the dose controller utilize a common cylinder.
22: The machine according to claim 11, wherein the device further
includes a compacting roller, and wherein a displacement in
translation of the compacting roller is integral with a
displacement of the distributor.
23: A process for additive manufacturing by sintering or melting
powder using an energy beam acting on a powder layer in a working
zone, the process comprising steps of: dosing, using a dose
controller, a quantity of the powder to be transferred from a
storage apparatus to a feeder; feeding, using the feeder, the
quantity of the powder from the storage apparatus to a distributor
by gravity; and distributing, using the distributor, the quantity
of the powder on the working zone, wherein the storage apparatus,
the feeder, and the dose controller move integrally with the
distributor while the distributor travels over the working zone,
and wherein the dosing step, the feeding step, and the distributing
step are repeated successively in a plurality of layering stages.
Description
[0001] The invention relates to the machines and processes for
powder-based additive manufacturing by sintering or melting
granules of said powder using an energy beam such as
electromagnetic radiation (for example a laser beam) or a beam of
particles (for example an electron beam).
[0002] More specifically, the invention relates to the means and to
the processes for layering, that is to say for preparation, of the
bed of powder prior to sintering or to melting of said layer using
the energy beam.
[0003] Document EP-1641580-B1 in particular discloses a layering
device for sintering of powders (metallic or ceramic) by laser.
This device comprises a feed tray permitting the powder to be
stored and to be delivered in a controlled quantity to a grooved
cylinder capable, on the one hand, of transferring and distributing
said quantity of powder on the depositing tray during a first
passage of the cylinder on the working zone and, on the other hand,
of compacting the powder by a rolling movement of the cylinder
during a second passage. The powder is then subjected to the laser
beam. One disadvantage of this configuration is the size and the
considerable cost of the feed tray. Another disadvantage is derived
from the fact that the length of the working zone is limited by the
useful perimeter of the cylinder.
[0004] Document WO-2011/007087-A2 discloses a layering device for
melting powders by laser. This device comprises a feed tray
permitting the powder to be stored and to be delivered in a
controlled quantity to a scraper system capable of feeding the
depositing tray and cylinder(s) capable of distributing and
compacting said quantity of powder on the depositing tray. The
powder is then subjected to the laser beam. One disadvantage of
this configuration is the size and the considerable cost of the
feed tray as well as the necessary complexity of the machine
because of the large number of tools to be controlled (scraper,
distribution and/or compacting cylinder(s), rams for the
trays).
[0005] Document US-2005/0263934-A1 discloses a layering device for
sintering powders by laser. This device comprises feeding and
dosing means permitting the powder to be delivered in a controlled
quantity in the vicinity of the working zone. Feeding takes place
by gravity from a stock of powder situated above. A scraper permits
the regulation of the thickness of a mass of powder, which is then
subjected to a preheating operation. A rotary cylinder then permits
said quantity of preheated powder to be transferred and distributed
on the working zone. A quantity of powder may likewise be deposited
on the cover of the carriage carrying the cylinder from one side to
the other of the working zone and is accordingly only applied
during the return of the cylinder. One disadvantage of this
configuration is the risk of a part (even a very small part) of the
powder being retained on the cover and subsequently falling into
the working zone during the passage of the carriage above the bed
of powder. This risk is not acceptable in the context of industrial
use.
[0006] An additional problem that is common to the different
proposals of the prior art is the difficulty and sometimes the
impossibility of achieving a homogeneous thickness and density for
the powder layer over the entire extent (length, width) of the
working zone.
[0007] The object of the invention is thus to overcome at least one
of the disadvantages described above.
[0008] The invention proposes for this purpose a machine for
additive manufacturing by sintering or melting powder using an
energy beam acting on a powder layer in a working zone, said
machine comprising a device for producing a layer of said powder,
said device comprising: [0009] means for storing the powder, [0010]
means for distributing the powder able to travel over the working
zone in order to distribute the powder in a layer having a final
thickness adapted to additive manufacturing, [0011] feeding means
able to transfer the powder from the storage means to the
distributing means, [0012] dosing means able to control the
quantity of powder transferred from the storage means to the
distributing means, said machine being characterised in that:
[0013] the storage means are located above the working zone, [0014]
the feeding means utilise gravity, and [0015] the feeding means and
the dosing means are able to move with the distributing means.
[0016] Feeding by gravity via the top of the working zone and in a
controlled quantity by dosing means integrated with the
distributing means ensures significantly improved uniformity of the
bed of powder than in the systems that are familiar from the prior
art.
[0017] The storage means preferably comprise a hopper, said hopper
being able to move together with the feeding means, the dosing
means and the distributing means.
