巴西专利BR112015029239B1 METHOD FOR FORMING A THREE-DIMENSIONAL ARTICLE

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专利摘要:
abstract method and apparatus for additive manufacturing a method for forming a three-dimensional article through the successive fusion of parts of a powder bed, parts of which correspond to successive cross sections of the three-dimensional article, said method comprising the steps of: providing a model of said three-dimensional article, providing a first layer of powder on a work table, directing a first beam of energy from a first source of energy beam on said working table causing the melting of said first layer of dust at first locations selected according to the said model, in order to form a first cross section of the said three-dimensional article, directing a second energy beam from a second energy beam source on the said work table causing the fusion of said first layer of dust in second locals selected according to the wound model, so as to form the first cross section of said three-dimensional article, wherein said first and second locations of said first layer of powder are at least partially overlapping each other. 1/1
公开号:BR112015029239B1
申请号:R112015029239-9
申请日:2014-04-04
公开日:2020-02-18
发明作者:Ulric Ljungblad；Anders Snis
申请人:Arcam Ab；
IPC主号:

专利说明:

“METHOD FOR FORMING A THREE-DIMENSIONAL ARTICLE”
Field of the Invention [001] The present invention relates to a method for the manufacture of three-dimensional additive articles.
Background of the Invention [002] Free-form or additive manufacturing is a method for forming three-dimensional articles by successively fusing selected parts of powder layers applied to a work table. A method and apparatus according to this technique is disclosed in US 2009/0152771.
[003] Such apparatus may include a work table on which the said three-dimensional article will be formed, a powder dispenser, arranged to establish a thin layer of dust on the work table for the formation of a dust bed, a cannon of rays to bring energy to the powder through which the powder melts, elements for controlling the energy released by the ray cannon on said powder bed for the formation of a cross section of said three-dimensional article through the fusion of parts of said bed of powder and a control computer, in which information about consecutive cross sections of the three-dimensional article is stored. A three-dimensional article is formed by consecutive cross-sectional fusions formed consecutively by layers of powder, successively glued by the powder distributor.
[004] Thus, there is a demand for additive production techniques that are capable of building ever larger three-dimensional articles. Increasing the construction volume also requires greater beam power from the beam power source and / or high deflection angles of the beam source which can lead to processing difficulties in order to keep the beam point quality equal throughout of the entire construction area.
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2/23
Description of the Invention [005] An objective of the invention is to provide methods and apparatus that allow large volumes of construction of three-dimensional articles produced by free-form or additive manufacturing without sacrificing the quality of the energy beam point.
[006] In a first embodiment of the invention, a method is provided for forming a three-dimensional article by successively merging parts of a powder bed, which corresponds in parts to successive cross sections of the three-dimensional article. Said method comprises the steps of: providing a model of said three-dimensional article, providing a first layer of powder on a work table, directing a first beam of energy from a first source of energy beam on said working table causing the fusion of said first layer of dust in first selected places according to said three-dimensional article, directing a second beam of energy from a second source of energy beam on said work table causing the fusion of said first layer of energy powder at second locations selected in accordance with said three-dimensional article, wherein said first and second locations of said first layer of powder are at least partially overlapping each other in an overlapping zone.
[007] An example of the advantage of the various embodiments of the present invention is that small deviations in the alignment of the beam gun may not affect the overall quality of the three-dimensional article as long as the two beams are at least partially overlapping each other. Another advantage of the present invention may be that greater beam deflection angles can be used without sacrificing the size of the beam point and the shape of the beam.
[008] In an example of an embodiment of the present invention,
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3/23 said first and second locations of said first powder layer, which are at least partially overlapping with each other, are simultaneously fused by said first and second beam of energy from said first and second beam source respectively.
[009] Another non-limiting advantage of this realization is that it relatively saves time, since both bundles are used at the same time.
[010] In yet another embodiment of the present invention, said first overlapping zone is simultaneously fused by said first and second energy bundles of said first and second energy bundles, respectively.
[011] Yet another non-limiting advantage of this realization is that the first and second beams are present simultaneously in the overlap zone, which can give some additional flexibility in terms of heat transfer, dimension control and micro structure control in the zone overlap.
