EP2534280B1 - Method for producing a component and such a component - Google Patents

Description

The invention relates to a method for producing a component and a component produced in this way according to the preamble of patent claim 9.

The publication EP 1 808 508 A1 discloses (see Figures 9 and 10, column 9, section 50 to column 10, section 55) a cold gas spraying process wherein a scale-like surface structure is produced by means of a mask. This surface structure causes an improvement in the flow.

For heavily loaded components such as blades of compressors or turbines, rotating components such as crankshafts, components with cyclic loading such as connecting rods, structural components with high thermal stress such as cooling structures and tools must often be compromised between different and conflicting requirements. Examples are a high fatigue strength at low weight or low brittleness at high hardness.

To meet these conflicting requirements, the components are made of reinforced metal alloys, which can only be processed by conventional manufacturing processes to a limited extent. Furthermore, it is disadvantageous that most of the entire body of the component consists of this metal alloy, so that individual component areas are not optimized individually depending on the load occurring. Furthermore, the metal alloy is mostly limited to a consideration of structural properties such as fatigue strength and weight. To achieve, for example, a high abrasion resistance or temperature resistance, the component is usually coated with a corresponding protective layer, which is applied in a subsequent and thus further manufacturing process. For example, in the patent US 6,365,222 B1 proposed to coat a blade ring of a compressor with a friable protective layer by cold gas spraying. In this case, an adhesive layer and then the protective layer are applied to the base body first. In addition, it is from the patent US Pat. No. 6,905,728 B1 known, the cold gas spraying for repair of turbine blades use. In this case, outbreaks are filled up by a corresponding material by cold gas spraying and then solidifies the thus repaired blade areas.

However, a disadvantage of the abovementioned cold gas spraying techniques is that the applied layers have a positive influence only on external properties such as temperature resistance and abrasion resistance of the component. Structural properties such as increasing the fatigue strength are not achievable with the known cold gas spraying. Furthermore, it is disadvantageous that the conventional production methods severely restrict the shape or geometry of the components, which in turn can adversely affect the component properties.

The object of the present invention is to provide a method for producing a component which eliminates the aforementioned disadvantages and has the individualized component regions adapted to a respective load, as well as a component produced in this way with optimized component regions.

This object is achieved by a method having the steps of patent claim 1 and by a component having the features of patent claim 9.

In a method according to the invention for producing a component, at least one load line of the component is calculated. Then, a core for the component is provided. Subsequently, at least in sections, a layer is applied by cold gas spraying onto the core, wherein at least one layer section is formed in the layer, the material and orientation of which is selected according to the load line.

The inventive method has the advantage that the component can be optimally dimensioned according to its required properties. The core serves virtually only as a substrate or support for the layer, in which due to the different materials and the consideration of the respective load lines, the required properties are integrated. Thus, for example, component regions with a high fatigue strength can consist of a different material and have a different geometry than component regions with a high temperature resistance. According to the invention, a hybrid-like layer is created which is optimally adapted to the mechanical loads, so that actually conflicting requirements can be optimally combined. The provision and attachment of separate structural reinforcement structures is no longer necessary. The inventive type of cold spraying technique relatively soft and quasi-organic overflowing transitions between the different materials are created. This type of transitions avoids a step formation and thus allows a harmonious load introduction and load distribution in or on the component. Furthermore, it is advantageous that only one manufacturing method, namely the cold gas spraying is used to form the component. The application of several different methods is therefore not necessary.

In one embodiment, the layer is applied in different layer thicknesses. This allows a flexible design of the component form or of component regions, regardless of the shape and size of the core. The layer thickness can certainly move in the centimeter range, so that, for example, rib-like reinforcing elements arise.

The production of the layer section can be strip-like in a width corresponding to a coverage distribution of a sprayed jet or by means of a mask that covers the areas on which the material is not to be applied during spraying.

In one exemplary embodiment, a plurality of layer sections are applied, the interstices of which are filled at least occasionally with another type of material. As a result, an optimal load structure is created, whose course corresponds to the load lines, wherein the material in the spaces next to the pure leveling serves to stabilize the layer sections.

In one embodiment, a plurality of layers are applied. For example, it is conceivable to apply a cover layer which defines a closed upper or outer surface of the component.

To achieve a final contour, the component can be subjected to a removing and / or hardening post-processing.

A component according to the invention has a core which, at least in sections, has a layer applied by cold gas spraying. According to the invention, the layer comprises at least one layer section, its material and orientation in accordance with at least one calculated load line is selected.

Such a component has optimum component properties and can be produced in almost any shape or geometry.

Preferably, the layer completely surrounds the core, so that the material and the shape of the core can be selected almost freely and the core can be embodied, for example, to be weight-optimized and / or has optimum adhesion conditions for the layer to be applied.