[0018] The dosing means preferably comprise a rotating dosing
cylinder provided with at least one cavity, preferably a groove
capable of defining a dose of powder during dosing.
[0019] The dosing means alternatively comprise a sliding
trapdoor.
[0020] The distributing means preferably comprise a scraper.
[0021] The distributing means alternatively comprise a distribution
cylinder, of which the height is preferably adjustable according to
its angular position.
[0022] According to a preferred embodiment of the invention, the
distributing means and the dosing means utilise a common
cylinder.
[0023] The machine according to the invention preferably in
addition comprises a compacting roller, of which the displacement
in translation is integral with the displacement of the
distributing means.
[0024] The invention likewise proposes a process for additive
manufacturing by sintering or melting powder using an energy beam
acting on a layer of powder in a working zone, said machine
comprising a device for layering said powder, said device
comprising: [0025] means for storing the powder located above the
working zone, [0026] means for distributing the powder able to
travel over the working zone in order to distribute the powder in a
layer having a final thickness adapted to additive manufacturing,
[0027] feeding means able to transfer the powder from the storage
means to the distributing means, [0028] dosing means able to
control the quantity of powder transferred from the storage means
to the distributing means, said process comprising layering stages
consisting successively of: [0029] dosing a quantity of powder to
be transferred from the storage means, [0030] feeding the
distributing means by gravity, [0031] distributing said quantity of
powder on the working zone using the distributing means, said
process being characterised in that the storage means, the feeding
means and the dosing means are integral with the distributing
means, while said distributing means travel over the working
zone.
[0032] The invention will be more readily appreciated from the rest
of the description, which is based on the following figures:
[0033] FIG. 1 is a schematic view in cross section of a machine
according to the prior art.
[0034] FIG. 2 is a schematic view in cross section of a machine
according to a first embodiment of the invention.
[0035] FIG. 3 is a schematic view in cross section of the layering
device of a preferred variant of the machine in FIG. 2.
[0036] FIG. 4 is a schematic view in cross section of the layering
device of a machine according to a second embodiment of the
invention.
[0037] FIG. 5 is a more detailed schematic view in cross section of
a preferred variant of the layering device in FIG. 4.
[0038] FIG. 6 is a schematic view in cross section of the layering
device of a machine according to a third embodiment of the
invention.
[0039] FIG. 7 is a more detailed schematic view in cross section of
a preferred variant of the layering device in FIG. 6.
[0040] FIG. 8 is a schematic view in cross section of the layering
device of a machine according to a fourth embodiment of the
invention.
[0041] FIGS. 9 to 12 are schematic views depicting the layering
device in FIG. 8 during successive stages of the layering
process.
[0042] In the different figures, identical or similar elements bear
the same references. The description of their structure and their
function is not repeated systematically, however.
[0043] In FIG. 1, a machine for additive manufacturing of a
component 40 according to the prior art is illustrated
schematically. A source of energy, in this case a laser source 10,
emits a laser beam 3 of which the orientation is controlled by
mirrors that are subjected to galvanometers 20. An optical lens 30
permits the beam 3 to be focussed at the level of the working zone
4 in order to heat the upper layer of the powder 2 according to a
precise pattern and thus to bring about melting of the powder in a
selective manner. After treatment of a powder layer by the beam,
the working tray 60 is lowered by a unit thickness and is covered
with a new powder layer, continuing in this manner in order to form
the component 40 layer by layer. Depending on the types of energy
beam and the powders that are used, the thickness of a powder layer
may vary from a few micrometres (for example 10 .mu.m) to several
hundred micrometres (for example 500 .mu.m=0.5 mm). When the
component 40 is finished, that is to say when the hundreds or the
thousands of layers necessary for its construction have been
successively solidified, the component is removed from the working
zone.
[0044] All of the parts of the machine permitting the application
of a new powder layer on the working zone are generally referred to
as the "layering device". The layering device that is familiar from
the prior art comprises storage means 5 and distributing means 6
for distributing the powder 2 on the working zone 4. As described
above, the storage means familiar from the prior art generally make
use of a vertically mobile tray 51 similar to the working tray 60.
The purpose of the distributing means 6 (not illustrated in detail
in FIG. 1) is to distribute a thin layer of powder on the whole of
the working zone. The purpose of the feeding means 7 (not
illustrated in detail in FIG. 1) is to transfer the powder from the
storage means to the distributing means 6. The distributing means
and the feeding means that are familiar from the prior art commonly
make use of scrapers and/or rollers carried by one or a plurality
of carriages, said carriages being mobile between the storage means
5 and the working zone 4. Dosing means 8, in this case means
permitting the raising of the mobile tray 51 to be controlled
precisely, permit the quantity of powder used for each operation of
the layering device to be controlled. Once the distributing means
have moved across the working zone (towards the left in FIG. 1),
the surplus powder is pushed into a recovery container 21.