[012] In yet another example of an embodiment of the present invention, a point of said first energy beam is at least partially superimposed with a point of said second energy beam during at least one occasion of said fusion of said first and second partially overlapping locations.
[013] The at least partial overlapping of the energy bundles has the advantage that the fusion strategy has no restrictions, as would be the case if they were never allowed to overlap each other.
[014] In another embodiment, said point of said first energy beam and said point of said second energy point are at least partially overlapping each other on said bed of dust during the deflection of said first and second energy beam along
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4/23 of a total length (L) of said overlap zone.
[015] An advantage of this example of embodiment which is the microstructure can be controlled within the overlap zone and kept equal or at least very similar to the microstructure outside the overlap zone. Another advantage is that the overlap from one beam to the other can be prolonged and dependent on the width of the overlap zone, which eliminates or at least reduces imperfections due to changes in the position of the beam point in the system.
[016] In yet another embodiment, said first and second locations of said first layer of powder which are at least partially overlapping with each other are firstly fused by said first energy beam from said first energy beam source, and after the fusion by said first energy bundle has ended, said second energy bundle from said second energy bundle merges the first and second locations, which are at least partially overlapping with each other.
[017] This realization can be advantageous in cases where an additional melting of a specific area can reduce imperfections defects in the powder. It can also be advantageous if there is a desire to change the microstructure in the overlap zone in relation to the non-overlap zone.
[018] In yet another example of the embodiment of the present invention, the sum of the power of the first and second beams in said overlap is maintained at a predetermined value, which can vary from being constant along the length (L) of the overlap zone.
[019] This realization has the advantage of making the melting process inside and outside the overlap zone as similar as possible.
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5/23 [020] In yet another example of the embodiment, said constant value can be equal to the melting power of the first and / or second beam outside said overlap.
[021] In yet another embodiment, the power of said first beam varies linearly from 100% to 0% from a first end of said overlap zone and ending at a second end of said overlap zone, varying simultaneously the power of said second beam linearly from 0% to 100% from the first end of said overlap zone and ending at the second end of said overlap zone.
[022] The advantage of this realization is that the transition from one beam to another can be done very smoothly.
[023] A further embodiment example may further comprise the steps of providing a second layer of powder on top of said first partially melted powder layer, directing the first beam of energy from the first beam energy source on said beam table. work causing the said second layer of powder to fuse at a third location selected according to the said model to form a first part of a second cross section of said three-dimensional article, and directing the second beam of energy from the second source of beam energy on said work table causing said second layer of powder to melt in a fourth location according to said model to form a second part of the second cross section of said three-dimensional article, said third and fourth selected locations of the second layer of dust are at least partially overlapping with each other, where third and fourth locations at least partially overlapping are laterally displaced.
[024] A non-limiting advantage of this achievement is that
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6/23 any dissimilarity in the overlap zone in relation to the non-overlap zone is not increased directly since the overlap zone is shifted in position from one layer to another.
[025] In yet another example of the present invention, the width of the overlapping region is the same in the first and second layers.
[026] In yet another example of embodiment, the distance offset laterally from said at least partially overlapping third and fourth locations is chosen to result in a non-overlapping of at least partially overlapping third and fourth locations and the first and second locations by least partially overlapping.
[027] An advantage of this realization is that any defect in the overlap region of a first layer is not present at the top of any defects in an overlap zone in an adjacent layer.
[028] In yet another example of embodiment, the laterally offset distance of said at least partially overlapping third and fourth locations is chosen to result in an overlap of at least partially overlapping third and fourth locations and at least the first and second locations partially overlapping.
[029] An example of the advantage of this realization is that the overlap zone is affecting a restricted area of the three-dimensional part.
[030] In yet another embodiment, the first energy beam and the second energy beam can be laser beams or electron beams. In yet another example of the embodiment, the first energy beam can be a laser beam and the second energy beam can be an electron beam.
[031] A non-limiting advantage of this realization is that different sources of energy bundles can be used to melt and / or heat the same area of a particular layer of the three-dimensional article. O
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7/23 laser may be more suitable for heating and the electron beam more suitable for melting, for example.
