CN108472727A - 用于生产增材制造的金属基复合材料的装置和方法及其制品 - Google Patents

用于生产增材制造的金属基复合材料的装置和方法及其制品 Download PDF

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CN108472727A
CN108472727A CN201680078140.8A CN201680078140A CN108472727A CN 108472727 A CN108472727 A CN 108472727A CN 201680078140 A CN201680078140 A CN 201680078140A CN 108472727 A CN108472727 A CN 108472727A
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metal
powder
product
powdered
equipment
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R·史瓦兹
J·巴比伦
B·克里斯特
E·戈尔
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Inpaserber objects
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Thurber's Objects LLC
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Priority to CN202410180494.XA priority Critical patent/CN118023550A/zh
Publication of CN108472727A publication Critical patent/CN108472727A/zh
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    • B22F10/20—Direct sintering or melting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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    • C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
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    • B22F7/04—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal
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Abstract

一种应用基于复合材料的增材制造(CBAM)方法来生产金属形式以及金属纤维混合物或复合材料形式的物体的方法、产品、设备和制品。该方法具有许多优点，包括能够比诸如铣削和铸造的常规方法生产更复杂的几何形状，改进的材料性能，更高的生产率以及排除复杂的夹具、复杂的工具路径和工具更换，以及在铸造的情况下，对模式和工具的需要。该方法通过以下方式来工作：将3D模型切片；基于模型对于每个层将流体选择性打印到基底材料片材上；使打印区域中流体所附着的粉末金属溢流到基底上；夹紧和对齐涂覆的片材堆叠；将堆叠的片材加热以熔化粉末金属并熔合基底层，并去除过量的粉末和未熔合的基底。

