CN102699324A - Novel method for plasma deposition modeling under ceramic mold restriction - Google Patents
Novel method for plasma deposition modeling under ceramic mold restriction Download PDFInfo
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- CN102699324A CN102699324A CN2012100361621A CN201210036162A CN102699324A CN 102699324 A CN102699324 A CN 102699324A CN 2012100361621 A CN2012100361621 A CN 2012100361621A CN 201210036162 A CN201210036162 A CN 201210036162A CN 102699324 A CN102699324 A CN 102699324A
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Abstract
The invention provides a novel method for plasma deposition modeling under ceramic mold restriction. The method is characterized by comprising the following steps of: 1. firstly, carrying out data processing: modifying and rolling over a three-dimensional CAD (Computer-Aided Design) mold of a component so as to obtain a ceramic type CAD mold for restriction; processing by using layering software to obtain cross section outline data of the ceramic mold for restriction; and converting the information into a layering plane scanning digital-control code; 2. molding through alterative laying operations: carrying out extrusion molding on a layer of ceramic molds under the control of a computer, and drying the ceramic molds; subsequently depositing a layer of metal materials on a plasma deposition working position; and repeating the process to deposit the second layer to the last layer of metal materials; and 3. after the component molding is accomplished, removing a ceramic sheet for restriction. With the restriction and support functions of the on-line molding ceramic sheet, the bottleneck problems that a large inclined angle and a strip cantilever are complex in structure and that the shaped components are hard to be molded directly are solved. By combing the rapid molding and metal solidification theory, the key technology in direct molding of complex high temperature alloy components is established; and a novel technology with integration of material, molding, texture and performance in direct rapid development of low-cost and thick large complex high temperature alloy components is obtained.
Description
Technical field
This invention belongs to the manufacturing process of high-melting-point, difficult processing, complicated shape hot parts; Mainly be based on laser beam and realized the incorporate manufacturing of material-shaping-tissue-performance; Through the two-dimensional constrains and the supporting role of online shaped ceramic matrix, solved the molten metal trickling in the plasma deposition forming process and be with the especially thick big complex parts of hanging structure complex parts to be difficult to the bottleneck problem of direct forming.The enforcement of this technology can be deepened the application of quick manufacturing, is widely used in the shaping of the high-melting-point in fields such as Aero-Space, energy source and power, defence and military, difficult processing, complicated shape hot parts.The direct forming that also can directly be used for metal die and gradient function part.
Background technology
The high energy beam that the manufacturing process of present existing high-melting-point, difficult processing, complicated shape hot parts mainly is based on laser beam, electron beam, beam-plasma is shaped, and this technology can be handled the direct manufacturing that the rear drive quickly shaping device is realized the difficult-to-machine metal part through hierarchy slicing by part C AD model.Therefore, this is a kind of design of part and material design, is shaped, processes incorporate short flow process, digitlization manufacturing technology, is representing the development of advanced manufacturing direction
[1]At present; Adopt the direct manufacturing approach of high energy beam current to mainly contain precinct laser sintering method (Selective Laser Sintering; SLS), the laser fusion forming process (Selective Laser Melting, SLM), laser near-net forming method (Laser Engineered Shape, LENS), electron-beam melting method (Electron Beam Melting; EBM) and beam-plasma deposition formation method (Plasma Deposition Manufacturing, PDM).
