CN102470439A - 制造三维物体的方法和设备 - Google Patents
制造三维物体的方法和设备 Download PDFInfo
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Abstract
本发明涉及一种使用粉状物料(7)来逐层地制造三维物体(6)的方法,通过用高能射束(4)照射粉状物料能使其固化,其中,本方法包括以下步骤:将第一粉状物料层施加到工作区域(5)上;通过用高能射束照射第一层而使所述第一层的一部分固化;以及将第二粉状物料层(8)施加到部分固化的第一层上。本发明的特征在于,本方法包括以下步骤:确定施加到第一层上之后的第二层(8)的温度上升的速率。本发明还涉及一种构造成根据以上方法运作的设备。
Description
技术领域
本发明涉及一种使用粉状物料(powdery material)来逐层地(layer bylayer)制造三维物体的方法和设备,通过用高能射束照射所述粉状物料能使其固化。
背景技术
从例如US 4863538、US 5647931和WO 2004/056511中获知了使用粉状物料来逐层地制造三维物体的装置,通过用电磁照射或电子束照射所述粉状物料可使其固化。这种装置包括例如粉末供给装置(supply of power)、用于将一粉末层施加到工作台的工作区域上的装置、以及用于将射束引导到工作区域上的装置。随着射束在工作区域上移动或扫过,使粉末烧结或熔化并固化。
为了产品质量,将所施加的粉末层均匀地分配到工作区域上并适当地限定层厚度以使其对应于一预定值是重要的。此外,为了保持尽可能高的生产率,快速地施加该层是有利的。
传统上,粉末施加装置包括进料件和分配件,其中,进料件将一定量的粉末从粉末供给装置传送至分配件,分配件又将粉末分配到工作区域上。WO 2006/121374公开了另一种变型,其中,布置有分配耙,以便可朝着粉末供给装置移动一定距离而进入到粉末供给装置中,从而既作为进料件又作为分配件。
为了确保质量,并为了使在粉末分配不正确的情况下重新施加一粉末层成为可能,将期望确定已施加到工作区域上的粉末层的厚度和均匀性。然而,无论使用的是哪种类型的粉末施加装置,如何以简单且有效的方式来进行这项工作都是不明显的。因此,通常已将重点放在提高粉末施加系统的可靠性上。
US 2002/0104973中公开了一种用于监控选择性沉积造型(SDM)设备中的层的表面高度/厚度的系统的实例。该系统使用光源,诸如激光,所述光源朝着未固化建造材料层向下引导光束。相对于光源成一角度地布置的光检测器检测来自未固化层的表面和下面的固化层的表面的散射光。于是借助于三角测量来计算未固化层的厚度。所述应用使用液体建造材料。尽管所公开的系统在某些情况下能很好地工作,但在使用非透明建造材料(诸如金属粉末)时,该系统将不能适当地工作。此外,该系统需要额外的装置,将这些装置安装在某些类型的设备中是困难的且昂贵的。
因此,仍需要一种用于检查已施加到工作区域上的粉末层的厚度和分配的系统/方法,特别是在使用金属粉末的情况下。
发明内容
本发明的一个目的在于,提供一种与常规的方法相比在层厚度确定上表现出改进的特性的方法。此目的通过由独立权利要求1和9中所包含的技术特征所限定的方法及对应的设备来实现。从属权利要求包含本发明的有利实施例、其他改良和变型。
本发明涉及一种使用粉状物料来逐层地制造三维物体的方法,通过用高能射束照射所述粉状物料能使其固化,所述方法包括以下步骤:将第一粉状物料层施加到工作区域上;通过用高能射束照射第一层而使所述第一层的一部分固化;以及将第二粉状物料层施加到部分固化的第一层上。
本发明方法的特征在于,其包括以下步骤:确定施加到第一层上之后的第二层的温度上升的速率。
由于与较薄的层相比设置在热表面上的较厚的层以较慢的速率变热,因此至少在层表面温度上,可使温度上升速率与层厚度有关。因此,本发明方法使得可通过确定温度变化的速率来确定层厚度。
