Surfacing of additively manufactured components and corresponding manufactured components of a turbomachine

{
  "publication_number": "US9862059B2",
  "country": "US",
  "kind": "B2",
  "title": "Surfacing of additively manufactured components and corresponding manufactured components of a turbomachine",
  "abstract": "The present invention relates to a method for manufacturing components, in particular components of turbomachines, such as aircraft engines, wherein an additive method is used at least partially for the manufacture of the component (1), wherein at least one surface region (3) of the additively manufactured portion of the component (1) is provided with a smoothing layer (2), which is deposited by vapor deposition. In addition, the invention relates to a correspondingly manufactured component of a turbomachine.",
  "claims": [
    "1. A method for manufacturing a component, wherein an additive method is used at least partially for the manufacture of a component from a plurality of layers each having edges, the plurality of layers defining a first surface region having a rough surface defined by the edges of the plurality of layers of the layerwise construction of the plurality of layers, wherein the first surface region of the additively manufactured part of the component is provided with a smoothing layer, which is deposited by vapor deposition, the smoothing layer including a diffusion layer that at least partially diffuses into the plurality of layers of the first surface region adhering thereto, whereby the smoothing layer forms a part of and remains on the component, and whereby the smoothing layer provides a protective coating to the first surface region during use of the component.",
    "2. The method according to claim 1, wherein the additive manufacturing method comprises a layerwise construction of the component from powder material that is joined to form a solid component, wherein the method is selected from a group that comprises selective laser melting, selective electron-beam melting, selective laser sintering, selective electron-beam sintering, and powder hardfacing.",
    "3. The method according to claim 1, wherein a second surface region on a portion of the component is provided with a smoothing layer.",
    "4. The method according to claim 1, wherein the vapor deposition is selected from the group that comprises physical vapor deposition, chemical vapor deposition, thermal deposition, electron-beam deposition, pulsed laser deposition, plasma-enhanced vapor deposition, and plasma-enhanced chemical vapor deposition.",
    "5. The method according to claim 1, wherein the smoothing layer has a thickness of 5 μm to 200 μm.",
    "6. The method according to claim 1, wherein the smoothing layer is formed from a material having one or more chemical elements of the base material of the component being coated.",
    "7. The method according to claim 1, wherein the smoothing layer is formed from a pure metal or an alloy or a chemical compound.",
    "8. The method according to claim 1, wherein the component with the smoothing layer is subjected to a heat treatment.",
    "9. The method according to claim 1, further comprising the step of: depositing another functional layer on the smoothing layer.",
    "10. The method according to claim 1, wherein the component is selected from the group that comprises flow duct limiting walls, rotating blades and guide vanes, and/or the component has as a base material an alloy from the group that comprises nickel-based alloys, nickel-based superalloys, iron alloys, titanium alloys, and cobalt alloys.",
    "11. The method according to claim 1, wherein the component is formed from a nickel-based alloy and the smoothing layer is formed from aluminum or nickel.",
    "12. The method according to claim 1, wherein the smoothing layer has an average roughness R a that is less than or equal to 10 μm.",
    "13. The method according to claim 1, wherein the component has at least one flow surface, and the at least one flow surface is provided with the smoothing layer.",
    "14. The method according to claim 5, wherein the smoothing layer has a thickness of 10 μm to 100 μm.",
    "15. The method according to claim 8, wherein the heat treatment is diffusion annealing.",
    "16. The method according to claim 12, wherein the smoothing layer has an average roughness R a that is less than or equal to 5 μm.",
    "17. The method according to claim 9, wherein the functional layer is a layer for corrosion protection.",
    "18. The method according to claim 9, wherein the functional layer is a thermal barrier coating."
  ],
  "description_excerpt": "Field of the Invention\n\nThe present invention relates to a method for manufacturing a component of a turbomachine, in particular an aircraft engine, with the use of a generative or additive manufacturing method, as well as a corresponding manufactured component.\n\nPrior Art\n\nAdditive manufacturing methods in which a component is built up layer by layer from a powder material, such as powder hardfacing, selective laser melting, selective laser sintering, selective electron-beam melting, selective electron-beam sintering, and the like are manufacturing methods of interest for components of turbomachines, such as stationary gas turbines or aircraft engines, since difficult-to-process materials, which are difficult to cast, for example, can be used with this method, and also components having near-final contours can be produced, so that complicated post-processing by means of machining methods such as milling can be dispensed with.\n\nOf course, in additively manufactured components, there is the problem that the surface quality in part does not fulfill requirements with respect to roughness, in particular for application in turbomachines. Thus, components having surfaces that are too rough as flow surfaces, that is, surfaces over which a fluid flows, have a flow resistance that is too high or negatively affect the flow conditions due to undesired vortexing of the fluid flow. In addition, rough surfaces are in part unsuitable for ambient conditions, since rough surfaces can be subjected to an elevated oxidation and/or corrosion attack(s).",
  "cpc": [
    "C23C 10/28",
    "B22F 10/28",
    "B22F 10/38",
    "B22F 10/64",
    "B22F 3/1055",
    "B22F 5/009",
    "B22F 5/04",
    "B23K 15/0086",
    "B23K 26/342",
    "C22C 1/0433",
    "C22C 1/0458",
    "C22C 33/02",
    "C23C 16/06",
    "C23C 16/56",
    "F05D 2230/22",
    "F05D 2230/31",
    "F05D 2230/313",
    "F05D 2230/314",
    "F05D 2300/175",
    "F05D 2300/516",
    "Y02P 10/25",
    "Y02P 10/295",
    "Y02T 50/60"
  ],
  "ipc": [
    "B23K 15/00",
    "B23K 26/342",
    "B22F 3/105",
    "B22F 5/00",
    "B22F 5/04",
    "C23C 10/28",
    "C23C 16/06",
    "C23C 16/56"
  ],
  "assignees": [
    "MTU Aero Engines AG"
  ],
  "inventors": [
    "Christian Liebl",
    "Karl Blumenschein",
    "Steffen Schlothauer",
    "Thomas Hess"
  ],
  "filing_date": "2015-09-01",
  "publication_date": "2018-01-09",
  "grant_date": "2018-01-09",
  "priority_date": "2014-09-08",
  "application_number": "US-201514842343-A",
  "family_id": "53835269",
  "cited_by_count": 15,
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    "US20130071562A1",
    "DE102011086889A1",
    "EP2692464A2",
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  ]
}