CN105328185A - 一种气相扩散/反应的激光金属3d打印系统及方法 - Google Patents
一种气相扩散/反应的激光金属3d打印系统及方法 Download PDFInfo
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- CN105328185A CN105328185A CN201510626630.4A CN201510626630A CN105328185A CN 105328185 A CN105328185 A CN 105328185A CN 201510626630 A CN201510626630 A CN 201510626630A CN 105328185 A CN105328185 A CN 105328185A
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- laser
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- shower nozzle
- tracheae
- phase diffusion
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- 239000002184 metal Substances 0.000 title claims abstract description 21
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 21
- 238000009792 diffusion process Methods 0.000 title claims abstract description 18
- 238000006243 chemical reaction Methods 0.000 title claims abstract description 17
- 238000010146 3D printing Methods 0.000 title claims abstract description 14
- 230000004048 modification Effects 0.000 claims abstract description 30
- 238000006011 modification reaction Methods 0.000 claims abstract description 30
- 238000009423 ventilation Methods 0.000 claims abstract description 15
- 239000000126 substance Substances 0.000 claims abstract description 8
- 238000003754 machining Methods 0.000 claims description 11
- 238000005273 aeration Methods 0.000 claims description 10
- 238000007493 shaping process Methods 0.000 claims description 7
- 241000894007 species Species 0.000 claims description 5
- 239000011521 glass Substances 0.000 claims description 3
- 230000001681 protective Effects 0.000 claims description 3
- 230000001360 synchronised Effects 0.000 claims description 2
- 238000002844 melting Methods 0.000 abstract description 4
- 229910052799 carbon Inorganic materials 0.000 abstract description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical compound 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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/003—Apparatus, e.g. furnaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/1039—Sintering only by reaction
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
本发明公开了一种气相扩散/反应的激光金属3D打印系统,包括激光选区熔化成形设备,还包括通气设备,通气设备包括储气罐、气管和喷头,气管安装在所述储气罐上,喷头固定安装在所述激光选取熔化成形设备的激光头上,并且喷头上设置有上下贯通的激光通孔,以使所述激光头发射的激光束从所述激光通孔处穿过所述喷头;所述喷头上还设置有上下贯通的通气孔,以使所述气管中流动的气体从所述通气孔处穿过所述喷头,从而喷到零件上需要进行化学热处理的部位。本发明不仅可以制造复杂结构的零部件,并且可以实现零件中任何区域的改性,包括渗氮/碳增强、氧化物弥散增强等,在实现结构复杂化的同时也可以实现零件的性能设计。
Description
技术领域
[0001] 本发明属于增材制造技术领域,更具体地,涉及一种气相扩散/反应的激光金属3D打印方法及其系统。
背景技术
[0002] 激光3D打印技术基于逐层制造的原理,采用高能激光束作为能源熔化金属粉末逐层堆积成复杂的三维零件结构。该技术将复杂的三维加工转变为简单的二维加工,极大降低了复杂零件的成形难度,可解决传统技术难加工或无法加工复杂结构零部件的难题,在航空航天、汽车、模具、电子等诸多领域具有广泛的应用前景。