施加到工作区域上的粉末层通常由于来自定位在下方的热的部分固化的层的相对快的传热而相对快地变热。众所周知,使用温度感测装置(诸如温度记录(IR)照相机或高温计)来测量所施加的粉末层的表面的温度。然而,这些测量通常为了检查固化之前的温度而进行,并与温度曲线已稳定时(即所施加的粉末层的温度已达到和超过最高温度时)的时间点有关。与这种常规的测量相比,本发明方法涉及温度曲线已稳定之前的粉末物料层的温度上升的速率。
温度上升速率能以几种方式来表示。通常,位于所施加的粉末层的表面处的一定位置中的温度取决于自那个位置处的粉末的施加以来所流逝的时间。另外,一定位置中的温度上升速率(或者导数dT/dt)通常将随着时间而下降,并渐近地接近零(由于驱动力(即温差),因此随着时间下降)。表示所确定的温度上升速率的一个实例用于说明其与从粉末的施加(在特定位置中)至达到最高温度(在相同的位置中)时的时间点的时间段的长度相对应。另一实例用于确定一定时间点处的实际温度上升率。又一实例用于为测得的取决于温度的时间的数据拟合一数学函数,并从该函数拟合产生与温度上升速率相对应的参数。无论怎样表示所确定的温度上升速率,其都与层厚度有关。
在本发明的一实施列中,本方法包括以下步骤:使用温度感测装置测量所述第二层的至少一个位置中的温度。这是一种获得用于进行本发明方法的数据的适当方式。此外,在许多情况下,温度感测装置(诸如温度记录照相机或高温计)已经形成用于本文中所论述的三维物体的这类制造的设备的一部分。
优选地,测量温度的步骤包括以下步骤:在所述第二层的相同的至少一个位置中执行多次相继的温度测量,其中,在第二层已达到最高温度之前,进行所述多次测量。这意味着,在第二层的温度上升的时间段内,以获得了温度(作为时间的函数)的数据系列。这种数据系列对于确定温度上升速率是非常有用的。
在本发明的再一实施例中,本方法包括以下步骤:测量所述第二层的多个位置中的温度,其中,在第二层上分配所述多个位置。从而,变得可确定第二层的较大部分(优选地是这个层)上的温度上升速率,这又使得可确定该层是否均匀地分配。
在本发明的再一实施例中,温度感测装置是温度记录照相机,优选地使所述温度记录照相机对准第二层的上表面。
在本发明的再一实施例中,本方法包括以下步骤:将所确定的温度上升速率与一个或几个参考值相比较。这种比较能用来确定温度上升速率且因此粉末层的厚度是否处于一定可接受的区间内。这种比较还能用来确定实际层厚度。
在本发明的再一实施例中,本方法包括以下步骤:为从所述多次相继的温度测量获得的数据拟合一数学函数。这是一种处理测得的数据的有效方式,再者,拟合的函数(即拟合的参数)对于确定温度上升速率是有用的。优选地,用于拟合的函数是恰当的用于温度平衡(涉及来自下层的热传导和来自第二上层的热辐射)的理论函数。
本发明还涉及一种使用粉状物料来逐层地制造三维物体的设备,通过用高能射束照射所述粉状物料能使其固化,本设备构造成根据以上方法运作。
附图说明
下文中参照下图给出对本发明的描述,图中:
图1以示意图示出了适用于执行本发明方法的设备,
图2示出了“薄的”粉末层的测得的并拟合(fit)的温度数据的一示意性实例,
图3示出了“厚的”粉末层的测得的并拟合的温度数据的一示意性实例。
具体实施方式
图1以示意图示出了一种使用粉状物料来逐层地制造三维物体6的发明设备1的一优选实施例,通过用能量射束照射所述粉状物料可使其固化。所述设备1适用于应用本发明方法。设备1包括能够在真空室2中产生电子束的电子枪3。粉末层7(即设置在彼此的顶部上的多个部分固化层)定位在一个高度可调的工作台9上。粉末(其在该实例中由金属材料制成)来自粉末供给装置(未示出),并使用粉末分配件12逐层地施加到工作台9上。粉末层(powder bed)7的上部形成工作区域5,电子束4在照射过程中在所述工作区域上扫过。在施加到工作区域上5的第一上粉末层的所选部分的照射并熔合到一起之后,将第二新粉末层8分配到位于粉末层7的顶部上的工作区域5上。对于本领域技术人员而言,这些部分、以及如何控制电子枪3、如何在室2中建立真空等等是众所周知的。
