CN103476523B - 用于通过固体自由成型制造来构建金属物件的方法和装置 - Google Patents

用于通过固体自由成型制造来构建金属物件的方法和装置 Download PDF

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CN103476523B
CN103476523B CN201280016671.6A CN201280016671A CN103476523B CN 103476523 B CN103476523 B CN 103476523B CN 201280016671 A CN201280016671 A CN 201280016671A CN 103476523 B CN103476523 B CN 103476523B
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metal material
torch
transferred arc
plasma transferred
arc power
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CN103476523A (zh
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费迪南德·斯特姆普费尔
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Norsk Titanium Components AS
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Norsk Titanium Components AS
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    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
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    • B23K26/0608—Shaping the laser beam, e.g. by masks or multi-focusing by a combination of beams in the same heat affected zone [HAZ]
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Abstract

本发明涉及通过固体自由成型制造来制造物件、尤其是钛及钛合金物件的方法和装置，其中通过供应丝形式的金属进料并采用两个气体转移电弧，一个等离子体转移电弧用于加热在基材上的沉积区以及一个等离子体转移电弧用于加热和熔化进料丝来提高沉积速率。

Description

用于通过固体自由成型制造来构建金属物件的方法和装置
技术领域
本发明涉及用于通过固体自由成型制造（solidfreeformfabrication）来制造物件，尤其是钛及钛合金物件的方法和装置。
背景技术
通常由坯料开始通过浇铸、锻造或机械加工来制造由钛或钛合金制成的结构化金属部件。在制造中，这些技术具有昂贵钛金属的高材料使用以及较长的生产周期的缺点。
可以通过称为快速原型制造、快速制造、分层制造或添加制造的制造技术来制作完全致密的物理物件。这种技术采用计算机辅助设计软件（CAD）来首先构建待制作的物件的虚拟模型，然后将虚拟模型变换成通常是水平定向的薄平行片或层。然后可以通过放样（layingdown）类似于虚拟层的形状的液体糊、粉末或片材形式的原材料的连续层直到形成整个物件制造物理物件。将各层融合在一起以形成固体致密物件。在沉积待融合或焊接在一起的固体材料的情况下，该技术也被称为固体自由成型。