[0045] FIG. 2 represents a first embodiment of the machine 1
according to the invention and, in particular, an embodiment of its
layering device. The source and the control of the energy beam are
illustrated in a manner that is identical to the prior art. This is
only one example. As described in the preamble to the application,
the invention is applicable in reality to all the types of
powder-based additive manufacturing by sintering or by total
melting of the granules of said powder using an energy beam such as
electromagnetic radiation (for example a laser beam) or a beam of
particles (for example an electron beam). The rest of the present
description thus concentrates principally on the process and the
layering device.
[0046] The storage means 5 have the form of a hopper 52 located
above the plane of the working zone 4. The distributing means 6 use
a scraper 61. The scraper is integral with the hopper. The feeding
means 7 simply use a lower opening 71 in the hopper in order to
transfer the powder towards the distributing means 6 by gravity.
Dosing means, in the form of a rotating dosing cylinder 81
comprising at least one cavity, permit the quantity of powder
transferred to be controlled. Said cavity, preferably a groove 82,
defines a reproducible dose of powder. The one or more grooves 82
extend substantially for the whole of the useful length of the
dosing cylinder 81, that is to say substantially for the whole of
the width of the working zone 4. The dimensions and the form of the
cross section of the grooves 82 may vary along the length of the
cylinder 81 in order to further improve the distribution of the
powder on the whole of the working zone.
[0047] In FIG. 3, the device in FIG. 2 is depicted during the
layering operation. The thicknesses of powder are generally shown
highly magnified in the present application in order for them to be
readily visible by the reader, as is often also the case in the
documents associated with the prior art. It is, in point of fact,
impossible to show a thickness of 50 .mu.m and a working zone of
500 mm in length, for example, in the same drawing while faithfully
respecting the proportions.
[0048] In FIG. 3, the hopper 52 is displaced towards the left of
the figure at the same time as the scraper 61. The scraper
distributes and smoothes the powder layer on the working zone 4.
The mass 22 of powder situated ahead of the scraper is dosed by the
dosing cylinder 81. The application of powder may take place on a
single occasion for each layer. The dosage is preferably
progressive, however, that is to say that the application of powder
takes place progressively by delivering the contents of a groove on
a number of occasions in the course of the passage over the working
zone, which permits the variability of the working conditions of
the scraper to be reduced and, accordingly, an improved regularity
of the thickness and the compactness of the resulting bed of powder
to be guaranteed.
[0049] FIG. 3 illustrates in addition a preferred variant of the
first embodiment of the invention, in which a compacting roller 9
is used in addition. The final thickness 24 of the layer 23 of
powder is thus the result of two successive operations. A first
thickness is defined by the distributing means 6, in this case the
scraper 61. This thickness is then reduced and is made even more
homogeneous by the action of the compacting roller 9. The roller is
displaced together with the hopper and the scraper. More
preferably, the roller is counter-rotating, that is to say that it
is motorized in such a way as to rotate in the opposite direction
to its displacement relative to the bed of powder (as indicated by
the arrow, which shows a rotation in the clockwise direction, while
the roller is moving towards the left).
[0050] Depicted in FIG. 4 is a second embodiment of the layering
device, in which the distributing means 6 use a distribution
cylinder 62 in place of the scraper of the first embodiment. The
displacement of the distribution cylinder 62 is linked to that of
the hopper 51, as in the case of the scraper 61 in the first
embodiment. The cylinder 62 may be fixed in rotation or
counter-rotating. When the distribution cylinder is fixed, its
fixation 63 is preferably eccentric, which permits the fine
regulation of its height and thus of the final thickness 24 of the
resulting powder layer 23.
[0051] As depicted in FIG. 5, a counter-rotating compacting roller
9 may be advantageously associated with the layering device
according to the second embodiment under the same conditions as
those described above with reference to FIG. 3.
[0052] FIG. 6 depicts a third embodiment. It differs in principle
from the first embodiment in that the dosing means 8 use a sliding
trapdoor 84, of which the duration and the amplitude of opening
influence the quantity of powder transferred to the distributing
means 6. Preferably, the storage means 5 use a flexible hopper 53
carried by a hopper support 54 in order to reduce the risk of
blocking of the powder. Depending on the types of powder used,
supplementary active unblocking means (not illustrated here) may be
deployed.
[0053] Depicted in FIG. 7 is a variant of the third embodiment
comprising in addition a counter-rotating compacting roller 9, of
which the displacements are integral with the scraper and the
hopper, as described above with reference to FIG. 3.
