• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The method for manufacturing a metal alloy part or metal matrix composite material is characterized in that it consists in obtaining a semi-finished part to constitute an additive manufacturing preform then forging this preform in a single step between two matrices in order to obtain the final shape of the part to be obtained.
    公开号:FR3020291A1
    申请号:FR1453875
    申请日:2014-04-29
    公开日:2015-10-30
    发明作者:Serio Emile Thomas Di；Lionel Duperray；Christophe Desrayaud
    申请人:Saint Jean Industries SAS；
    IPC主号:
    专利说明:

    [0001] The invention relates to the technical sector of the manufacture of metal parts or composite metal matrix for the particular embodiment and the manufacture of metal parts or composite metal matrix for the realization in particular of and for the production of metal parts not limited to components and equipment for the automotive and aerospace sector. Additive manufacturing which makes it possible to manufacture parts by melting or sintering of several successive layers is developing, the basic concept being defined in US Pat. No. 4,575,330 dated 1984.
    [0002] Additive manufacturing is defined by ASTM as a process for shaping a workpiece by adding material by stacking successive layers, as opposed to shaping by material removal such as machining. It is also the name given to three-dimensional printing technology. This technology has developed to make metal alloy parts by melting or sintering powder beds or by welding wires. Tests on metal matrix composite materials have shown great promise. The technologies used to cite them in a non-exhaustive way range from selective laser sintering (Sintering) to electron beam melting (Electron Beam Melting) and laser metal sintering (Sintering). laser metal deposition (Laser Metal Deposition) or laser melting (Selective Laser Melting). These technologies make it possible to manufacture parts that have a high geometric complexity with satisfactory mechanical properties at the cost of a cycle time that is often long. Indeed, for each successive layer a roller must spread the powder and the electron beam or laser must scan the entire surface of each layer to obtain good cohesion of the powder. To reduce this cycle time, the manufacturers' strategy is to increase the power and the number of beams to be able to melt or sinter each layer faster, thus driving up the price of the manufacturing machine. The metals used are mainly titanium alloys for the Electron Beam Melting technology but the technologies using the laser are more versatile. They make it possible to manufacture parts in ferrous alloys, alloys based on titanium, aluminum, cobalt-chromium, nickel ... as well as in composite materials with metallic matrix (titanium-titanium carbide, aluminum-alumina, aluminum-carbide Silicon ...) Parts from additive manufacturing, however, often have a residual microporosity. This deteriorates the mechanical properties of the parts including ductility and fatigue strength. A step of HIP (Hot Isostatic Pressing), which consists in putting under high pressure at high temperature of the workpiece, is often necessary to obtain a satisfactory fatigue resistance.
    [0003] The additive manufacturing parts also have a coarse surface roughness due to the particle size of the powder used as well as the residual trace of the various layers during additive manufacturing.
    [0004] These parts also include a foundry microstructure due to the melting of the powder during its production or during the production of the part. This structure is particularly lamellar for titanium-based alloys and does not meet most of the specifications for aeronautical structural parts. Indeed, for better mechanical properties a bimodal microstructure, both lamellar and nodular is required. This structure can be obtained for then only by hot deformation operations of the forge type, and under specific conditions of expensive implementation.
    [0005] In view of these disadvantages, the Applicant's approach was to reflect and find a solution to overcome these problems.
    [0006] In a completely independent way and without any link with additive manufacturing, the Applicant has developed since 1983, that is to say at a period corresponding to that of the aforementioned US patent a new concept combining the technologies of the foundry and forging a piece of aluminum or aluminum alloy. This technology was developed in the European patent 119365 implementing a first casting phase of a piece of aluminum or aluminum alloy in a mold to form a preform, the latter then being subjected to a forging operation in a matrix of smaller dimensions and to obtain the final form to obtain with very specific properties recalled in said patent. This so-called "poured-cast" technology is marketed under the "COBAPRESS" brand, which is now widely used worldwide.
    [0007] It is clear that since this period 1983-1984, that is to say for 30 years, the solutions made to overcome the drawbacks of additive manufacturing mentioned above are long and expensive and no solution has been found to obtain a bimodal microstructure required for the most part to aeronautical structural parts made of titanium alloy. The Applicant, faced with the problems to be solved for additive manufacturing, has found that the problem of microporosity encountered in this so-called manufacturing is also present during the manufacture of castings. The Applicant's approach was therefore oriented towards the search for an unexpected combination of the two technologies of additive manufacturing and seemingly incompatible cast-forged, since these two technologies have been known since the period 1983-1984. Quite unexpectedly, and from tests carried out by the Applicant, it appears that the combination of the two technologies is likely to meet and overcome the disadvantages found in additive manufacturing. According to the invention, the developed solution consists in obtaining a piece of metal alloy or metal matrix composite materials by additive manufacturing to form a preform, then forging this preform hot, half-hot or cold in a step between two matrices in order to obtain the final shape of the part to be obtained.
    [0008] The piece is thus obtained in its final form, which after deburring or without deburring, has the functional dimensions to meet the need without requiring additional machining other than the functional areas with restricted tolerance intervals.
    [0009] Quite unexpectedly, this method overcomes the aforementioned drawbacks and the observed limits of parts obtained by additive manufacturing.
    [0010] The forging step, which consists of a deformation of the pet material, makes it possible to close and reweld the microporosities with a homogeneous bond between the different layers of the additive structure. This gives a gain of ductility and fatigue strength.