[032] In yet another example of an embodiment, the distance offset laterally from said third and fourth locations at least partially overlapping is random within a predetermined range.
[033] An advantage of this example of realization is that any repeated defect can be eliminated due to randomization.
[034] In another embodiment of the present invention, a device for forming a three-dimensional article is provided by successive fusions of parts of a powder bed, such parts corresponding to successive cross sections of the three-dimensional article, such an apparatus comprising a computer model of the said three-dimensional article, a first source of energy beam providing a first energy beam on said work table causing said first layer of powder to fuse at the first location selected according to said model to form a first part of a first cross section of said three-dimensional article, a second source of energy beam providing a second energy beam on the work table causing the first layer of powder to fuse at the second location selected according to said model to form a second part of a first cross section of that article three-dimensional, a control unit for controlling an overlap of said first selected location and said second selected location and a power of said first and second beam of energy in said overlap.
[035] With such an apparatus, large articles with controlled quality can be produced.
Brief Description of the Drawings [036] Several embodiments of the invention will be additionally
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8/23 described below, in a non-limiting manner with reference to the attached figures. The same reference characters are used to indicate similar corresponding parts in all the different figures:
[037] Figure 1A shows a top view of a first layer of molten powder;
[038] Figure 1B illustrates a first example of realization of power versus position diagram for the first and second beams;
[039] Figure 1C represents a second example of realization of the power versus position diagram for the first and second beam;
[040] Figure 2 represents a top view of a second example of an embodiment according to the present invention of a first and second layer of molten powder;
[041] Figure 3 represents an apparatus according to an embodiment of the present invention;
[042] Figure 4 represents a top view of another example of an embodiment according to the present invention of overlapping regions;
[043] Figure 5 represents a flow diagram of the method according to an embodiment of the present invention;
[044] Figures 6A-C represent a perspective view of an example of an embodiment of the present invention with two beam sources and two selected locations that are partially overlapping with each other; and [045] Figure 7 schematically represents a top view of overlapping zones of two adjacent layers and their position in relation to another.
Description of Realizations of the Invention [046] To facilitate understanding of the various realizations of the
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9/23 of the present invention, a number of terms are defined below. The terms defined in this document have meanings as generally understood by one skilled in the art in the areas relevant to the present invention. Terms such as one, one and o are not intended to refer only to a single entity, but include the general class to which a specific example can be used for illustration. The terminology is used in this document to describe the specific embodiments of the invention, but its use does not limit the invention, except as described in the claims.
[047] The term three-dimensional structures and the like, as used in this document generally refers to intentional or fabricated three-dimensional configurations (for example, of material or structural materials) that are intended to be used for a specific purpose. Such structures can, for example, be designed with the aid of a three-dimensional CAD system.
[048] The term electron beam as used in this document in various embodiments refers to any beam of charged particles. The charged particle beam sources can include an electron gun, a linear accelerator, and so on.
[049] Figure 3 depicts an example of making an additive or freely manufactured apparatus 300 in accordance with the present invention. Said apparatus 300 comprises two electron guns 301, 302; two powder funnels 306, 307; a start plate 316; an accumulation tank 312; a powder dispenser 310; a construction platform 314; a vacuum chamber 320 and a control unit 340. Figure 3 discloses only two beam sources for simplicity. Obviously, any number of beam sources can be used in a similar embodiment as the two beam sources used to describe the invention. It is obvious to a person skilled in the art after seeing the inventive concept as described in this
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10/23 document, using only two beam sources that can apply them to any specific number that can serve your purpose.
[050] The vacuum chamber 320 is capable of maintaining a vacuum environment by means of a vacuum system, this system may include a turbomolecular pump, a spiral pump (or scroll compressor), an ion pump and one or more valves which are well known to a person skilled in the art and therefore do not need further explanation in this context. The vacuum system is controlled by the control unit 340. In another embodiment, the accumulation tank can be supplied in an attachable chamber supplied with ambient air and ambient pressure. In yet another embodiment example, said accumulation chamber can be provided in an open environment.