Description

用于生产增材制造的金属基复合材料的装置和方法及其制品
本申请要求2015年11月17日提交的美国临时申请号62/256,436的权益。该申请以引用方式并入以下申请(包括其附图)：申请号US 61/528,537；PCT/US12/52946；US 13/582,939；EP20120828967；US 61/769,724；PCT/US14/18806；US 14/835,685；US 14/835,690；US 14/835,697；US 14/703,372；US 62/243,590；US 61/773,810；US 14/199,603；US61/914,613；和US 14/566,661。
技术领域
本发明大体上涉及三维制造。
发明背景
标题为"Methods and Apparatus for Three-Dimensional Composites"的国际公开号WO 2014/134224 A2(对应于申请号PCT/US14/18806)(以及申请号US 61/528,537；PCT/US12/52946；US 13/582,939；EP20120828967；US 61/769,724；US 14/835,685；US 14/835,690；US 14/835,697；US 14/703,372；US 62/243,590)描述了一种用于生产三维物体的称为"基于复合材料的增材制造"或CBAM的"分层"方法和设备，所述方法通常使用基底(通常为纤维基底和聚合物)生产三维物体。本发明参考国际公开号WO 2014/134224 A2，并且描述了将国际公开中描述的技术与金属一起使用。
发明内容
国际公开号WO 2014/134224 A2中描述的CBAM方法扩展了可以与3D打印一起使用以生产三维物体的材料的范围。直到最近，该技术的工作集中在使用各种基底，包括尤其是碳纤维、基于聚合物的材料和天然纤维以及各种聚合物作为粘合剂。本申请描述了应用CBAM方法和设备生产金属形式、金属纤维混合物或复合材料形式的物体。本申请还描述了其制品。
这种方法具有许多优点，包括：能够比诸如铣削和铸造的常规方法生产更复杂几何形状；与常规金属相比改进的材料性能；更高的生产率；排除复杂的夹具、复杂的工具路径和工具更换；以及在铸造的情况下，对模式和工具的需要。
附图简述
图1是通过本申请中描述的方法制成的金属片。
图2是说明根据本发明的教导生产3D金属物体的步骤的流程图。
图3示出了在本发明的说明性实施中用于选择性沉积液体(粉末附着于其上)的设备。
图4是在本发明的说明性实施中处理器的高级框图
图5示出了已经在其中放置了许多基底片(层)之后的压缩装置，在压缩装置中的一个基底片在另一个基底片之上。通过将压缩装置的对准销分别插入每个片的对准孔中来将片对齐。
图6示出了已经其中插入具有环状圆环的所有"切片"的基底层之后的压缩装置。压缩装置中的弹簧将基底层压在一起。
图7是示出控制用于制造3D物体的设备的多个组件的处理器的框图。
具体实施方式
技术的输出
图1是通过本申请中描述的方法制成的金属片100。下面详细描述制造这种金属片的方法。
技术说明
图2是说明根据本发明的教导生产3D金属物体的步骤的流程图：
1.如(国际公开号WO 2014/134224 A2，0055；还参见美国申请号US 61/528,537和US 61/769,724)所描述，通过使用像Netfabb这样的切片机程序生成被切成层(步骤104)的CAD模型(步骤102)。每个切片还包括对准孔，该对准孔将用于精确地将完成物体内的每个打印基底层定向(国际公开号WO 2014/134224 A2，00121)。
2.将切片机的输出(例如可以是位图文件)发送到喷墨打印机(步骤106)。对于每个层，打印机将流体选择性打印到基底材料片材上(步骤108)(国际公开号WO 2014/134224A2，00113)。流体可以是液体形式的粘合剂本身；或者它可以是粉末粘合剂所附着的液体。基底可以包括纤维玻璃、高温玻璃纤维、硼纤维或碳纤维。
3.如果使用粉末粘合剂，则使它溢流到打印基底上(国际公开号WO 2014/134224A2，0059)。粉末附着在打印区域。过量的粉末通过气流、真空、振动或其他机械手段去除。
4.基底的涂覆片材以按压或夹紧方式堆叠(步骤110)(国际公开号WO 2014/134224 A2，00124)，使用每个层的对准孔使堆叠内每个片材的打印部分对齐(国际公开号WO 2014/134224 A2，00106)。
5.然后将聚集的片材在炉中加热并可能压缩以熔化粘合材料并熔合基底层以形成3D物体(步骤112)(国际公开号WO 2014/134224 A2，00149)。