Preferably, a plurality of layer sections are provided for forming a load structure, which can form dendritic and / or organic structural sections for harmonic load initiation and load transfer.

In one embodiment, the materials differ from at least some structural sections. This allows the materials to be individually adjusted to the loads.

The core, which can be both sheet-like and skeletal or framework-like, can consist of almost any material. In one embodiment, it is made of a different material or materials than the layer.

Other advantageous embodiments are the subject of further subclaims.

In addition, the method according to the invention can also be used when, for example, components have to be marked without negatively influencing their strength properties. Examples are the counterfeit-proof marking of metallic or hybrid components with manufacturer's mark or series marking. Likewise, the inventive method for aesthetic or practical design of everyday objects such as knife cutting and jewelry application can be found.

• Figur 1 einen Querschnitt durch ein erstes erfindungsgemäßes Bauteil,
• Figur 2 eine Detaildarstellung des Bauteils aus Figur 1,
• Figur 3 eine weitere Detaildarstellung des Bauteils aus Figur 1,
• Figur 4 einen Längschnitt durch ein zweites erfindungsgemäßes Bauteil,
• Figur 5 einen Querschnitt durch das Bauteil aus Figur 4, und
• Figur 6 einen Querschnitt durch ein drittes erfindungsgemäßes Bauteil.

In the following preferred embodiments of the invention will be explained in more detail with reference to schematic representations. Show it:

• FIG. 1 a cross section through a first component according to the invention,
• FIG. 2 a detailed representation of the component FIG. 1 .
• FIG. 3 a further detail of the component FIG. 1 .
• FIG. 4 a longitudinal section through a second component according to the invention,
• FIG. 5 a cross section through the component FIG. 4 , and
• FIG. 6 a cross section through a third component according to the invention.

In the figures, the same structural elements bear the same reference numerals, wherein for reasons of clarity in several identical structural elements in a figure only one element is provided with a reference numeral.

FIG. 1 shows a cross section through a highly simplified inventive component 2. The component 2 has a full-body-like core 4, which is covered by a layer 6. The layer 6 was applied by cold gas spraying and, according to the invention, absorbs the actual load on the component 2. It has a nose-like loading structure 8 which extends away from the core 4 and runs along calculated load lines such as stress and force lines. The layer 6 is applied in different layer thicknesses and surrounded to form a closed surface 10 by a cover layer 12 with a constant layer thickness, which was also applied by cold gas spraying.

The layer thicknesses and the materials of the layer 6, the load structure 8 and the cover layer 12 are selected according to the loads to be absorbed and can accordingly vary. The core 4 serves primarily as a substrate for the layer 6 and accordingly has a core material which is chosen virtually independent of the loads to be absorbed. Due to the sheathing of the core 4 with the layer 6 or the cover layer 12, its outer contour has in principle no influence on the desired geometry or final contour of the component 2. This is defined exclusively by the layer 6 or the cover layer 12.

FIG. 2 shows a plan view of a portion of the component 2 according to the invention in the region of another in FIG. 1 not shown load structure 8, which runs along load lines. The load structure 8 extends away from the core 4 and has a plurality of layer sections 14 or reinforcing elements, which are applied by cold gas spraying. The material of the respective layer section 14 is selected according to the load to be absorbed. Likewise, their geometry corresponds to the expected load and can vary individually. By way of example, a free end portion 16 of the load structure 8 is formed triangular or ramp-like and merges steplessly into the core 4. The layer sections 14 define gaps 18 which are of a different material than the layer sections 14 are filled by cold gas spraying. The load structure 8 with the filled-in spaces 18, ie the layer 6, is as in FIG FIG. 1 illustrated surrounded by the cover layer 12 to form the closed surface 10.

According to FIG. 3 the layer 6 in cross-section on a plurality of approximately oval layered bodies 20 with peripheral projections, which consist of different materials according to the load lines and are arranged according to the load lines to each other. The different materials are in the FIG. 3 represented by the different hatches - strip-like and dotted. Due to the application of the cold gas spraying technique according to the invention, the laminates 20 apparently interlock and form relatively soft and organic transitions, which has an advantageous effect on the introduction or absorption and distribution of the load on the component 2. Occasionally, 20 air chambers 22 are formed selectively between the laminates depending on the function of each layer area. The air chambers 22 can be designed specifically for influencing the damping behavior or the heat transfer, for example.

Furthermore, in FIG. 3 it can be seen that unevennesses 24 in the core 4 of the component 2 are compensated by the layer 6, and that the layered bodies 20 likewise form an apparently splined connection with the core 4.