[051] The 301, 302 electron guns are generating electron beams that are used for melting or melting powder material together 318 provided on the start plate 316. At least a portion of the 301, 302 electron guns can be supplied in the vacuum chamber 320. The control unit 340 can be used to control and manage the electron beams emitted from the 301, 302 beam electron guns. A first 301 electron beam source may be emitting a first 351 electron beam and a second electron beam source 302 may be emitting a second electron beam 352. The first electron beam 351 can be deflected between at least a first extreme position 351a and at least a second extreme position 351b that defines a first selected area 1. The second electron beam 352 can be deflected between at least one first extreme position 352a and at least one second extreme position 352b definin second selected area 2. At least one of said first or second extreme positions 351a, 351b of said first electron beam 351 can be superimposed on one of said at least first
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11/23 or second extreme positions 352a, 352b of said second electron beam 352 and thus creating an overlapping region 3.
[052] At least one focus coil (not shown), at least one deflection coil and an electron beam power source can be electrically connected to said control unit. In an example of an embodiment of the invention, said first and second electron beam source can generate a focusable electron beam with an acceleration voltage of about 60 kV and with a beam power in the range of 0-3kW. The pressure in the vacuum chamber can be in the range of 10 - ³ - 10 - ⁶ mBar during the construction of the three-dimensional article by melting the powder layer by layer with the energy beam sources 301, 302.
[053] Instead of melting the powder material with two electron beams, two or more laser beams can be used. Each laser beam can normally be deflected by one or more of a movable mirror arranged in the path of the laser beam a between the source of the laser beam and the work table on which the powder material is arranged which should be melted by the said laser beam. The control unit 340 can manage the deflection of the mirrors in order to drive the laser beam to a predetermined position on the work table.
[054] The powder funnels 306, 307 comprise the powder material to be supplied on the start plate 316 in the accumulation tank 312. The powder material can be, for example, pure metals or metal alloys, such as titanium, titanium alloys, aluminum, aluminum alloys, stainless steel, Co-Cr-W alloys and the like. Instead of two powder funnels, a powder funnel can be used. Other models and / or mechanisms for supplying powder can be used, for example, a powder container with a height-adjustable floor.
[055] The powder dispenser 310 is willing to lay a thin layer of powder material on the start plate 316. During a
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12/23 work the construction platform 314 will be lowered successively in relation to the ray gun after each additional layer of powder material. In order to make this movement possible, the construction platform 314 is, in an embodiment of the invention, movably arranged in the vertical direction, that is, in the direction indicated by the arrow P. This means that the construction platform 314 starts at a starting position, in which a first layer of powder material of the required thickness has been established on said starting plate 316. A first layer of powder material can be thicker than the other applied layers. The reason for starting with a thicker first layer than the other layers is that you do not want a melted mass of the first layer on the start plate. The construction platform is then lowered in connection with the establishment of a new layer of powder material for the formation of a new cross section of a three-dimensional article. Means for lowering and constructing platform 314 can for example be via a servomotor equipped with gear, adjusting screws and the like.
[056] A flow chart of an example of carrying out a method according to the present invention for forming a three-dimensional article through the successive fusion of parts of a powder bed, whose parts correspond to successive cross sections of the three-dimensional article, comprising a first step 502 of providing a model of said three-dimensional article. This model can be a computer generated model using a CAD (Computer Aided Design) tool.
[057] In a second step 504 a first layer of powder is provided on the start plate 316. The powder can be distributed evenly on the work table according to various methods. One way to distribute the powder is to collect the fallen material from the funnel 306, 307 by a rake system. The racket
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13/23 is moved over the accumulation tank, distributing the powder over the start plate. The distance between a lower part of the racket and the upper part of the starting plate or previous dust layer determines the thickness of the powder distributed on the starting plate. The thickness of the powder layer can be easily adjusted by adjusting the height of the construction platform 314. Instead of starting to build the three-dimensional article on said start plate, said three-dimensional article can be built on said construction platform 314 which can be removable. In yet another example of embodiment, said three-dimensional article can be started to be built on a bed of dust.