固体自由成型是允许以相对较快的生产速度来制造几乎任何形状的物件的灵活的技术，对于每个物件通常为数小时至数天。因此，该技术适合于形成样机和小制作系列，但较不适合于大批量生产。
现有技术
可以将分层制造的技术扩展到包括沉积建筑材料的片的，即，将物件的虚拟模型的每个结构层分成一组片，当其并排放样时形成层。这允许通过以连续条的方式将焊丝焊接到基板上、按照物件的虚拟分层模型来形成每一层、并对于每一层重复上述过程，直到形成整个物理物件来形成金属物件。焊接技术的准确性通常太粗糙以至于不允许直接形成具有可接受的尺寸的物件。因此，形成的物件将通常被认为是生料物件或预成型件，其需要被机械加工至可接受的尺寸精度。
Taminger和Hafley[1]披露了直接由计算机辅助设计数据并结合电子束自由形状制造（EBF）来制造结构化金属件的方法和设备。通过在连续层上焊接金属焊接丝（其是通过由电子束提供的热能加以焊接）来制造结构化部件。该方法示意性地示于图1，其是[1]的图1的副本。EBF方法涉及将金属丝进料至在高真空环境下由聚焦电子束形成并维持的熔池。是通过具有沿着一个或多个轴（X、Y、Z、和旋转）可移动铰接的电子束枪和定位系统（支持基板）并且通过四轴运动控制系统来调节电子束枪和支持基板的位置来获得电子束和焊接丝的定位。声称上述方法在材料使用方面具有几乎100%的效率并且在功率消耗方面具有95%的效率。对于本体金属沉积（bulkmetaldeposition）和精细沉积（finerdetaileddepositions）均可使用上述方法，并且声称和机械加工金属部件的常规方法相比，上述方法可以获得生产周期缩短的显著效应并降低材料和加工成本。电子束技术具有依赖于在沉积室中10-1Pa以下的高真空的缺点。
已知的是，使用等离子体电弧来提供用于焊接金属材料的热量。可以在大气压或更高压力下使用此方法，从而允许更简单和更低成本的工艺设备。一种这样的方法称作气体保护钨极电弧焊（GTAW，还表示为TIG），其中，在非消耗的钨电极和焊接区之间形成等离子体转移电弧。通常通过等离子炬供给的气体形成围绕电弧的保护层来保护等离子体电弧。TIG焊接可以包括将金属丝或金属粉末供给到熔池或等离子体电弧作为填料。
由US2010/0193480已知的是，采用TIG焊炬通过固体自由成型制造（SFFF）来构建物件，其中将具有低延伸性的金属原料的连续层施加在基板上。通过使用电弧极激励流动气体来产生等离子流，其中上述电弧极具有施加于其的可变幅度电流。将等离子流定向至预定目标区域以在沉积以前预热预定目标区域。调节电流并将原料引入等离子流以在预定目标区域中沉积熔融原料。在冷却阶段中，调节电流并在高温下缓慢冷却熔融原料，通常高于原料材料的脆性-延性转变温度，以尽量减少材料应力的发生。
另一个例子是US2006/185473，其披露了使用TIG炬来代替在固体自由成型制造（SFFF）方法中通常使用的昂贵的激光器，其具有通过以一定方式结合钛进料和合金成分的相对较低成本的钛进料材料从而大大降低原材料的成本。更具体地，在一个方面，本发明采用其成本低于合金丝的纯钛丝（CPTi），并在SFFF方法中通过在焊炬或其它高功率能量束的熔化物中使CPTi丝和粉末状合金成分结合来原位结合CPTi丝和粉末状合金成分。在另一种实施方式中，本发明采用与合金元素混合海绵状钛材料并形成其中它可以在SFFF方法中与等离子焊炬或其它高功率能量束结合使用的丝，以产生近终形状的钛部件。
在接触氧气以后被加热高于400℃的钛金属或钛合金可能会受到氧化。因此必须保护焊接和通过分层制造所形成的加热的物件以免受在环境大气中的氧气的影响。