    [0011] This forging step between two polished dies also drastically reduces the surface roughness, which improves the fatigue strength and the surface appearance. The tests carried out appear very promising. No indication of each of the technologies known since 1983-1984 could suggest their combination because the state of obtaining the preform was different, one by foundry in the technology of "cast-forged," and the other by melting or sintering of successive layers during additive manufacturing.
    [0012] In the context of the implementation of the invention, the part may be of metal alloy (steel, iron, aluminum, inconel, nickel, titanium, chromium-cobalt ...) or of metal matrix composite materials (titanium- titanium carbide, aluminum-alumina, aluminum-silicon carbide, etc.) The second step of the process according to the invention for forging the preform obtained from an additive manufacturing process can be carried out hot, at medium temperature. hot, or cold. The matrices can be, if necessary, polished.
    [0013] This stamping technology of a preform derived from additive manufacturing can also be applied to preforms which comprise non-welded or partially consolidated powder areas which will be deformed and welded during the forging step.
    [0014] The forging of powder preforms made by uni-axial or isostatic compaction is already an existing process. The technique used in the invention is innovative in the sense that the powder is trapped within the preform which has the welded periphery. The fact of not welding the entire powder allows to have a significant gain in cycle time during manufacture. Indeed, to sinter or melt the powder during additive manufacturing, the laser or the electron beam must scan the entire surface of the part for each layer. By optimally realizing the powder melting only on the outer contour of the preform, which thus consists of a solid welded shell enclosing the partially consolidated or unconsolidated powder inside, a preform in the form of solid shell filled with unwelded powder. The forge of this preform makes it possible to obtain the final piece. The welding of the powder during hot deformation is all the more effective on the preforms manufactured in EBM (Electron Beam Melting) because of a manufacturing under vacuum which makes it possible not to trap gas within the material.
    [0015] This technique also has the advantage of obtaining a fine-grained microstructure because there is no melting of the powder. Indeed, grain growth by epitaxy on the lower layer was observed during the additive manufacturing of titanium alloy. This growth results in a microstructure with rather coarse grains which is not good for the mechanical properties. Without fusion of the powder, we have a conservation of the fineness of the microstructure. The non-welded zones of the preform thus give zones with a very fine microstructure on the final part since the welding takes place in the solid phase during the forging step. This fine structure which does not have a crystallographic texture is very good for the static and cyclic mechanical properties of the part. The advantages and unexpected results in the implementation of the invention thus highlighted constitute a considerable development in the treatment of metal parts or composite metal matrix, derived from additive manufacturing. 25
    权利要求:
    Claims (7)
    [0001]
    1. A method of manufacturing a metal alloy part or metal matrix composite materials, characterized in that it consists in obtaining a semi-finished part to form a preform by additive manufacturing and forging this preform into a single step between two dies in order to obtain the final shape of the part to be obtained.
    [0002]
    2 - Process according to claim 1, characterized in that the metal alloy part is an alloy based on iron, aluminum, nickel, titanium, chromium or cobalt.
    [0003]
    3- A method according to claim 1, characterized in that the composite material part is made of titanium alloy-titanium carbide, aluminum-alumina alloy, aluminum alloy-silicon carbide.
    [0004]
    4- Process according to any one of claims 1, 2 and 3, characterized in that the forging operation of the preform obtained by additive manufacturing is obtained in mid-hot or cold or hot.
    [0005]
    5. Process according to any one of claims 1, 2, 3 and 4, characterized in that the preform contains areas where the powder is not welded or partially consolidated.
    [0006]
    6 - Process according to any one of claims 1, 2, 3 and 4, characterized in that the powder is welded only to the outer contour of the preform, the latter thus consisting of a solid welded shell trapping the powder partially consolidated or unbound inside.
    [0007]
    7 - Parts obtained according to the implementation of the method according to any one of claims 1 to 6.5
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    ES2668373T3|2018-05-17|
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    FR3020291B1|2017-04-21|
    RU2016142183A|2018-04-27|
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    CN106413946A|2017-02-15|
    JP6644007B2|2020-02-12|
    EP3137242B1|2018-04-11|
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    法律状态:
    2015-03-19| PLFP| Fee payment|Year of fee payment: 2 |
    2015-10-30| PLSC| Publication of the preliminary search report|Effective date: 20151030 |
    2016-03-23| PLFP| Fee payment|Year of fee payment: 3 |
    2017-03-22| PLFP| Fee payment|Year of fee payment: 4 |
    2018-03-22| PLFP| Fee payment|Year of fee payment: 5 |
    2020-03-19| PLFP| Fee payment|Year of fee payment: 7 |
    2021-04-30| PLFP| Fee payment|Year of fee payment: 8 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1453875A|FR3020291B1|2014-04-29|2014-04-29|METHOD FOR MANUFACTURING METAL OR METAL MATRIX COMPOSITE ARTICLES MADE OF ADDITIVE MANUFACTURING FOLLOWED BY A FORGING OPERATION OF SAID PARTS|FR1453875A| FR3020291B1|2014-04-29|2014-04-29|METHOD FOR MANUFACTURING METAL OR METAL MATRIX COMPOSITE ARTICLES MADE OF ADDITIVE MANUFACTURING FOLLOWED BY A FORGING OPERATION OF SAID PARTS|
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