[058] In a third step 506 a first energy beam is directed from a first energy beam source on said start plate 316 or construction platform 314 causing said first powder layer to melt in the first selected location 1 according to said model to form a first cross section of said three-dimensional article 330. A first energy beam 351 can reach a predetermined area that depends on the maximum deflection angle and the distance between the beam source of energy 301 to the work table. For this reason, the first energy beam 351 can only reach a portion of the total construction area, that is, a portion of a first cross section of the three-dimensional article 330.
[059] The first 351 energy beam can be an electron beam or a laser beam. The beam is directed over said start plate 316 from instructions given by a control unit 340. In control unit 340, instructions on how to control beam source 301, 302 can be stored for each layer of the three-dimensional article .
[060] In a fourth step 508 a second energy beam 352 is directed from a second source of energy beam 302 on said start plate 316 causing said first layer of dust
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14/23 undergoes fusion at the selected location 2 according to said model to form the first cross section of said three-dimensional article 330.
[061] As with the first energy beam 351, the second energy beam 352 can also reach a predetermined area that depends on the maximum deflection angle and the distance between the energy beam source and the start plate 316 or the layer of powder to be melted. For this reason, the second energy beam 352 can reach only a portion of the total construction area, that is, a portion of a first cross section of the three-dimensional article 330.
[062] Said first and second selected locations 1, 2 of said first layer of powder are at least partially overlapping each other in the overlapping region 3. The first selected location 1 of said first layer of powder undergoes fusion with the first energy beam 351 and the second selected location 2 of said first powder layer undergoes fusion with said second energy beam 352. To make sure that the fusion is completed along a first full cross-section of said three-dimensional article, the first selected location 1 and the second selected location 2 are at least partially overlapping each other. This means that the same area (overlapping region) of the first cross section of the three-dimensional article can be fused twice, once with the first energy beam and once with the second energy beam. In another embodiment, said overlapping region can be fused simultaneously with said first and second energy beam 351,352.
[063] Figure 1A illustrates a work table or a starting plate or a bed of dust 100. A first beam of energy can reach the first selected location, called 1. A second beam of energy can reach a second location selected, called 2. The first and second selected locations can be superimposed on each other
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15/23 defining an overlapping zone indicated by 3. A length of the overlapping zone is indicated by L. The first selected location 1 can be closed on a first line 110 and the second selected location can be closed on a second line 120. A second line 120 is provided within the first selected location 1 which can be fused by the first energy beam 351 and the first line 110 is provided within the second selected location 2 which can be fused by the second energy beam 352.
[064] In an example of an embodiment of the present invention, said first and second locations 1, 2 of said first layer of powder that are at least partially superimposed on each other in the overlap zone 3 can be simultaneously fused by said first and second beam of energy 351, 352 of said first and second energy beam sources 201, 302, respectively.
[065] Simultaneous fusion by said first and second beam 351, 352 in said overlap zone 3 can be carried out in different ways.
[066] A first way is to melt or heat the powder with the first beam 351 in a first pass in said overlap zone 3 simultaneously as the second beam 352 may be melting or heating the powder in a second pass, which is separate from the said first pass. The first passage fused by said first beam can be refused by the second beam after said first beam has left said passage, that is, the first and second beams are not simultaneously in the same position at any time.
[067] A second way is to melt or heat the powder with the first and second bundles, so that said first and second bundles 351, 352 are simultaneously at least once in the same position at the same time. Figure 1B illustrates a possible way to control
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16/23 first and second beams 351, 352 when they are about to merge the same position as the overlap zone 3. The sum of the power of the first and second beams 351,352 in a region where they overlap each other can be maintained at a value constant. This means that there is no extra energy added to the melting process, nor any lack of energy in the melting process when there are two beams that are melting the powder simultaneously instead of one beam.
[068] The power of a single beam in the non-overlapping region and the power of the two beams in the overlapping region can be equal. Controlling the beam power in any position can be important for controlling the microstructure of the finished three-dimensional article. In the embodiment example in Figure 1B, energy is shown as constant throughout the first and second areas. Obviously this is just a simplification of the real case. In the real case, the beam power can change from one position to the other, in order to make sure that the construction temperature and the melting process is proceeding according to a predetermined program. In such a case, it may be important to know that the sum of the first and second bundles will be reduced to the desired value, which can be determined before the fusion process in a simulation.