由WO2011/0198287已知对于此问题的一种解决方案，其披露了在与环境大气封闭的反应室中通过进行固体自由成型制造来制造物件，尤其是钛及钛合金物件的用于提高沉积速率的方法。通过使沉积室足够没有氧气，不再需要采用保护措施来避免环境大气中的氧气氧化新焊接区，以使可以更高的速度进行焊接过程，这是因为焊接区可以被允许具有更高的温度而没有焊接点的过度氧化的风险。例如，在钛或钛合金物件的生产中，不再需要将焊接区冷却至低于400℃来避免氧化。
由US6268584已知用于提高沉积速率的另一种解决方案，其披露了由以下特征组成的沉积头组件（depositionheadassembly）：用于产生粉末到沉积区域的会聚流的输出粉末喷嘴阵列、其使得多个束能够聚焦到沉积基板上的中心孔、以及用于每个粉末喷嘴以集中来自这些喷嘴的粉末流从而提供在喷嘴和沉积头组件之间的更长的工作距离的同轴气流。在加工过程中，为了确保熔融金属颗粒不附着于沉积装置，更长的工作距离是至关重要的。尤其是，本发明包括设计在沉积头组件中的歧管系统，其可以同时将一个以上的激光束用于沉积过程。沉积头组件还结合有用于主动集中来自每个孔的粉末流以提高材料利用率的装置。
WO2006/133034披露了使用组合的气体金属电弧和激光焊接来解决与Ti的反应性和使得非常难以形成DMD产品的它的熔融特性有关的问题。气体金属电弧技术具有若干缺点，其严重限制它们应用于沉积Ti。这些缺点包括金属转移的不稳定性、过度飞溅、和沉积层形状的不良控制、以及在沉积期间引起薄截面的变形的高热量输入。另外，由于在沉积期间发生的阴极斑点的漂移，生产率的提高是不可能的。根据WO2006/133034针对这些问题的解决方案是包括提供基板和将来自金属原料的金属沉积到基板上的步骤的直接金属沉积过程。在金属原料和基板之间产生电弧并将电弧暴露于激光照射以在基板上形成金属熔池。冷却金属熔池以在基板上形成第一固体金属层。
本发明的目的
本发明的主要目的是提供用于通过固体自由成型制造来构建金属物件的装置。
本发明的另一个目的是提供用于快速分层制造钛或钛合金物件的方法。
发明内容
本发明是基于以下认识：可以通过供应丝形式的金属进料以及采用两个气体转移电弧，一个等离子体转移电弧用于加热在基材上的沉积区以及一个等离子体转移电弧用于加热和熔化进料丝来提高沉积速率。
因此，在第一方面，本发明涉及用于通过固体自由成型制造来制造金属材料的三维物件的方法，其中通过将金属材料的连续沉积物融合在一起到支持基板上来制作物件，
其特征在于上述方法包括：
-采用由与待制作物件类似的金属材料制成的支持基板，和
-获得每种连续沉积物，通过；
i）采用第一等离子体转移电弧（PTA）在基材中将要沉积金属材料的位置处预热并形成熔池，
ii）将待沉积的金属材料以丝的形式进料至在熔池上方的位置，
iii）采用第二等离子体转移电弧（PTA）来加热和熔化上述丝，以使熔融金属材料滴入熔池，以及
iv）相对于第一和第二PTA的位置以预定图案移动支持基板，以使熔融金属材料的连续沉积物凝固并形成三维物件。
在第二方面，本发明涉及用于通过固体自由成型制造来制造金属材料的三维物件的装置，其中该装置包括：
-具有供给金属材料的丝的集成丝进料机的焊炬，
-用于相对于焊炬来定位和移动支持基板的系统，以及
-控制系统，其能够读取待形成的物件的计算机辅助设计（CAD）模型并采用该CAD模型来调节用于使支持基板定位和移动的系统的位置和移动，以及能够操作具有集成丝进料机的焊炬从而通过将金属材料的连续沉积物融合到支持基板上来构建物理物件，
特征在于
-由与待制作的物件类似的金属材料制成支持基板，
-焊炬包括
i）电连接至基材的第一等离子体转移电弧（PTA）炬和
ii）电连接至金属材料的进料丝的第二等离子体转移电弧（PTA）炬，
-控制系统能够独立地操作和调节第一PTA炬以在基材中将要沉积金属材料的位置处形成并维持熔池，以及