本发明设备1进一步包括数字温度记录照相机14(有时也被称作例如“IR照相机”)形式的温度感测装置,所述温度感测装置以位于工作区域5上方一定高度处且位于所述工作区域一侧的方式定位在室2的外部,并成一角度地向下对准(direct towards)工作区域5(即对准最上面的粉末层的上表面)。能透过相关照射波长的窗15定位在室2的壁中,以允许照相机14感测工作区域5的温度。照相机14电子地连接至控制单元11,所述控制单元又出于控制的目的而电子地连接至例如电子枪3和驱动粉末分配件12的装置。电子连接用虚线13表示。为了减小照相机14与工作区域5之间的角度,照相机14和窗15能改为布置在室2的上侧、距电子枪3的一侧一定距离处。
通过控制单元11处理并分析来自温度记录照相机14的信号。温度记录照相机以及通过这类照相机对所生成的信号的处理/分析是众所周知的,并在此不做详细描述。可能会提到,信号处理可在照相机14自身中完成,或者在连接至照相机14和/或控制单元11的辅助单元中完成。还可能会提到,在此所述的这类现有技术设备的至少一部分装配有温度感测装置,例如温度记录照相机。然而,已出于其他目的而使用了现有技术设备的温度感测装置。
当已将第二新粉末层8施加到先前已施加到工作区域5上的部分固化的第一粉末层上时,在本发明方法中,使用温度记录照相机14来确定施加到第一层上之后的第二层8的温度上升的速率。这用来检查第二层的厚度和均匀性。
本发明方法的一优选实施例包括以下步骤:
A)在第二层8的多个位置中执行多次相继的温度测量,其中,在第二层8的温度已达到最高温度T1(参见下文)之前,完成所述多次测量,并且其中,在第二层8上分配所述多个位置。
B)为从步骤A得到的数据拟合数学函数,其中,为第二层8的所述多个位置中的每个位置拟合一个函数。
C)使用来自步骤B的结果确定所述多个位置中的每个位置的温度上升速率。
D)储存所确定的温度上升速率。
E)将每个所确定的温度上升速率与一个或几个参考值相比较。
F)在任何所确定的温度上升速率都低于或高于一设定值的情况下,将粉状物料层重新施加到工作区域5上。
通过受控制单元11控制的温度记录照相机14来进行步骤A中的测量。使照相机14对准第二层8的上表面,这意味着所述照相机原则上可记录第二层8的表面温度(即使从略微定位在该表面下方的物料发出的热也可达到照相机14)。照相机14的位置和方向还意味着上面的步骤A中所称的“位置”原则上是侧向平面(即第二层8的上表面的一部分)中的二维区域单位。每个“位置”的大小能改变,并取决于例如照相机14的分辨率(像素的个数)、照相机14与第二层8之间的距离、以及用于每个“位置”的像素的个数。
将照相机14控制成,对于所有位置,进行分配在由于来自下方的层的热传导而加热第二层8的时间段内的一系列温度测量。经过一段时间,第二层8(第二层的表面)达到最高温度T1(参见图2和图3)。大体上,在该时间点处,从下方的层传导热的速率等于从第二层8的上表面辐射热的速率。在那个点之后,第二层8的温度下降(以中等速率)。
在粉末的施加之后,由于温度上升速率随着时间而下降并且由于达到最高温度的时间相当短(对于上述装置而言,典型地在1秒左右),因此应尽快开始相继的温度测量。由于粉末分配件12在工作区域5上从一侧移动至另一侧,因此将粉末层8施加到工作区域5上的时间点根据层8的位置而改变。因此,在将第二层8施加到一特定位置中之后,应尽快开始第二层8的那个特定位置中的相继的温度测量。优选地,在第二层8已达到其最高温度之时或之后,也进行了大量的温度测量。
照相机14在粉末分配件12移动时也记录数据。这意味着,在粉末施加之后,能使用于恰好在件12后方的位置处所“观看到”的像素来立刻(在0.1秒左右之内)获得测量数据。
在第二层8已达到最高温度T1之前在每个位置中所进行的多次相继的温度测量包括至少两次温度测量。从这两个数据点,能估计出温度上升速率,特别是如果还获得了在第二层8已达到其最高温度之时和/或之后的至少一个另外的数据点。然而,由于温度上升速率是非线性的,因此推荐在第二层8已达到最高温度T1之前执行至少三次温度测量。原则上,数据点(即温度测量)的个数越多,函数拟合就越好。已证明10Hz(即每0.1秒一次测量)左右的测量频率工作良好。
对于本领域技术人员而言,数据点的数学函数的拟合是众所周知的。尽管标准参数拟合(y=a0+a1x+a2x2+...+anxn)或许能用在本情况中,但优选地通过使用适当的用于温度平衡(涉及来自下层的热传导和来自第二上层的热辐射)的理论函数来进行拟合。这种理论函数能包含例如以下参数:层厚度、粉状物料的物料特征、粉末粒度分配。使用适当的理论函数的优点之一在于,所得到的层厚度由相关的物理关系而来。