The SLS method can adopt the laser forming complicated shape metal part of smaller power, but will obtain complicated post processings such as high-compactness need infiltrate, high temperature insostatic pressing (HIP), and part strength and precision in most cases do not reach requirement
[2]-[5]The SLM technology of improvement is proposed in nineteen ninety-five on the SLS basis by German Fraunhofer research institute first, and studies successfully in 2002, compare the SLS method, but SLM direct forming compactness is near 100% metal parts
[6]-[8]In recent years; Because numerous advantages of SLM technology; Attracting increasing mechanism to study, carrying out research and developed relevant device around material, technology and principle like the EOS company of Germany, Concept Laserts company, MCP company, Belgian Univ Louvain, Britain CRDM company, Japanese OSAKADA laboratory, NUS, the domestic Central China University of Science and Technology, South China Science & Engineering University etc.Yet also there is weak point in the SLM technology: in the scanning forming process splash in the molten bath, factors such as nodularization and sticking powder cause the drip molding surface roughness higher, and forming efficiency is low, and equipment investment, operation and maintenance cost are high
[2]In addition, because the light-conducting system of SLM equipment uses galvanometer, its slewing area has limited the sweep limits of laser, has determined the less thin-walled parts of the only suitable processing dimension of SLM technology
[9]
The LENS technology is through the metal dust or the silk material of high power laser light fusing synchronous transport, and under the routing motion of deposition substrate, material is successively piled up in pointwise, and constantly growth produces part.This technology proposes and launches research by U.S. Sandia and Los Alomos National Laboratory the earliest
[10]And releasing business-like LENS system by Optomec company in 1998, the University of Birmingham of the Stanford University of the U.S., University of Michigan, Britain, University of Manchester, University of Liverpool and Canadian National Research Council etc. have developed and have been referred to as SDM (Shape Deposition Manufacturing), DMD (Direct Metal Deposition), DLF (Direct Laser Fabrication), DLD (Direct Laser Deposition), LDC (Laser Direct Casting), LC principles and the method technology consistent with LENS such as (Laser Consolidation) respectively subsequently
[11]-[14]Domestic research at the LENS technical elements is started late; Since late 1990s, solidification technology National Key Laboratory of Northwestern Polytechnical University, China YouSe metal are studied units such as total institute, Tsing-Hua University, BJ University of Aeronautics & Astronautics and Shanghai Communications University and are concentrated the shaping research of having carried out nickel base superalloy and titanium alloy.At present, the LENS technology is used for manufacturing, reparation and the remodeling of high value metals Aero-Space part morely.In recent years; Domestic research institution has also obtained many phasic results; Adopt different alloys to process laser cladding forming spare like Northwestern Polytechnical University, China YouSe metal research institute with definite shape; Tsing-Hua University has developed the coaxial powder feeding system that is applied to laser cladding forming, and has studied the closed-loop control of process, and professor Wang Huaming of BJ University of Aeronautics & Astronautics has developed " free plane contact/dynamic seal (packing)/inert atmosphere protection " titanium alloy structure spare
[15]Professor Huang Weidong of Northwestern Polytechnical University adopts laser fast forming to deposit the Ti6Al4V alloy part
[16]Through various countries researcher's unremitting effort for over ten years, the LENS technology has obtained rapid progress.Yet, make this technology in industry, obtain extensive use, also need solve Several Key Problems: the one, forming efficiency is low, and the LENS stackeding speed is about 0.1-4.1cm
3/ mim; The 2nd, the control of crackle
[17]The 3rd, the control of internal soundness, this technology is little and cooled and solidified speed is very fast because of laser spot diameter, makes metallurgical process be difficult to fully carry out, and causes possibly existing in the formation of parts molten particle and pore
[18]-[23]
EBM method and LENS principle are similar.Since calendar year 2001 Sweden Arcam company proposed the EBM technology, because this technological unique advantage, North Carolina university, Britain UNIVERSITY OF WARWICK, Nuremberg, Germany university, Boeing and Sweden VOLVO company had actively developed correlative study work
[24]-[30]At present, aspect the quick manufacturing equipment of electron beam, Arcam company has developed integrated EBM S-12 and EBM S-12T; At process aspect, U.S. Calcam company