-控制系统能够独立地操作和调节丝进料机和第二PTA炬以在一定位置处熔化金属材料进料，以使熔融金属材料滴入熔池。
如在本文中所使用的，术语“类似金属材料”是指，金属材料是和参照金属材料相同的金属或金属合金。
如在本文中所使用的，术语“基材”是指来自第一PTA炬的热量的目标材料以及由其形成熔池。当沉积金属材料的第一层时，这将是支持基板。当在支持基板上已沉积一层或多层金属材料时，基材将是沉积的金属材料的上层，其将沉积金属材料的新层。
如在本文中可互换使用的，术语“等离子体转移电弧炬”或“PTA炬”是指通过电弧放电能够将惰性气体流加热并激发为等离子体，然后通过孔（喷嘴）将包含电弧的等离子气体流转移出以形成收缩股流（constrictedplume）其延伸出孔并将电弧的强热转移到目标区域的任何装置。将电极和目标区域电连接至直流电源以使PTA炬的电极成为阴极而目标区域成为阳极。这将确保，包含电弧的等离子体柱流将高度集中的热流递送到目标区域的较小表面积，并极好地控制由PTA炬供给的热通量的面积的范围和大小。等离子体转移电弧具有提供了具有几乎无漂移并对于在阴极和阳极之间的长度偏差具有良好公差的稳定并且一致的电弧的优点。因此，PTA炬适用于形成在基材中的熔池并且适用于加热和熔化金属丝进料。PTA炬可以有利地具有由钨制成的电极和由铜制成的喷嘴。然而，本发明并不限于PTA炬的任何具体选择或类型。可以应用能够充当PTA炬的任何已知的或可设想的装置。
使用独立控制的第一PTA炬来预热基材并形成熔池并且使用独立地第二PTA炬来熔化金属材料的进料丝会提供以下优点：可以独立于对基板的供热来增加对金属丝的进料的供热，使得可以增加进入进料材料的热通量而没有产生“喷射电弧”（其产生飞溅）的风险。因此，可以提高熔融金属进料的沉积速率而没有同时过度加热基板以及没有飞溅或形成过度熔池并因而放松对沉积材料的凝固的控制的风险。通过连接直流电源以使第一PTA炬的电极成为负极性而使基材成为正极性来限定电路其中通过在第一PTA炬的电极和基材之间的电弧放电来转移电荷，以及通过将第二PTA炬的电极连接至直流电源的负极并将金属材料的进料丝连接至正极以形成电路其中通过在第二PTA炬的电极和金属材料的进料丝之间的电弧放电来转移电荷来获得此特征。
第一和第二PTA炬可以有利地具有独立的电源和用于调节到各自的炬的功率的装置。用于调节功率的装置可以有利地包括用于监测基材的沉积区的温度的装置和用于调节电弧的宽度和定位的装置，如即磁性电弧偏转装置。另外，用来在基材中形成熔池的第一PTA炬可以有利地形成宽弧，如即通过气体保护钨极电弧焊炬（GTAW炬，在文献中还表示为TIG炬）所形成的，以在基材表面的更宽区域中形成熔池。
如在本文中可互换使用的，术语“计算机辅助设计模型”或“CAD模型”是指待形成物件的任何已知的或可设想的虚拟三维图象，其可以在根据本发明的第二方面的装置的控制系统中使用以调节支持基板的位置和移动以及操作具有集成丝进料机的焊炬，以根据物件的虚拟三维模型产生构建物理物件的图案，通过将金属材料的连续沉积物融合在支持基板上构建物理物件。这可以例如通过形成三维模型的虚拟矢量化分层模型来获得：通过首先将虚拟三维模型分成一组虚拟平行层，然后将每个平行层分成一组虚拟的准一维片。然后，可以通过接合控制系统按照物件的虚拟矢量化分层模型的第一层的图案将金属材料进料的一系列准一维片沉积和融合在支持基板上而形成物理物件。然后，通过按照物件的虚拟矢量化分层模型的第二层的图案将可焊接材料的一系列的准一维片沉积和融合在先前沉积的层上重复此顺序用于物件的第二层。对于物件的虚拟矢量化分层模型的每个连续层继续逐层重复沉积和融合过程直到形成整个物件。然而，本发明并不限于用于运行按照本发明的装置的控制系统的任何具体的CAD模型和/或计算机软件，并且本发明也不限于任何特定类型的控制系统。可以使用能够通过固体自由成型制造来构建金属三维物件的任何已知的或可设想的控制系统（CAD模型、计算机软件、计算机硬件和传动装置等），只要可以调节控制系统以独立地操作第一PTA炬来形成熔池和第二PTA炬来将金属材料的进料丝熔化入熔池。
