# US 11,077,498 B2 · Method for manufacturing a component by thermal spraying

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- Number: US 11,077,498 B2
- Document ID: US11077498B2
- Status: Granted
- Kind: B2
- Application number: 15/565,974
- Filed: 2016-03-30
- Published: 2018-03-01
- Granted: 2021-08-03
- Earliest claimed: 2015-04-16
- Assignees: Siemens Aktiengesellschaft
- Applicants: Siemens Aktiengesellschaft
- Inventors: Oliver Hofacker; Ursus Krueger
- Web page: https://patentgrep.com/patent/US11077498B2

## CPC

- B22F 3/115: by spraying molten metal, i.e. spray sintering, spray casting
- B22D 23/003: {Moulding by spraying metal on a surface}
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 12/37: Rotatable
- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- C23C 24/04: Impact or kinetic deposition of particles
- B22F 12/44: characterised by the configuration of the radiation means
- B22F 12/49: Scanners
- B22F 2998/10: Processes characterised by the sequence of their steps
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- Y02P 10/25: Process efficiency
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

The present disclosure relates to manufacturing methods. The teachings thereof may be used to manufacture a component in which the component is applied by thermal spraying with a coating jet carrying building material. For example, a method for manufacturing a component may include: producing a mold for the component layer-by-layer on a building platform using a generative process incorporating data describing the mold; building the component in the mold by filling the mold with a building material using thermal spraying with a coating jet; and removing the mold from the component.

## Claims

### Claim 1

A method for manufacturing a component, the method comprising:
producing a mold for the component layer-by-layer on a horizontal building platform using a generative process incorporating data describing the mold, wherein the mold includes at sidewalls having at least a portion of non-vertical walls;
building the component in the mold by filling the mold with a building material using thermal spraying with a coating jet;
pivoting the building platform from horizontal to a different angle to change an orientation of the coating jet with respect to the sidewalls, resulting in the coating jet spraying tangentially to the non-vertical portion of the sidewalls; and
removing the mold from the component;
wherein the mold includes an interior wall surface defining a contour of the component and struts transferring forces from the interior wall to the building platform, and wherein the struts maintain the interior wall surface to eliminate distortion of the contour as the component is built.

### Claim 2 (depends on 1)

The method as claimed in claim 1, wherein the thermal spraying comprises cold-gas spraying.

### Claim 3 (depends on 1)

The method as claimed in claim 1, wherein the generative process comprises at least one of the group consisting of: selective laser melting, selective laser sintering, and selective electron-beam melting.

### Claim 4 (depends on 1)

The method as claimed in claim 1, further comprising alternating generating a layer of the mold with filling the mold with a layer of the building material.

### Claim 5 (depends on 1)

The method as claimed in claim 1, wherein the struts form a framework.

### Claim 6 (depends on 1)

The method as claimed in claim 1, further comprising applying the building material to the component on a wall surface of the mold with a direction of the coating jet that lies within a spray cone provided for the thermal spraying with respect to a surface of the component and outside the spray cone provided for the thermal spraying with respect to the wall surface.

### Claim 7 (depends on 1)

The method as claimed in claim 1, further comprising using the generative production process to produce a partial volume of the component.

### Claim 8 (depends on 1)

The method as claimed in claim 1, further comprising using the thermal spraying process to produce a partial volume of the mold.