[31]Adopt the EBM technology to prepare the Ti6Al4V wheel member that full densification, mechanical property are superior to forge piece.Tsing-Hua University has taken the lead in carrying out the research work that electron beam is made fast at home, and develops the electron beam rapid forming system.Xibei Inst. of Non-Ferrous Metals has been carried out the research of electron beam fast shaping technology, and produces complicated titanium alloy impeller exemplar.Yet because of EBM technology is high to hardware and environment requirement, whole forming process must be carried out in vacuum chamber, and equipment investment and operating cost are high, are not used to make big-and-middle-sized part as yet; Simultaneously, in forming process, there is the surface melting metal phenomenon of " gathering ball "; In addition, the distinctive powder problem of blowing can appear
[32]
The PDM forming process is to utilize the plasma beam that produces high temperature and high speed through the transferred arc of electromagnetism, geometry and hot compression, makes metal reach molten state, and is shaped by the track layer by layer deposition of setting.As a kind of new type of metal part direct forming method, the PDM technology starts from the later stage eighties 20th century, proposes along with the development of digitlization layering manufacturing.Because the PDM method has plurality of advantages such as metallurgical process is abundant, is easy to obtain at low cost the full density high temperature alloy part that structure property is superior to the vacuum foundry goods; The gas that uses is Ar gas, can effectively protect the oxidation of metal surface in the deposition formation process; Capacity usage ratio, forming efficiency, stock utilization height; Equipment investment and operating cost can be carried out the advantages such as direct manufacturing of metal parts based on conventional plasma arc welding (PAW) technology far below SLM and EBM method
[33], PDM technology becomes the research focus very soon.At present; The Central China University of Science and Technology, Xi'an Communications University, Dalian University of Technology, Northwestern Polytechnical University, University Of Nanchang, armored force engineering institute etc. have launched research and have obtained phasic results around aspects such as forming technology, formation system, drip molding structure property, drip molding distortion and controls, have set up the direct metal rapid forming system of controlling based on plasma arc welding (PAW) and manipulator like Hu Xiaodong etc.
At full density, the low cost of thick big high temperature alloy part, the direct manufacture view of high efficiency, beam-plasma deposition formation method has clear superiority and has a high potential.Yet; Along with deepening continuously of plasma deposition Research of Forming Technology; The PDM method also exposes some shortcomings: at first be molten metal trickling and the not high problem of size of formed part precision in the plasma deposition process, because the plasma deposition shaping is to carry out with the molten long-pending mode of high temperature fluent metal, therefore; Molten metal can trickle because of the gravity effect, thereby influences the precision and the forming efficiency of drip molding; Next is the problem that the complicated shape part is difficult to direct forming, and because of the shortage of molten metal trickling and supporting condition, the complicated shape part forming difficulty of high inclination-angle or band cantilever design has greatly limited its range of application; The 3rd is the fire check problem in the plasma deposition process; The plasma deposition forming process is a metallurgical process, and the process of setting of liquid metal is along with the propelling of liquid, liquid/solid interface is carried out, the solid-liquid stage in process of setting; Because the influence of dendrite skeleton; Thereby crack, the generation of crackle often causes forming process to be given up halfway, and the existence of crackle also can reduce the performance of part greatly; Be the microstructure of drip molding and the problem that performance remains further improvement at last; Though the plasma deposition forming technology has the characteristics of rapid solidification, microstructure mainly is made up of the elongated dendrite that the direction of growth differs, and the microstructure of drip molding is superior to cast member; But because the input of heat repeatedly in the forming process; Crystal grain has the trend of growing up, and therefore, microstructure and performance how further to improve drip molding also are that problem to be solved is arranged.Thus it is clear that, adopt the plasma deposition forming process to realize that metal parts does not have problems such as the trickling supported in the direct forming process, fire check and become the bottleneck that serious restriction PDM technology further develops and uses.