可以根据电源对第二PTA炬的影响来有利地控制和调节金属材料的进料丝的进料速率（丝速度）和定位，以确保当进料丝到达在基材中的熔池上方的预定位置时被连续加热和熔化。这可以通过使用常规气体金属电弧焊炬（GMAW炬，还表示为MIG炬）作为丝进料机而没有在MIG炬中形成电弧来获得。丝进料机的这种实施方式具有能够将进料丝电连接于第二PTA炬的DC电源以及非常精确地定位进料丝的优点。金属材料的进料丝可以具有任何实际上可实现的尺寸，如即1.0mm、1.6mm、2.4mm等。
如在本文中所使用的，术语“金属材料”是指任何已知的或可设想的金属或金属合金，其可以形成为丝并用于固体自由成型过程来形成三维物件。适合的材料的实例包括但不限于钛和钛合金如即Ti-6Al-4V合金。
对第一和第二PTA炬的供给效果将取决于使用的金属材料、进料丝的直径、基材的耐热性、沉积速率等。因此，本发明并不限于电源的任何具体窗口，而是可以使用任何实际上运作的电位差和电流，其导致功能操作第一和第二PTA炬。通过试验和试错测试技术人员将能够发现这些参数。由本申请人进行的实验已表明，当向第一PTA炬提供约150A而第二PTA炬提供约250A时，在3.7至3.8kg/小时的沉积速率下，通过采用由5级钛合金制成的具有1.6mm直径的丝，可以制造具有和钛的常规物件类似的机械性能的三维物件。据认为，在有效保护气氛中，如即在WO2011/0198287中披露的反应室中，通过根据本发明的第一和第二方面进行SFFF沉积可以获得高达10kg/小时的沉积速率。该结果得到由本申请人使用丝直径2.4mm、5级钛进行的另一个实验的证实，当向第一PTA炬供应约250A的电流并且向第二PTA炬供应约300A的电流时其给出9.7kg/h的沉积速率。
作为一种替代方法，本发明还可以包括用于在熔池中产生热脉冲以打破在熔池中生长晶体枝晶的倾向的装置。由于改善的晶粒结构，此特征使得能够形成具有增强的机械性能的金属物件。可以采用第三DC发电机来获得热脉冲，其中上述第三DC发电机传递脉冲式DC电位并将DC发电机的负极连接至第二PTA炬的电极而将正极连接至基材以形成电路，其中通过在第二PTA炬的电极和基材之间的脉动电弧放电来转移电荷。将根据施加的脉冲式DC电位来接通和关断在第二PTA炬的电极和基材之间的电弧放电从而形成进入基材中的熔池中的脉冲式热通量。脉冲的频率可以在从1Hz上达至数kHz以上的范围内，即10kHz。
附图说明
图1是Taminger和Hafley[1]的图1的副本，其示出固体自由成型制造的原理的示意图。
图2是US2006/0185473的图1的副本，其示出等离子体转移电弧固体自由成型制造的原理的示意图。
图3是示出根据本发明的第二方面的装置的截面观的示意图。
图4是示出包括热脉冲的本发明的第二实施方式的截面观的示意图。
具体实施方式
将通过示例性实施方式更详细地说明本发明。不应将这些实施例解释为限制本发明的想法的一般范围，上述本发明的想法是使用两个PTA炬：一个用来形成在基材中的熔池而一个用来熔化进料。
第一示例性实施方式
在图3中示意性地示出根据本发明的第二方面的装置的第一示例性实施方式。该图示出形状为长方体的由Ti-6Al-4V合金制成的支持基板1，通过固体自由成型制造在其上形成由相同Ti-6Al-4V合金制成的三维物件。该图示出沉积过程的起始部分，其中正在沉积Ti-6Al-4V合金的第一焊接条2。
通过丝进料机4来不断提供由Ti-6Al-4V合金制成的丝3，该丝进料机4定位丝3，以使它的远端位于支持基板1上的沉积区处的熔池5的上方。以由图中的上方箭头所示的速度（其对应于远端的加热和熔化速率）给予丝3，使得将熔融丝的小滴6不断提供到熔池5。