表达“(数学)函数的拟合”被认为是还覆盖了仅有两个数据点可用的情况(在这种情况下,为两个点“拟合”一直线或曲线)。
对分配在第二层8上的所有位置进行在步骤A中获得的测量数据的分析。由于位置的适当分配,这提供了关于整个层8上的温度上升速率的信息。
在函数的拟合之后的步骤中,确定每个所述位置的温度上升速率。该步骤可被视为是拟合步骤的一部分。典型地,在拟合步骤中确定一参数,所述参数代表温度上升速率。该速率又直接与第二粉末层8的厚度有关。
所确定的温度上升速率的存储(例如存储在连接至控制单元11的存储器中)不但对于使数据可用于计算和比较是有用的,而且为了确保质量也是有用的。例如,如果通过本发明方法制造的物体在使用过程中在一定程度上损坏,那么其可有助于回到生产数据,并查明粉末层的厚度和/或均匀性是否已被修正。在制造之后,当层厚度测量不满足预定的质量值时,也可丢掉这种所制造的物体。
在接下来的步骤中,将每个所确定的温度上升速率与一个或几个参考值相比较。如果任何所确定的速率(或以已知方式与对应的速率有关的另一参数)都低于或高于一设定值,那么在该步骤之后是将粉状物料层重新施加到工作区域5上的步骤。这意味着如果第二层例如没有充分均匀地分配在工作区域上,那么粉末分配件12将用另一粉状物料层来对此进行补充。
图2示出了“薄的”第二粉末层8(或者第二层中的这样的位置,即,在该位置中,该层是“薄的”)的测得的并拟合的温度数据的一示意性实例。作为比较,图3示出了“厚的”第二粉末层8(或者第二层中的这样的位置,即,在该位置中,该层是“厚的”)测得的并拟合的温度数据的一示意性实施。因此,与图2中的数据相比,图3中的数据涉及更厚的粉末层。
图2中的数据点20代表相继的温度测量,同时曲线21代表为数据点20拟合的函数,即曲线21代表粉末层的表面处的温度。可以看出,温度在开始时(在粉末的施加之后不久)非常快地上升,这意味着温度上升速率(即曲线21的导数)在开始时是非常大的。速率逐步地下降,并在t=t1(在该时间点,温度已达到其最高温度T1)时变成零。在此之后,温度缓慢地下降。
在图2所示的示意性实例中,代表相继的温度测量的数据点20的个数是六;三个在温度已达到其最高温度T1之前,三个在已达到最高温度T1时的时间点t1之时或之后。
与图2类似,图3中的数据点30代表相继的温度测量,同时曲线31代表为数据点30拟合的函数,即曲线31代表“厚的”粉末层的表面处的温度。同样在这种情况下,数据点30的个数是六,但是在这种情况下,这些数据点中的五个涉及在温度已达到其最高温度T1之前的时间段。达到最高温度T1的时间点在图3中表示为t2。
通过将图2和图3相比较,可以看出,不同厚度的层的主要差异在于,在图3的“厚的”层中,温度更缓慢地上升,这意味着,在“厚的”层中,温度上升速率较低。在这两种情况下,速率逐步地下降,并在温度已达到其最高温度T1时变成零,在这两种情况下,所述最高温度T1具有几乎相同的值。然而,直至达到最高温度T1所流逝的时间不同;t2>t1。
每个单独的温度测量20、30(即每次温度的“采样”)优选地在这样的短的时间段内进行温度,即,在该时间段内,温度变化是可忽略的。
现有技术设备的温度感测装置通常已用来检查固化之前的温度,并与温度曲线已稳定时(即所施加的粉末层的温度已达到和超过最高温度时)的时间点有关。这种现有技术温度测量对应于位于图2和图3所示的温度曲线的极右边处的一个点。
与使用可见光形成图像的普通照相机类似,温度记录照相机(有时也被称作红外(IR)照相机或热照相机)通常被视为是一种能通过红外辐射来形成图像的装置。数字温度记录照相机能被视为是一种温度感测装置,其中,每个像素形成单独的温度感测单元。温度测量(即图2和图3中的数据点20、30)能基于来自单个像素或者来自几个像素的信号。
本发明不受上述实施例的限制,而是在权利要求书的范围内能以不同的方式进行修改。例如,能使用高温计来代替温度记录照相机14,或者作为温度记录照相机的补充。然而,所述类型的照相机的优点在于,其允许层的几个位置中的温度上升速率的确定,这又使得可确定层的均匀性(即粉末层的竖直均一性)。