The FIGS. 4 and 5 This has a discrete load structure 8, which is formed from a plurality of spaced apart and mutually parallel rib-like reinforcing elements 26a, 26b or layer portions. The reinforcing elements 26a, 26b have a rectangular cross-section and extend for optimal adjustment of the component 2 with regard to its strength, its vibration behavior and, for example, its temperature behavior along expected or occurring load and force lines. In the exemplary embodiment shown, the reinforcing elements 26a, 26b are therefore set at an angle a to the component longitudinal axis. They are applied in layers by cold gas spraying, wherein their width b preferably corresponds to the coverage angle of the sprayed jet. As indicated by the hatching they consist of a different material than the base material or Kemmaterial of the component 2 and are fully enclosed in the base material or covered by this. The material of the reinforcing elements 26a, 26b depends on the expected or occurring loads.

FIG. 6 shows a cross section through a third inventive component 2, the load structure 8 of a plurality of spaced apart and mutually parallel rib-like reinforcing elements 26a, 26b or layer sections with a rectangular cross-section sections, the surface 10 of the component 2 forms. For this purpose, the reinforcing elements 26 are formed in the component 2 or integrated in this, that one of its outer surfaces 28 is exposed and flush merges into the surface 10 of the component 2 due to the different materials between the base material of the component 2 and the material of the reinforcing elements 26a , 26b, this embodiment is particularly suitable for the formation of the component 2 with zonal surface different hardnesses and / or abrasion resistance. Of course, the reinforcing elements 26a, 26b may also be made of different materials.

In a method according to the invention, for example for the production of the component 2 from the Figure 1 to 3 First, the load lines of the component 2 are determined as a result of, for example, absorbed forces, vibrations or temperatures. Then, the core 4 is provided from a core material, wherein the core 4 already has such a surface finish that cleaning or corresponding surface treatments are eliminated. Now, the layer 6 is formed on the core 4 by cold gas spraying. In this case, the load structure 8 is aligned along the calculated load lines and a material suitable for the respective load is used. Preferably, a spray gun is used with a spray cone which corresponds to the width of the respective layer section 14 or reinforcing element 26a, 26b. After producing the load structure 8, the interstices 18 between the layer sections 14 are filled with the core material by cold gas spraying. Subsequently, the cover layer 12 is sprayed on the layer 6 to form a closed surface 10 consisting of the core material by cold gas spraying. Finally, the component 2 to achieve a correspondingly resilient end contour of a post-processing in the form of an erosive and / or a solidified process.

Other methods according to the invention provide a material other than the core material as material for filling in the intermediate spaces 18 or as material for the cover layer 12. The choice of the respective material for the filling of the gaps 18 and the cover layer 12 depends in particular on the function to be performed, such as, for example, improvement of damping properties, abrasion resistance or temperature resistance.

Disclosed is a component comprising a cold spray applied layer having at least one layer portion or reinforcing member whose material and orientation is selected according to a strain line, and a method of manufacturing such a component by cold gas spraying.

Claims (14)

1. Method for producing a component (2), having the steps:

   - calculation of at least one load line of the component (2) that is to be expected,

   - provision of a core (4), and

   - application of a layer (6) at least in sections to the core (4) by ccld-gas spraying, wherein formed in the layer (6) there is at least one layer section (14, 26), the material and orientation of which are chosen in accordance with the load line.
2. Method according to claim 1, wherein the layer (6) is applied in different layer thicknesses.
3. Method according to claim 1 or 2, wherein the layer section (14, 26) is produced in the manner of strips in a width corresponding to a coverage distribution of a sprayed jet.
4. Method according to claim 1, 2 or 3, wherein the layer section (14, 26) is produced by laying on a mask during the spraying.
5. Method according to one of the preceding claims, wherein a plurality of layer sections (14, 26) is applied, the interstices (18) of which are filled at least here and there by a different kind of material.
6. Method according to one of the preceding claims, wherein a plurality of layers (6) is applied.
7. Method according to one of the preceding claims, wherein a cover layer (12) is applied that forms an outer surface (10).
8. Method according to one of the preceding claims, wherein the component (2) is subjected to abrasive and/or strengthening after-treatment in order to obtain a final contour.
9. A component (2) having a core (4) which, at least in sections, has a layer (6) that is applied by cold-gas spraying, characterised in that the layer (6) has at least one layer section (14, 26), the material and orientation of which are selected in accordance with at least one calculated load line.
10. A component according to claim 9, wherein the layer (6) encases the core (4).
11. A component according to claim 9 or 10, wherein a plurality of layer sections (14, 26) is provided in order to form a load structure (8).
12. A component according to claim 9, 10 or 11, wherein the layer sections (14, 26) form dendritic and/or organic structure sections.
13. A component according to claim 11 or 12, wherein at least individual layer sections (14, 26) have different materials.
14. A component according to one of claims 9 to 13, wherein the layer (6) consists of materials that are different from that of the core (4).

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