The trickling problem of not having the additional support direct forming about the complicated shape part; U.S. Michigan university, Southern Methodist university, NUS etc.; The employing microtomy of changing direction; Select the maximum direction of supporting condition as part forming principal direction, or the complicated shape part is resolved into some simple shape parts be shaped successively, and develop five with multiaxis direct forming machining software
[34]This technology has effectively been improved the supporting condition of growth and shaping; But cause space interference check and forming path planning complicated; Problem such as programming and long processing time, difficulty are big; And still be difficult to fundamentally solve the trickling problem for the complicated shape part, cause part forming dimensions and complex-shaped degree still restricted
[34]
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Summary of the invention
The purpose of this invention is to provide the plasma deposition shaping new method under a kind of ceramic die sheet constraint; Overcoming prior art adopts the plasma deposition forming process to realize that metal parts does not have problems such as the trickling supported in the direct forming process, fire check; Intensive quick shaping and metal freezing are theoretical; Set up the key technology of complicated high temperature alloy part direct forming, obtain the integrated new technology of material-shaping-tissue-performance low-cost, that thick big complicated high temperature alloy part is directly developed fast.
Technical scheme of the present invention is: the plasma deposition shaping new method under a kind of ceramic die sheet constraint is characterized in that:
1, at first carry out data: the three-dimensional CAD model by part obtains retraining after revising, turning over type using the ceramic mould cad model, handles obtaining two-dimensional constrains with ceramic matrix cross section profile data through delamination software, is the plane scan numerical control code with this information translation;
2, the layering blocked operation is shaped: under computer control, and first extrusion molding one deck pottery matrix, drying of ceramic matrix; Then on the plasma deposition station, deposit the layer of metal material; Press this process repeated deposition the 2nd to last one deck metal material;
3, treat that part forming finishes, remove constraint and use potsherd.
Plasma deposition shaping new method under the aforesaid ceramic die sheet constraint is characterized in that: the described dry plasma arc that adopts scans drying fast.
Plasma deposition shaping new method under the aforesaid ceramic die sheet constraint, it is characterized in that: said manufacturing process is online carrying out.
Through the constraint and the supporting role of online shaped ceramic matrix, solve high inclination-angle and be with cantilever design complicated shape part to be difficult to the bottleneck problem of direct forming.Intensive quick shaping and metal freezing are theoretical, set up the key technology of complicated high temperature alloy part direct forming, obtain low-cost, the direct integrated new technology of material-shaping-tissue-performance of exploitation fast of thick big complicated high temperature alloy part.This technology can directly apply to the shaping of the high-melting-point in fields such as Aero-Space, energy source and power, defence and military, difficult processing, complicated shape hot parts.Also can be used for the direct forming of metal die and gradient function part, can shorten the lead time significantly, reduce development cost.
Description of drawings
Accompanying drawing 1 is an embodiment of the invention flow chart of data processing sketch map;
Accompanying drawing 2 is embodiment forming technology process sketch mapes;
Accompanying drawing 3 is embodiment last handling process sketch mapes.
Accompanying drawing 4, the photo contrast of the inventive method drip molding interior tissue and conventional method.
The specific embodiment
Below in conjunction with description of drawings one embodiment of the present of invention.
Accompanying drawing 1-3 is a two-dimensional constrains plasma deposition forming technology schematic flow sheet.
Two-dimensional constrains plasma deposition of the present invention is shaped the technological process embodiment of acid tube alloy part shown in accompanying drawing 1-3, and the part of desiring moulding is divided into 26 layers, then with method layering blocked operation shaping of the present invention.
Referring to Fig. 1; At first carry out data; Three-dimensional CAD model by part obtains retraining after revising, turning over type using the ceramic mould cad model, handles obtaining two-dimensional constrains with ceramic matrix cross section profile data through delamination software, is the plane scan numerical control code with this information translation; Promptly
At first, design out the cad model such as the step 1 (a) of acid tube part, confirm corresponding ceramic model such as step 1 (b) according to the design feature of part, carry out layering according to the part height and handle, every layer height is 4mm, amounts to 26 layers like step 1 (c).
