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EP-4741080-A1 - IMPROVED WELDING OF CONFORMAL CHANNELS

EP4741080A1EP 4741080 A1EP4741080 A1EP 4741080A1EP-4741080-A1

Abstract

The invention provides, amongst other aspects, a device comprising a substrate; a wall which is welded onto the substrate thereby defining a channel; and a covering layer extending over the substrate and covering at least the wall, wherein the wall is prefabricated, and wherein the covering layer is integrally formed. The invention further provides, amongst other aspects, a method of manufacturing a device comprising a channel preferably the device according to the present invention, the method comprising providing a substrate; welding a wall onto the substrate for defining the channel; and depositing a covering layer covering at least the wall and extending over the substrate, wherein the wall is prefabricated, and wherein the covering layer is deposited by means of a single additive manufacturing step.

Inventors

  • ANTONISSEN, JOACHIM
  • Debel, Michiel

Assignees

  • Guaranteed

Dates

Publication Date
20260513
Application Date
20241107

Claims (15)

  1. A device (1) comprising: - a substrate (2); - a wall (3) which is welded onto the substrate (2) thereby defining a channel (7); and - a covering layer (5) extending over the substrate (2) and covering at least the wall (3), wherein the wall (3) is prefabricated, and wherein the covering layer (5) is integrally formed.
  2. The device according to claim 1, wherein the channel (7) is multi-directional and comprises twists and turns.
  3. The device according to claim 1 or claim 2, wherein the channel (7) is conformal to the contour of the substrate (2) and preferably to the contour of the covering layer (5).
  4. The device according to any one of claim 1-3, where the wall (3) is prefabricated by using high-accuracy printing.
  5. The device according to any one of claims 1-4, wherein the covering layer (5) is deposited by using high-deposition-rate printing.
  6. The device according to any one of claims 1-5, wherein the covering layer (5) extends over the substrate (2) at least two times the width of the wall (3), preferably at least three times the width of the wall (3), more preferably extending across the width of the substrate (2).
  7. The device according to any one of claims 1-6, wherein the wall (3) comprises two legs (3a), wherein each leg (3a) comprises a foot welded onto the substrate (2), wherein each leg (3a) comprises a section which tapers towards the respective foot.
  8. The device according to any one of claims 1-7, wherein at least two of the substrate, the wall, and the covering layer comprise different materials, preferably wherein all of the substrate, the wall, and the covering layer comprise different materials.
  9. The device according to any one of claims 1-8, wherein the substrate (2) comprises a first layer formed of a first material and a second layer formed of a second material atop the first layer, wherein the wall (3) is welded onto the second layer, preferably wherein the first material is a forged or cast material, and the second material is a printed material.
  10. The device according to any one of claims 1-9, further comprising a groove (6) in the substrate (2) thereby further defining the channel (7) in the substrate (2), preferably wherein the groove (6) is formed in the second layer of the substrate (2).
  11. The device according to claim 10, wherein an inner surface of the groove (6) is made of the second material, preferably, the inner surface of the channel (7) is made of the second material.
  12. The device according to claim 10 or claim 11, wherein the wall (3) is flat and flush with the substrate (2).
  13. The device according to any one of claims 1-12, wherein the channel (7) has a diameter of less than or equal to 30 mm, preferably less than or equal to 20 mm, even more preferably less than or equal to 10 mm.
  14. A method of manufacturing a device (1) comprising a channel (7), preferably the device (1) according to claims 1-13, the method comprising: - providing a substrate (2); - welding a wall (3) onto the substrate (2) for defining the channel (7); and - depositing a covering layer (5) covering at least the wall (3) and extending over the substrate (2) for obtaining the device (7), wherein the wall (3) is prefabricated, and wherein the covering layer (5) is deposited by means of a single additive manufacturing step.
  15. A kit comprising: - a substrate (2); - a wall (3) which is to be welded on the substrate (2) for defining a channel (7); and - a set of instructions and/or illustrations directing a user to weld the wall on the substrate and to integrally form a covering layer extending over the substrate and covering at least the wall.