[069] Figure 1B and Figures 6A-C illustrate an embodiment in which two beam sources 301, 302 are used for the fusion of a predetermined area. A first selected location 1 is merged with the first beam 351. When said first beam reaches the overlap zone 3 the second beam 352 begins to merge said overlap zone 3 simultaneously and in the same position as said first beam 351 in said overlap zone 3. As the first beam 351 continues to deviate into overlap zone 3, its power is reduced while the power of the second beam 352 is increased. The sum of the first and
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17/23 second bundles 351, 352 can be kept constant in the overlap zone 3. A second selected location 2 is merged with the second bundle 352 only. The first beam was stopped on the first line 110.
[070] Yet another example of an embodiment according to the present invention is shown in Figure 1C. In Figure 1C it is described that the first and second beams 351, 352 are each having half the power required, that is, 50% of the power required for the first beam 351 and 50% of the power required for the second beam 352. In Alternatively, these values can be divided unevenly, for example, the first beam may have 30% of the required power and the second beam may have 70% of the required energy.
[071] In an electron beam gun the quality of the beam depends on the angle of deflection. Under no or few deflection angles is the desired beam spot size more or less the size of the actual beam spot. As the deflection angle is increased, the point size tends to increase and / or the shape of the point tends to be no longer circular. As one of the beams has a deflection angle greater than a predetermined value, the beam's power can be switched from one beam to two beams. When using two beams, each with less power than would be necessary if only one beam were used in order to reach the desired beam power, the size and shape of the beam point can be controllable although the deflection angle is relatively larger . The reason for this is that a beam with a smaller beam power has a smaller spot size compared to a beam with a higher beam power. When using two low-power beams instead of one with high power, the shape and size of the combined beams in a position where at least one of the beams has a relatively high deflection angle may not be greater than a predetermined value or move in a circular way more than one value
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Predetermined 18/23. In the overlap zone there can be a first beam from a first beam source with a greater deflection angle and a second beam from a second beam source with a deflection angle less than the first beam.
[072] When using more than one energy beam source, the construction temperature of the three-dimensional construction can be maintained more easily compared to if only one beam source is used. The reason for this is that two bundles can be in more locations simultaneously than just one bundle. The increase in the number of beam sources will make the construction temperature control even easier. When using a plurality of energy beam sources a first energy beam source can be used to melt the powdered material and a second energy beam source can be used to heat the powdered material in order to maintain the temperature of construction within a predetermined temperature range.
[073] After the completion of a first layer, that is, the melting of the powder material to manufacture a first layer of the three-dimensional article, a second layer of powder is provided on the said work table 316. The second layer of powder it can be in certain realizations distributed according to the same way as the previous layer. However, there may be other methods on the same additive manufacturing machine to distribute the powder on the work table. For example, a first layer can be provided by means of a first powder distributor, a second layer can be provided by another powder distributor. The design of the powder dispenser is automatically changed according to the instructions on the control unit. A powder dispenser in the form of a single rake system, that is, where a rake is collecting dust that has fallen from the left dust funnel 306 and a right dust funnel 307, the rake as such may have its model changed.
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19/23 [074] After the distribution of the second layer of dust on the working table 316, the first energy beam 351 of the first source of energy beam 301 can be directed on said working table 316 causing said second powder layer undergoes fusion at a third location selected according to said model to form a second cross section of said three-dimensional article.
[075] Fused portions in the second layer can be connected to fused portions of said first layer. The melted portions in the first and second layer can be melted together by melting not only the powder in the top layer but also by melting at least a fraction of a layer thickness directly below said top layer.
[076] The second energy beam 352 of the second energy beam source 302 can be directed on said work table 316 causing said second layer of powder to melt in a fourth location selected according to said model for forming the second cross-section of said three-dimensional article, said third and fourth locations selected from said second layer of powder may be, at least partially overlapping each other, wherein the third and fourth locations 4,5 at least partially overlapping may be laterally displaced with respect to the first and second locations 1, 2 partially overlapping, see Figure 7. In Figure 7 it is shown that an overlapping zone 6 in the second layer is displaced laterally in relation to the overlapping zone 3 in the first layer. The displacement can be large, since the overlapping zones 3, 6 are not overlapping one another. The offset may be within a predetermined range, so that the overlapping zones still overlap with each other. The length L of the overlap zone can vary from one layer to another.