Referring to Fig. 2; In the forming process, under computer control, ceramic extruder head is extruded the ceramic matrix of orlop (the 1st layer) earlier; Utilize plasma arc to scan drying fast, then on the plasma deposition station of orlop pottery matrix, use the plasma gun deposit metallic material; Ceramic then extruder head is extruded time ceramic matrix of lower floor's (the 2nd layer) again, then on the plasma deposition station of inferior lower floor pottery matrix, deposits the 2nd layer of metal material with plasma gun; So repeat to accomplish the 3rd layer of deposition to the 26th layer of metal material; Promptly
Utilize ceramic extruder head basis one deck pottery matrix of combined shaping lathe, and utilize plasma arc to scan fast, not powder feeding in the scanning process; Afterwards, utilize plasma gun deposition formation one deck alloy-layer, so alternate repetition; Last one deck up to part is accomplished, like Fig. 2.
Concrete parameter such as table 1 in the forming process
Table 1 plasma parameter
Referring to Fig. 3, treat that part forming finishes, remove constraint and use ceramic mould.
The layering quantity of part is the amount doesn't matter, selects by general knowledge according to the complexity and the permissible accuracy of workpiece.Part all is three-dimensional, is convenient to here narrate adopted two-dimentional sketch map, and its content that on three-dimensional, discloses is self-evident.
Suitable do a little bright and clean processing,, also be admissible, but be not necessary, depend on the circumstances such as abrasive jet cleaning.
The obvious refinement of tissue such as Fig. 4 that the interior tissue of the part that arrives through this process obtains than conventional method.
Claims (3)
1. the plasma deposition shaping new method under a ceramic die sheet retrains is characterized in that:
(1), at first carry out data: the three-dimensional CAD model by part obtains retraining after revising, turning over type using the ceramic mould cad model; Obtaining two-dimensional constrains with ceramic matrix cross section profile data through the delamination software processing, is the plane scan numerical control code with this information translation;
(2), the layering blocked operation is shaped: under computer control, first extrusion molding one deck pottery matrix, drying of ceramic matrix; Then on the plasma deposition station, deposit the layer of metal material; Press this process repeated deposition the 2nd to last one deck metal material;
(3), treat that part forming finishes, remove constraint and use potsherd.
2. the plasma deposition shaping new method under the ceramic die sheet constraint as claimed in claim 1 is characterized in that: the described dry plasma arc that adopts scans drying fast.
3. the plasma deposition shaping new method under according to claim 1 or claim 2 the ceramic die sheet constraint, it is characterized in that: said manufacturing process is online carrying out.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN103498141A (en) * | 2013-09-03 | 2014-01-08 | 航天特种材料及工艺技术研究所 | High-temperature alloy rib structure laser solid forming method |
| CN106312069A (en) * | 2016-11-22 | 2017-01-11 | 赵晴堂 | Melt pool control method for additive manufacturing |
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| CN101422963A (en) * | 2008-10-14 | 2009-05-06 | 欧客思国际有限公司 | Manufacture method and device of three-dimensional workpiece |
| CN101561674A (en) * | 2009-05-22 | 2009-10-21 | 南京师范大学 | Molding method of components of heterogeneous materials |
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| CN1799821A (en) * | 2006-01-16 | 2006-07-12 | 南京师范大学 | Method for manufacturing three-dimensional object by use of spray coating successively |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN103498141A (en) * | 2013-09-03 | 2014-01-08 | 航天特种材料及工艺技术研究所 | High-temperature alloy rib structure laser solid forming method |
| CN103498141B (en) * | 2013-09-03 | 2016-02-17 | 航天特种材料及工艺技术研究所 | A kind of superalloy muscle rib structure laser solid forming method |
| CN106312069A (en) * | 2016-11-22 | 2017-01-11 | 赵晴堂 | Melt pool control method for additive manufacturing |
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