通过PTA炬8来形成第一等离子体转移电弧7，其中上述PTA炬8电连接至DC电源9，以使PTA炬的电极10成为阴极而支持基板1成为阳极。等离子体转移电弧7是连续的并且是定向的以在沉积点处加热和熔化基材（在SFFF方法的此阶段，其是支持基板）以使获得熔池5。通过控制系统（未示出）来调节DC电源9的作用以维持熔池5具有恒定的尺寸和范围。PTA炬8是气体保护钨极电弧焊（GTAW）炬，其装配有磁性弧偏转器（未示出）以控制电弧8的尺寸和位置。
通过PTA炬12来形成第二等离子体转移电弧11，该PTA炬电连接至DC电源13使得PTA炬12的电极14成为阴极而进料丝3成为阳极。等离子体转移电弧11是连续的并且是定向的以加热和熔化丝3的远端。根据丝的供给速度来调节DC电源13的作用以维持加热和熔化速率，使得定时形成小滴6以维持熔融丝的连续滴进入熔池5。通过控制系统来连续调节和控制由DC电源13提供的作用和离开丝进料机4的丝3的供给速度，使得以提供预期的沉积速率的Ti-6Al-4V合金的速率向熔池5提供熔融丝。控制系统同时接合至传动装置来操作和调节传动装置（未示出），传动装置不断地定位并移动支持基板1，使得将熔池定位于如由待形成的物件的CAD模型所给出的所预期的沉积点。在SFFF方法的此阶段，如由下方箭头所指的移动支持基板1。
第二示例性实施方式
本发明的第二示例性实施方式是包括用于在熔池5中形成热脉冲的另外的装置的上文给出的第一示例性实施方式。
用于形成热脉冲的装置是DC电源15，其电连接于第二PTA炬12使得电极14成为阴极而支持基板1成为阳极。另外，存在用于脉冲发送由DC电源15传送的功率的装置16，使得电弧11除加热和熔化丝3以外还将以和脉冲电源相同的频率进入熔池5从而将脉冲式热通量递送到熔池。可以通过控制系统调节装置16并以1kHz的频率将脉冲电弧放电提供到熔池。
参考文献
1.Taminger,K.M.andHafley,R.A.,”ElectronBeamFreeformFabricationforCostEffectiveNear-NetShapeManufacturing”,NATO/RTOAVT-139Specialists’MeetingonCostEffectiveManufactureviaNetShapeProcessing(Amsterdam,theNetherlands,2006)(NATO).pp9–25,http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20080013538_2008013396.pdf

Claims (10)

1.一种通过固体自由成型制造来制造金属材料的三维物件的方法，其中通过将所述金属材料的连续沉积物融合到支持基板上来制作所述物件，
其特征在于，所述方法包括：
-采用由与待制作的所述物件类似的金属材料制成的支持基板，和
-通过以下步骤获得每个连续沉积物：
i)采用第一等离子体转移电弧以在基材中将要沉积所述金属材料的位置处预热并形成熔池，
ii)以金属材料的进料丝的形式将待沉积的所述金属材料进料至在所述熔池的上方的位置，
iii)采用第二等离子体转移电弧来加热并熔化金属材料的进料丝以使熔融金属材料滴入所述熔池，以及
iv)相对于所述第一和第二等离子体转移电弧的位置以预定图案移动所述支持基板以使熔融金属材料的连续沉积物凝固并形成所述三维物件。
2.根据权利要求1所述的方法，其中，
-通过电连接至直流电源的气体保护钨极电弧焊炬形成所述第一等离子体转移电弧以使所述气体保护钨极电弧焊炬的电极成为阴极而所述基材成为阳极，和