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20/23 [077] The energy beam, which can be a laser beam or an electron beam, not only melts the last layer of powder applied, but also at least the layer of material beneath the layer of resulting powder in a melt comprising the powdered material and the material already melted from a previous melting process.
[078] In yet another example of the embodiment according to the present invention, a width 190, 192 of the overlap zone can be the same in the first and second layer. In other embodiments, the length 190, 192 of the overlap zone can be different compared to the first layer for the second layer. In yet another embodiment, said length of the overlap zone is randomized between a minimum predetermined value and a maximum value for at least one layer.
[079] In yet another example of an embodiment of the present invention, the distance offset laterally from said at least partially overlapping third and fourth locations can be chosen to result in a non-overlap of at least partially overlapping third and fourth locations and the first and at least partially overlapping locations. This means that, for a first layer, the overlapping region is arranged in a first position. In the second layer the overlapping region is arranged in a second position that does not overlap with the first position in the first layer. This can improve the construction quality of the three-dimensional article since the overlap is not provided on top of each other by two adjacent layers.
[080] In yet another embodiment example the laterally offset distance from the third and fourth locations at least partially overlapping can be chosen for a value that results in an overlap of the third and fourth locations at least partially overlapping, and from the first and second locations by least partially overlapping, see Figure 2 where the
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21/23 overlap of the two adjacent layers are overlapping each other but the second layer is displaced in relation to the first layer.
[081] The distance offset laterally from said third and fourth sites at least partially overlapping can be randomized within a predetermined range.
[082] Figure 4 represents a top view of another example of an embodiment according to the present invention of overlapping regions. In Figure 4 different energy beam sources are used, each capable of melting a predetermined area of the dust layer. A first energy beam from a first energy beam source can fuse a first area called 41. A second energy beam from a second energy beam source can fuse a second area called 42. A third energy beam from a third A beam of energy source can fuse a third area called 43. A fourth beam of energy from a fourth source of energy beam can fuse a fourth area called 44.
[083] The first area 41 and the second area 42 can overlap each other in a first overlap area called 45. The first area 41 and the third area 43 can overlap each other in a third overlap area called 47. The third zone 43 and the fourth zone 44 can overlap each other in a second overlap area called 46. The fourth area 44 and the second area 42 can overlap each other in a fourth overlap zone called 48. The first, second, third and fourth areas are superimposed on each other in a fifth overlap area called 49. For example, the first overlap area 45 defines the boundaries of the first and second beams, that is, the solid line of the left end of the first overlapping area 45 defines the leftmost position of the second energy beam and the rightmost solid line of the first overlapping area defines the rightmost position the do
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22/23 first beam of energy. Within the first overlapping area the actual overlapping zone can be defined and positioned. The same applies, mutatis mutandis, to the second, third, fourth and fifth overlapping areas 46, 47, 48 and 49.
[084] In a first layer an overlapping zone 140 of the first area 41 and the second area 42 can be arranged in a first position within said overlapping area 45. In a second layer an overlapping zone 140 of the first area 41 and the second area 42 can be arranged to a second position within said overlapping area 45. The first and second positions can be partially overlapped with one another, totally overlapping one another, or else not overlapping. The first and second positions of the said overlap zone can be randomized for each layer and each overlap area. The length of the overlapping zone 140, 150, 160, 170 can be different for different overlapping regions within the same layer and can be different for the same overlapping region in different layers.
[085] In yet another example of making a device for forming a three-dimensional article by successively merging parts of a bed of dust, whose parts correspond to successive cross sections of the three-dimensional article. Said device comprises a first source of energy beam adapted to melt a first layer of powder at the first location selected according to a model, in order to form a first cross section of said three-dimensional article. Said device further comprises a second source of energy beam adapted to melt a first layer of powder at the second location selected according to said model, in order to form a first cross section of said three-dimensional article. Said device further comprising a unit
Petition 870190085097, of 08/30/2019, p. 31/36
23/23 control adapted to control said first and second energy beam sources so that said first and second locations of said first powder layer are at least partially overlapping each other.