[0054] FIG. 8 depicts a fourth embodiment of the layering device
according to the invention, in which the dosing means 8 and the
distributing means 6 use a common rotating cylinder 64. The dosage
function is assured by a groove 82 in the common cylinder 64
according to the principle described above with reference to FIG.
2. The distribution function is assured by a smoothing section 65
of the common cylinder 64 according to the principle described
above with reference to FIG. 4. One advantage of this embodiment is
that it permits further lightening of the layering device of the
machine according to the invention. The common cylinder 64 is
preferably fixed in rotation during its displacement on the working
zone. The smoothing section 65, that is to say the part of the
common cylinder that is intended for the distribution of the
powder, is delimited symbolically by dotted lines in FIGS. 8 to 12.
This section preferably includes a swelling 66. This swelling of
low overall height (for example a few tenths of a millimetre at
most) is scarcely perceptible in the figures in spite of its
magnification.
[0055] The operation of this embodiment is illustrated in detail in
FIGS. 9 to 12, which show the successive configurations of the
device in the course of a layering cycle.
[0056] In FIG. 9, the layering device is in a waiting
configuration, for example between two successive layers. The
powder 2 is retained in the closed hopper 52 by the hermetic
contact of the common cylinder 64. The groove 82 is then able to
charge itself with powder.
[0057] In FIG. 10, the common cylinder 64 has rotated through about
half a revolution in the anticlockwise direction and has deposited
a dose of powder in the vicinity of the working zone 4.
[0058] In FIG. 11, the common cylinder 64 has rotated through about
a quarter of a revolution in the clockwise direction in order to
bring the smoothing section 65 into contact with the mass of powder
22 and at the appropriate height. The fact that the smoothing
section includes a swelling 66 permits the fine regulation of the
smoothing thickness by the choice of the angle adopted by the
common cylinder 64.
[0059] In FIG. 12, the layering device passes over the working zone
4, as described previously, pushing the mass of powder 22 above the
component 40 in order to smooth a powder layer 23 having a final
thickness 24. In order to limit the variations in pressure over the
entire length of the working zone, the feed phase described in
FIGS. 9 and 10 may be repeated on one or a number of occasions in
the course of a single passage over the working zone, in which case
the dose defined by the groove 82 preferably represents a fraction
of the quantity of powder necessary for a complete layer.
[0060] Alternatively, the powder depositing phase may be performed
several times in succession in the absence of any smoothing
movement in order to create, in the configuration in FIG. 10, a
mass 22 corresponding to a plurality of unit doses as defined by
the groove 82.
[0061] It should be noted (as explained above) that the thicknesses
of the layers, the volumes of the masses, the grooves or the
swelling 66 are not represented on a consistent scale and, quite
the reverse, are deliberately distorted for the purpose of making
the figures legible.
[0062] Of course, as described above for the other embodiments of
the invention (see, for example, the embodiment in FIG. 7), the
layering device in FIGS. 8 to 12 may preferably comprise in
addition a counter-rotating compactor roller (not illustrated
here), of which the displacement is integral with the displacement
of the feeding means and the dosing means, that is to say in this
case with the hopper 52 and the common cylinder 64.
[0063] Alternatively, the smoothing section 65 of the common
cylinder 64 may exhibit a reduction in radius at the point of the
increase in the radius (swelling 66) illustrated and described with
reference to FIGS. 9 to 12. Whether this involves an increase or a
reduction in the radius, it is this variation in the radius that
permits the adjustment of the height of the cylinder (and thus the
fine adjustment of the smoothing thickness) by the choice of the
angle adopted by the common cylinder 64.
[0064] It will be appreciated that a layer may be produced
according to the invention in a single pass, that is to say in a
single passage over the working zone. The quantity of powder stored
in the hopper is preferably sufficient to produce hundreds, and
even thousands, of layers, that is to say that the machine could
achieve additive manufacturing of a single complete component, or
even of a plurality of complete components, without recharging the
hopper. Recharging of the hopper preferably takes place at the
moment when the manufacturing of a component is completed, and the
finished component is preferably removed before new manufacturing
commences.
[0065] The powder used is preferably a metallic or ceramic powder.
Depending on the types of energy beams that are used and depending
on the thickness of the final layer referred to here, the average
diameter of the particles of the powder may vary from a few microns
(for example 5 .mu.m) to 300 or 400 .mu.m.
[0066] A person skilled in the art will appreciate that the
different embodiments described and illustrated here are specific
examples of combinations of means according to the invention. Other
obvious combinations or substitutions of the different means are
likewise part of the invention, for example the replacement in the
third embodiment (FIGS. 6 and 7) of the scraper 61 by a
distribution cylinder 62 according to the second embodiment in
FIGS. 4 and 5.
* * * * *