-通过电连接至直流电源的任何常规等离子体转移电弧炬形成所述第二等离子体转移电弧以使所述等离子体转移电弧炬的电极成为阴极而所述金属材料的进料丝成为阳极。
3.根据权利要求1或2所述的方法，其中，所述金属材料是钛或合金钛。
4.根据权利要求1或2所述的方法，其中，通过以下步骤由所述物件的特征尺寸获得所述物件的固体自由成型制造：
-采用计算机辅助设计工具来形成所述物件的虚拟三维模型、将所述模型分成一组虚拟平行层并进一步分成对于每个平行层的一组虚拟准一维片以形成所述物件的虚拟矢量化分层模型，
-将所述物件的虚拟矢量化分层模型加载入能够调节所述支持基板的位置和移动、所述第一和第二等离子体转移电弧炬的激活、和供给所述金属材料的进料丝的丝供给系统的激活的控制系统，
-接合所述控制系统来按照根据所述物件的虚拟矢量化分层模型的第一层的图案来将所述金属材料的进料丝的一系列的准一维片沉积并融合在所述基材上，
-通过按照根据所述物件的虚拟矢量化分层模型的第二层的图案将所述金属材料的进料丝的一系列的准一维片沉积并融合在先前沉积层上形成所述物件的第二层，和
-对于所述物件的虚拟矢量化分层模型的每个连续层逐层重复所述沉积和融合过程直到形成整个所述物件。
5.根据权利要求2所述的方法，其中，使用所述第二等离子体转移电弧通过将所述等离子体转移电弧炬的电极电连接至直流电源的负极并将所述基材电连接至所述直流电源的正极，来将热脉冲递送到所述熔池，以及用来以在从1Hz至10kHz范围内的频率脉冲发送所述直流功率。
6.一种通过固体自由成型制造来制造金属材料的三维物件的装置，其中，所述装置包括：
-具有集成丝进料机的焊炬，其中所述集成丝进料机供给所述金属材料的丝，
-用于相对于所述焊炬定位和移动支持基板的系统，以及
-控制系统，所述控制系统能够读取待形成的物件的计算机辅助设计模型并采用所述计算机辅助设计模型来调节用于定位和移动所述支持基板的系统的位置和移动，以及能够操作所述具有集成丝进料机的焊炬以使得通过将所述金属材料的连续沉积物融合在所述支持基板上来构建物理物件，
其特征在于，
-所述支持基板由和待制作的物件类似的金属材料制成，
-所述焊炬包括
i)电连接至基材的第一等离子体转移电弧炬，和
ii)电连接至所述金属材料的进料丝的第二等离子体转移电弧炬，
-所述控制系统能够独立地操作和调节所述第一等离子体转移电弧炬以在所述基材中在将要沉积所述金属材料的位置处形成并维持熔池，和
-所述控制系统能够独立地操作和调节所述丝进料机和所述第二等离子体转移电弧炬以使熔融金属材料滴入所述熔池的位置处熔化所述金属材料进料。
7.根据权利要求6所述的装置，
-所述第一等离子体转移电弧炬是气体保护钨极电弧焊炬，其电连接至直流电源以使所述气体保护钨极电弧焊炬的电极成为阴极而所述基材成为阳极，和
-所述第二等离子体转移电弧是任何常规等离子体转移电弧炬，其电连接至直流电源以使所述等离子体转移电弧炬的电极成为阴极而金属材料的进料丝成为阳极。
8.根据权利要求7所述的装置，其中，所述气体保护钨极电弧焊炬和所述等离子体转移电弧炬的直流电源是两个独立调节的直流电源。
9.根据权利要求6或7所述的装置，其中
-所述丝进料机是MIG炬，并且
-金属材料的进料丝由钛或合金钛制成并具有以下一种的直径：1.0mm、1.6mm和2.4mm。
10.根据权利要求7所述的装置，其中
-所述第二等离子体转移电弧的电极电连接至直流电源的负极并且所述基材电连接至所述直流电源的正极，和
-以在1Hz至10kHz范围内的频率脉冲发送来自所述直流电源的电位。
CN201280016671.6A 2011-03-31 2012-03-30 用于通过固体自由成型制造来构建金属物件的方法和装置 Active CN103476523B (zh)

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