[086] It should be understood that the present invention is not limited to the above described embodiments and many modifications are possible within the scope of the following claims. Such modifications may, for example, involve the use of a different source of energy beam than the exemplified electron beam, such as a laser beam. Additionally or otherwise, materials other than metallic powder can be used, such as the non-limiting examples of polymer powder or ceramic powder.

权利要求:
Claims (5)
[1]
Claims
1. METHOD FOR FORMING A THREE-DIMENSIONAL ARTICLE (330) by merging successive parts of a powder bed (100), parts of which correspond to successive cross sections of the three-dimensional article (330), the method characterized by comprising the steps of:
providing a three-dimensional article template (330);
applying a first layer of powder on a work table (316);
directing a first energy beam (351) from a first energy beam source (351) on the work table (316), directing the first energy beam causing the first powder layer to melt in first places selected according to the model, in order to form a first part of the first cross section of the three-dimensional article (330); and directing a second energy beam (352) from a second energy beam source (302) on the work table (316), directing the second energy beam (352) causing the second layer of powder in second locations selected according to the model, so as to form a second part of the first cross section of the three-dimensional article (330), in which the first and second locations of the first layer of powder are at least partially overlapping with each other in a first overlap zone (45), the method further comprising the steps of simultaneous melting of the first and second locations of the first layer of powder through the first and second bundles of energy (352) from the first (301) and second bundles of energy (302), respectively, overlapping a point of the first energy beam (351), at least partially, with a point of the second energy beam (352) during at least one occasion of the fusion of the first zone overlap (45),
Petition 870190085097, of 08/30/2019, p. 33/36
[2]
2/3 maintaining the sum of the power of the first (351) and second (352) beam in the first overlap zone (45) with a predetermined value, in which the individual power of each of the first (351) and second (352) beam in the first overlapping zone (45) is half that of each of the first (351) and second (352) beam outside the first overlapping zone (45) or the predetermined value is equal to the individual power of at least one of the first (351) or the second (352) beam outside the first overlapping zone (45).
2. METHOD for forming a three-dimensional article (330) by merging successive parts of a bed of dust (100), parts of which correspond to successive cross sections of the three-dimensional article (330), the method characterized by comprising the steps of:
providing a three-dimensional article template (330);
applying a first layer of powder on a work table (316);
directing a first energy beam (351) from a first energy beam source (351) on the work table (316), directing the first energy beam (351) causing the first powder layer to melt in first places selected according to the model, in order to form a first part of the first cross section of the three-dimensional article (330); and directing a second energy beam (352) from a second energy beam source (302) on the work table (316), directing the second energy beam (352) causing the second layer of powder in second locations selected according to the model, so as to form a second part of the first cross section of the three-dimensional article (330), in which the first and second locations of the first layer of powder are at least partially overlapping with each other in a first
Petition 870190085097, of 08/30/2019, p. 34/36
[3]
3/3 overlap zone (45), the method further comprising the stages of simultaneous melting of the first and second locations of the first layer of powder through the first (351) and second (352) energy bundles from the first (301) and second energy beam source (302), respectively, overlapping a point of the first energy beam (351), at least partially, with a point of the second energy beam (352) during at least one occasion of the fusion of the first overlap zone (45), power variation of the first beam (351) linearly from 100% to 0% starting from a first end of the overlap zone (45) and ending at a second end of the overlap zone (45) ; and simultaneous variation of the power of the second beam (352) linearly from 0% to 100% starting from a first end of the first overlapping zone (45) and ending at the second end of the overlapping zone (45).
METHOD, according to claim 2, characterized in that the sum of the variable power of the first (351) and the second (352) beam between the first and the second end of the overlap zone (45) is maintained at a predetermined value .
[4]
4. METHOD according to claim 3, characterized in that the predetermined value is a constant value.
[5]
5. METHOD according to claim 3, characterized in that the predetermined value is equal to the individual power of at least one of the first (351) or the second (352) beam outside the first overlapping zone (45).

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