6.然后通常通过喷砂材料或化学手段去除3D物体周围的未熔合基底(步骤114)(国际公开号WO 2014/134224 A2，0081)。
金属与技术一起使用的问题
已经发现金属可以与这种技术一起使用。在一个实例中，所使用的基底是无纺碳纤维面纱，诸如可从Hollingsworth and Vose获得。也可以使用已经金属涂覆的面纱。使用例如具有主要为去离子水、吡咯烷酮和醇的溶液的HP45热喷墨头，在喷墨打印机上如上所描述打印面纱或基底。溶液可以具有抗蒸发剂，包括二醇和吡咯烷酮。将流体打印在将成为物体一部分的基底区域上，即，打印区域对应于物体的层形状。如前面的应用中所述，这是针对每个层完成的。每个层都充溢金属粉末，例如焊料粉末。过量的粉末通过机械、真空、振动或压缩空气或这些方法的组合去除。这使得焊料粉末选择性沉积。在这种方法中使用金属粉末的问题之一是粉末氧化，因此当加热到其熔点时，粉末颗粒将不会很好地熔合在一起。这个问题有很多解决方案，其中一种解决方案是将金属粉末与充当还原剂的粉末助焊剂诸如松香混合。典型的助焊剂与金属粉末的比为约50/50。另一种方法是将粉末在还原、真空和/或惰性气氛炉中熔化。以这种方式，可以使用其他金属或合金，例如铝、钢、不锈钢、铜、黄铜和钛等等。另外，液体助焊剂可以用作打印流体或与打印流体结合使用，通过诸如喷墨打印的选择性沉积方法。
例如，可以在金属粉末沉积在基底上之前使金属粉末与粉末助焊剂混合。然后如先前申请中所述将物体的所有层打印并以对准方式堆叠。如先前申请中所述将它们压缩和加热。加热温度升高到粉末的熔点。各层熔合在一起并产生构建块。在将构建块从压缩夹具上移除之后，对构建块进行喷砂，并且喷砂掉没有粉末附着的区域，即，没有涂覆金属的物体部分，未涂覆的碳纤维非常易碎。剩下的是由CAD模型表示的部分的三维碳纤维金属复合材料。
图3示出了在本发明的说明性实施中用于选择性沉积液体(粉末附着于其上)的设备。对准引导销501穿过基底层503插入以便适当地对齐基底层503。电磁阀或喷墨头或头505用于通过喷嘴509将液体从贮液器507选择性分配到基底层503上。喷嘴509在平行于基底层503并位于基底层503之上的2D平面510中被光栅化，使得液体选择性地沉积在基底层503的期望的x、y坐标处，并且不沉积在基底层503的其他区域中。为了实现这种光栅化，步进电机511致动两个皮带(未示出)，该皮带使得支撑构件(未示出)在平行于x轴的方向沿着两个轨道(未示出)移动。第二步进电机(未示出)和第三皮带(未示出)安装在支撑构件上，并且用于使喷嘴支撑件(未示出)在平行于y轴的方向上移动。喷嘴509附接到喷嘴支撑件上。两个步进电机一起可以将喷嘴509移动到基底层上方的任何期望的x、y坐标。也可以使用页宽头。微处理器513控制步进电机和电磁阀或喷墨头，由此控制在基底层503上何时和何处分配液体。或者，除了以逐行模式的光栅化外，步进电机可以使一个或多个喷嘴509在2D平面中以其他2D模式移动，以使液体沉积在某些x、y坐标处。图2没有示出用于加热和按压多层基底或用于去除过量基底的装置。在一些实施中，在这些步骤发生之前将基底层移动到不同的位置。
图4是本发明说明性实施中处理器的高级框图。使用远程处理器601创建STL文件格式的期望3D物体的CAD模型。这种处理器601使用软件(诸如Netfabb.RTM.Studio软件)创建机器特定的构建文件。机器特定的构建文件被输出到第二处理器603。取决于特定的实施，这种第二处理器控制操作，包括以下装置的移动：(1)选择性地沉积液体的喷墨头或其他装置，(2)振动槽(和/或压缩空气)，其将基底上的粉末展开，然后去除过量的粉末。或者，本发明可以用处理器的其他配置来实现。例如，可以使用多于一个的远程处理器和多于一个的板载处理器，并且任何上述任务可以由这些不同处理器中的一个或多个处理。
图5示出了已经在其中放置了许多基底层(例如801)之后的压缩装置803，一个基底层依序在另一个基底层之上。
图6示出了在压缩装置903中被压缩的基底层。压缩装置中的螺钉905、907、909、911，板913、915和弹簧917用于施加压力。
图7是可以在本发明中使用的一些硬件的高级框图。一个或多个处理器1301控制敷料器1303、加热元件1305、致动器1307、人造压力源1309和液体容器中的搅拌器1311。敷料器1303将粉末沉积在基底层的正区域而不是负区域中。加热元件1305将粉末转变成流动随后硬化的材料。得到的硬化材料以渗透基底层的空间模式布置。人造压力源1309可以包括用于压缩基底层的压机、夹具、弹簧、弹性元件或其他装置。搅拌器可以用来搅拌用于去除过量基底的液体。