此外,高能射束可以是由激光源产生的激光束,而非例示的电子束。另外,粉状物料不一定必须由金属制成,而是能由例如塑料或复合材料制成。
如果将粉末施加到工作区域5上的一定位置中的时间点是已知的,那么足以(在达到最高温度之前)在这个位置处仅进行一次温度测量,以确定或至少估计出温度上升速率。该粉末施加的时间点可从关于粉末分配件12的位置的信息(凭借控制单元11)或者从光学信息获得。然而,确定用于粉末施加的精确时间点可能是复杂的,再者,仅使用单次温度测量来确定温度上升速率会将显著的不确定性带到所获得的结果中。通过执行“遵循”温度曲线的多次相继的温度测量,无需设立用于粉末施加的时间点;如果需要,此时间点能使用拟合的函数来计算。
Claims (9)
1.一种使用粉状物料(7)来逐层地制造三维物体(6)的方法,通过用高能射束(4)照射所述粉状物料能使所述粉状物料固化,
所述方法包括以下步骤:
将第一粉状物料层施加到工作区域(5)上;
通过用高能射束照射所述第一层而使所述第一层的一部分固化;
将第二粉状物料层(8)施加到部分固化的所述第一层上;
其特征在于,
所述方法包括以下步骤:
确定施加到所述第一层上之后的所述第二层(8)的温度上升的速率。
2.根据权利要求1所述的方法,
其特征在于,
所述方法包括以下步骤:
使用温度感测装置(14)测量所述第二层(8)的至少一个位置中的温度。
3.根据权利要求2所述的方法,
其特征在于,
所述方法包括以下步骤:
在所述第二层(8)的相同的至少一个位置中执行多次相继的温度测量,其中,在所述第二层(8)已达到最高温度(T1)之前进行所述多次测量。
4.根据权利要求2或3所述的方法,
其特征在于,
所述方法包括以下步骤:
测量所述第二层(8)的多个位置中的温度,其中,在所述第二层(8)上分配所述多个位置。
5.根据权利要求2-4中的任一项所述的方法,
其特征在于,
所述温度感测装置是温度记录照相机(14)。
6.根据权利要求5所述的方法,
其特征在于,
使所述温度记录照相机(14)对准所述第二层(8)的上表面。
7.根据上述权利要求中的任一项所述的方法,
其特征在于,
所述方法包括以下步骤:
将所确定的温度上升速率与一个或几个参考值相比较。
8.根据权利要求3所述的方法,
其特征在于,
所述方法包括以下步骤:
为从所述多次相继的温度测量获得的数据拟合一数学函数。
9.一种使用粉状物料(7)来逐层地制造三维物体(6)的设备(1),
通过用高能射束(4)照射所述粉状物料能使所述粉状物料固化,
其特征在于,
所述设备构造成根据上述权利要求中的任一项运作。
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EP2454039B1 (en) | 2014-09-03 |
US20160303687A1 (en) | 2016-10-20 |
KR20120050408A (ko) | 2012-05-18 |
RU2507032C2 (ru) | 2014-02-20 |
CN102470439B (zh) | 2016-03-02 |
US9399321B2 (en) | 2016-07-26 |
JP2012533682A (ja) | 2012-12-27 |
EP2454039A4 (en) | 2013-05-01 |
US20120100031A1 (en) | 2012-04-26 |
KR101596432B1 (ko) | 2016-02-22 |
WO2011008143A1 (en) | 2011-01-20 |
EP2454039A1 (en) | 2012-05-23 |
JP5555769B2 (ja) | 2014-07-23 |
US10369662B2 (en) | 2019-08-06 |
RU2012105287A (ru) | 2013-08-20 |
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