Description

Field of the invention The present invention relates to the technical domain of additive manufacturing, such as three-dimensional (3D) printing or welding, of conformal channels. For instance, the present invention relates to a method of using additive manufacturing technologies, e.g., directed energy deposition (DED) based technologies, such as using wire, possibly in combination with powder-based technologies and/or coldspray technologies and/or other additive manufacturing technologies, to repair and/or manufacture parts, such as slow-moving parts or molds, with conformal channels. Background art Traditional mold cooling often relies on machining, such as drilling, interconnected channels into the mold and circulating a cooling fluid, such as water, through these channels. These channels are often created using conventional machining techniques, such as drilling. While effective for molds which have a simple shape, e.g., a flat surface, such an approach suffers from inherent limitations. One significant drawback is the non-uniform cooling it often produces. Circulating cooling fluid through bored channels often leads to uneven temperature distribution within the mold, thereby, resulting in undesirable effects on the part that is being molded, such as, part cycle times, part quality, and potentially even warping. Moreover, traditional methods struggle to deliver cooling fluid precisely where needed, especially near the actual molding surface of molds with complex, contoured shapes. Similarly in the application of heating, e.g., heating elements in molds where heated fluid is circulated through the channels, traditional methods struggle to deliver the heated fluid precisely where needed, especially near complex interfaces, e.g., complex interfaces of molds. Attempts have been made in the past to address these challenges through conformal cooling passages within molds. These passages are designed to closely follow the contour of the part being produced, allowing for more uniform cooling and potentially enhancing part quality. However, implementing conformal cooling in molds with intricate geometries remains a complex task, particularly when using traditional manufacturing techniques. US2019168433A1 describes welding a support into the mold structure, which can be susceptible to issues like cracking or inadequate weld adhesion between the weld support and the mold material. This can lead to potential leaks, decreased cooling efficiency, and reduced overall mold lifespan, highlighting the need for further innovation in this field. These challenges highlight the need for improved channels, improved devices comprising such channels, and improved methods of manufacturing such channels that can overcome these limitations. The present invention aims at addressing issues, such as the issues mentioned above. Summary of the invention According to a first aspect, the present invention provides a device comprising a substrate; a wall which is attached, e.g., welded or adhered, onto the substrate thereby defining a channel; and a covering layer extending over the substrate and covering at least the wall, wherein the wall is prefabricated, and wherein the covering layer is integrally formed. The prior art, such as US2019168433A1, describes creating an open channel in a molding surface of the mold, receiving a weld support in the channel, and filling a cavity defined by the weld support and the molding surface. However, US2019168433A1 does not disclose welding a wall onto the substrate (i.e., on the outer surface of the substrate). Furthermore, US2019168433A1 does not disclose a covering layer which extends over the substrate and covering at least the wall, and which is integrally formed. Therefore, in US2019168433A1, the created open channel adds complexity to welding of the weld support. The lateral walls in the open channel increase the difficulty of welding the weld support in a robust manner, leaving the weld support prone to fatigue and cracks, particularly at the welding of the weld support to the lateral walls. This is particularly due to the weld support being subjected to prolonged heating at high temperatures and simultaneously to cooling fluids. Additionally, cyclical mechanical loads resulting from frequent opening/closing and/or pressurizing of molds can result in fatigue. Furthermore, the filled cavity, particularly at the initiation sites (e.g., the weld beads in contact with the weld support) are also prone to propagation and fatigue, eventually leading to cracks. This is particularly due to the weld support being subjected to prolonged heating at high temperatures and fluctuations of temperatures caused by the cooling fluid. Thus, the invention may advantageously provide a more effective and robust device with channels. By comprising a prefabricated wall which may be attached, e.g., welded, onto the substrate and by comprising a covering layer extending over the substrate and covering at least the wall,