Claims (53)

1.一种用于生产物体的方法，其包括
获取3D物体的图层文件；
对于每个层，将流体选择性打印到基底材料片材上；
使附着在所述选择性打印的流体上的粉末金属溢流到所述基底上；
去除过量的粉末；和
将多个片材以堆叠对准方式加热和压缩以熔化所述粉末金属并熔合所述基底层。
2.如权利要求1所述的方法，其还包括去除所述基底片材的未熔合材料。
3.如权利要求1所述的方法，其中对准孔用于以对准方式堆叠所述片材。
4.如权利要求1所述的方法，其中所述基底材料包括纤维玻璃、高温玻璃纤维、硼纤维或碳纤维。
5.如权利要求1所述的方法，其中所述粉末金属是焊料粉末。
6.如权利要求1所述的方法，其中所述粉末金属是铝、钢铜黄铜钛或其他金属或合金。
7.如权利要求1所述的方法，其中所述过量的粉末通过气流、真空、振动或其他机械手段去除。
8.如权利要求1所述的方法，其中将所述粉末金属与充当还原剂的粉末助焊剂混合。
9.如权利要求1所述的方法，其中使所述粉末金属在还原气氛、真空或惰性气氛炉中熔化。
10.如权利要求1所述的方法，其中将所述加热温度升高到所述粉末的熔点。
11.如权利要求2所述的方法，其中未熔化的基底通过用磨料鼓风或化学手段去除。
12.如权利要求1所述的方法，其中所述基底材料是无纺碳纤维面纱。
13.如权利要求1所述的方法，其中所述基底材料是金属涂覆的面纱。
14.如权利要求1所述的方法，其中所述打印使用具有主要为去离子水、吡咯烷酮和醇的溶液的喷墨头进行。
15.如权利要求14所述的方法，其中所述溶液具有选自二醇和吡咯烷酮的抗蒸发剂。
16.一种由方法生产的产品，所述方法包括：
获取3D物体的图层文件；
对于每个层，将流体选择性打印到基底材料片材上；
使附着在所述选择性打印的流体上的粉末金属溢流到所述基底上；
去除过量的粉末；和
将所述片材以堆叠对准方式加热和压缩以熔化所述粉末金属并熔合所述基底层。
17.如权利要求16所述的产品，其中所述方法还包括去除所述基底片材的未熔合材料。
18.如权利要求16所述的产品，其中对准孔用于以对准方式堆叠所述片材。
19.如权利要求16所述的产品，其中所述基底材料包括纤维玻璃、高温玻璃纤维、硼纤维或碳纤维。
20.如权利要求16所述的产品，其中所述粉末金属是焊料粉末。
21.如权利要求16所述的产品，其中所述粉末金属是铝、钢铜黄铜钛或其他金属或合金。
22.如权利要求16所述的产品，其中所述过量的粉末通过气流、真空、振动或其他机械手段去除。
23.如权利要求16所述的产品，其中所述粉末金属与充当还原剂的粉末助焊剂混合。
24.如权利要求16所述的产品，其中使所述粉末金属在还原气氛、真空或惰性气氛炉中熔化。
25.如权利要求16所述的产品，其中将所述加热温度升高到所述粉末的熔点。
26.如权利要求16所述的产品，其中未熔化的基底通过用磨料鼓风或化学手段来去除。
27.如权利要求16所述的产品，其中所述基底材料是无纺碳纤维面纱。
28.如权利要求16所述的产品，其中所述基底材料是金属涂覆的面纱。
29.如权利要求16所述的产品，其中所述打印使用具有主要为去离子水、吡咯烷酮和醇的溶液的喷墨头进行。
30.如权利要求29所述的产品，其中所述溶液具有选自二醇和吡咯烷酮的抗蒸发剂。
31.一种用于生产物体的设备，其包括：
喷墨打印机，其用于获取3D物体的图层文件，并且对于每个层，将流体选择性地打印到基底材料片材上；
敷料器，其用于将附着在所述选择性打印的流体上的粉末金属溢流到所述基底上；
去除过量粉末的去除装置；以及
加热和压缩设备，用于将片材以堆叠对准方式加热和压缩以熔化所述粉末金属并熔合所述基底层。
32.如权利要求31所述的设备，其还包括去除装置以去除所述基底片材的未熔合材料。
33.如权利要求31所述的设备，其中所述基底材料包括纤维玻璃、高温玻璃纤维、硼纤维或碳纤维。
34.如权利要求31所述的设备，其中所述粉末金属是焊料粉末。
35.如权利要求31所述的设备，其中所述粉末金属是铝、钢铜黄铜钛或其他金属或合金。
36.如权利要求31所述的设备，其中所述过量的粉末通过气流、真空、振动或其他机械手段去除。
37.如权利要求31所述的设备，其中所述粉末金属与充当还原剂的粉末助焊剂混合。
38.如权利要求31所述的设备，其中使所述粉末金属在还原气氛、真空或惰性气氛炉中熔化。
39.如权利要求31所述的设备，其中将所述加热温度升高到所述粉末的熔点。
40.如权利要求31所述的设备，其中未熔化的基底通过用磨料鼓风或化学手段来去除。
41.如权利要求31所述的设备，其中所述基底材料是无纺碳纤维面纱。
42.如权利要求31所述的设备，其中所述基底材料是金属涂覆的面纱。
43.如权利要求31所述的设备，其中所述打印使用具有主要为去离子水、吡咯烷酮和醇的溶液的喷墨头进行。
44.如权利要求43所述的设备，其中所述溶液具有选自二醇和吡咯烷酮的抗蒸发剂。
45.一种三维制品，其包括多个由硬化金属材料渗透或涂覆并由硬化金属材料粘合在一起的基底层，其中每个基底层均为片状结构，所述片状结构为基本上平面或平坦的并且由可以被磨蚀、喷砂或化学去除的材料制成，并且其中基底层材料选自碳纤维、陶瓷纤维、聚合物纤维、玻璃纤维和金属纤维。
46.如权利要求45所述的制品，其中所述硬化材料表现出一组一种或多种特征，该组特征足以辨别由于已经将粉末定位在所述基底层上然后至少部分软化随后硬化而已经形成的硬化材料。
47.如权利要求45所述的制品，其中所述金属材料是合金。
48.如权利要求45所述的制品，其中所述金属材料包含铁氧体或金属颗粒。
49.如权利要求45所述的三维制品，其中所述物品具有不同取向的多个三维角度、曲线或平面。
50.一种三维制品，其包括多个由硬化金属材料渗透或涂覆并由硬化金属材料粘合在一起的基底层，其中每个基底层均为片状结构，所述片状结构为基本上平面或平坦的并且由可以被磨蚀、喷砂或化学去除的材料制成，并且其中所述硬化材料表现出一组一种或多种特征，该组特征足以辨别由于已经将粉末定位在所述基底层上然后至少部分软化随后硬化而已经形成的硬化材料。
51.如权利要求50所述的三维制品，其中所述物品具有不同取向的多个三维角度、曲线或平面。
52.如权利要求50所述的三维制品，其中所述基底层材料选自碳纤维、陶瓷纤维、聚合物纤维、玻璃纤维和金属纤维。
53.如权利要求50所述的三维制品，其中所述粉末由一种或多种金属制成。
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US11674207B2 (en) 2023-06-13
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US20170291223A1 (en) 2017-10-12
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