[0003]目前,根据金属粉末材料的输送方式激光3D打印技术主要分为基于同轴送粉的激光近形制造(Laser Engineering Net Shaping, LENS)技术和基于粉末床的激光选区恪化(Selective Laser Melting, SLM)技术。LENS技术在惰性气体保护之下,通过激光束恪化喷嘴输送的粉末流,使其逐层堆积,最终形成复杂形状的零件或模具。但该工艺成形难以成形复杂和精细结构,主要用于毛坯成形,且粉末材料利用率偏低。
[0004] SLM技术利用高能束激光熔化预先铺在粉床上薄层粉末,逐层熔化堆积成形。SLM制造的金属零件接近全致密,强度超过铸件水平并接近锻件水平,精度可达0.1mm/lOOmm,特别适合复杂精细零部件的制造。
[0005] 随着3D打印技术的发展,该技术也开始用于制造具有特殊性能设计的复杂零部件,即在特殊区域具有特殊性能的零件。如在复杂零件的表面和心部采用不同材料进行制造,使其具有高表面硬度、耐磨性和高心部韧性的零件。通过多材料3D打印技术虽然可以制造出上述零件,但多种材料容易相互污染,回收困难,同时多材料送粉机构复杂也提高了设备的成本。
[0006]另外,也有采用渗碳/渗氮技术对零件表面进行处理,传统的技术是将工件置入介质中,在一定温度下使介质中分解出的活性原子渗入工件表层,从而获得表层高碳/高氮,心部仍保持原有成分。这种技术一般是对整个工件的表面进行改性,而有些零件只有部分区域需要进行化学热处理改性,这就使得这种技术的应用受到了限制。而对于3D打印成形的零件,如需要进行化学热处理,则需要先打印完以后,然后才能再进行化学热处理工序,这样就降低了生产效率和延长了产品的成形时间。
发明内容
[0007] 针对现有技术的以上缺陷或改进需求,本发明提供了一种气相扩散/反应的激光金属3D打印方法及其系统,其基于可控气体与金属粉末气相扩散/反应的激光3D打印方法,可以实现多种金属零件不同部位在线改性和复杂结构的一体化成形。
[0008] 为实现上述目的,按照本发明的一个方面,提供了一种气相扩散/反应的激光金属3D打印系统,包括激光选区熔化成形设备和通气设备,其特征在于激光可以与通气设备同步运动,其中:
[0009] 所述通气设备包括储气罐、气管和喷头,所述气管安装在所述储气罐上,所述喷头固定安装在所述激光选区熔化成形设备的激光头上,并且所述喷头上设置有上下贯通的激光通孔,以使所述激光头发射的激光束从所述激光通孔处穿过所述喷头;此外,所述喷头上还设置有上下贯通的通气孔,以使所述气管中流动的气体从所述通气孔处穿过所述喷头,进而使气体喷到零件上需要进行化学热处理的部位。
[0010] 优选地,所述储气罐的数量为多个,所述气管和通气孔的数量也相应设置为多个,每个储气罐通过一气管与一通气孔连接,并且每个储气罐中的气体种类不同,另外,每个气管上均安装有流量阀。
[0011] 优选地,所述激光通孔处设置有保护镜。
[0012] 按照本发明的另一个方面,还提供了一种利用所述的3D打印系统进行3D打印的方法,其特征在于,包括以下步骤:
[0013] 1)在计算机上建立零件三维模型,然后将所述零件三维模型转成STL格式文件并导入到选择性激光熔化成形设备中;
[0014] 2)根据零件的服役条件确定零件的改性信息,再将零件三维模型进行分层切片并规划每一层的加工路径,然后输入计算机;其中,每一层的加工路径包括激光头的移动路径和喷头内的通气信息,改性信息包括零件的改性部位及改性部位的性能要求,通气信息包括喷头内的气体的启闭、流量种类;
[0015] 3)按照步骤2)规划的加工路径执行3D打印,完成零件的成形。
[0016] 总体而言,通过本发明所构思的以上技术方案与现有技术相比,能够取得下列有益效果:
[0017] 1)本发明采用逆向思维,利用激光3D打印高温金属液体的活性,通过在线控制气体种类、流量和通入位置,使气体与加工金属粉末在3D打印过程中发生可控的元素扩散或反应,从而实现多种类型复杂结构金属材料制备和改性,尤其适合制备航空航天、汽车、电子等应用领域所需的铝基、钛基、镍基、铁基材料。因为气体输入更易控制,并且避免了异种材料的污染,可以大大降低该类3D打印机的成本;
[0018] 2)本发明在激光3D打印过程中,通气装备按照所需改性部位的信息规划出通气设备移动路径,喷头与激光头同步移动,并定量通入所需气体,实现需要改性部位的气相扩散/反应;不需要改性的部位,激光头移动,但喷头内不通入气体,实现加工,因此在进行3D打印的同时也能进行零件化学热处理,能有效提高工作效率;
[0019] 3)本发明不仅可以制造复杂结构的零部件,并且可以实现零件中任何区域的改性,包括渗氮/碳增强、氧化物弥散增强等,在实现结构复杂化的同-时也可以实现零件的性能设计。
附图说明
[0020] 图1是本发明中3D打印系统的结构示意图;
[0021] 图2是本发明中3D打印系统进行加工时的结构示意图;
[0022]图3是本发明加工的一模具零件的结构示意图;
[0023]图4和图5分别是图3中的模具零件的不同部位横截面的示意图。
具体实施方式
[0024] 为了使本发明的目的、技术方案及优点更加清楚明白,以下结合附图及实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅仅用以解释本发明,并不用于限定本发明。此外,下面所描述的本发明各个实施方式中所涉及到的技术特征只要彼此之间未构成冲突就可以相互组合。
[0025] 参照图1、图2,一种气相扩散/反应的激光金属3D打印系统,包括选择性激光熔融成形设备1,还包括通气设备2,其中,
[0026] 所述通气设备2包括储气罐21、气管20和喷头23,所述气管20安装在所述储气罐21上,所述喷头23固定安装在所述激光选取熔化成形设备1的激光头11上,并且所述喷头23上设置有上下贯通的激光通孔231,以使所述激光头11发射的激光束12从所述激光通孔231处穿过所述喷头23 ;此外,所述喷头23上还设置有上下贯通的通气孔232,以使所述气管20中流动的气体从所述通气孔232处穿过所述喷头23,进而使气体喷到零件上需要进行化学热处理的部位。
[0027] 优选地,所述储气罐21的数量为多个,所述气管20和通气孔232的数量也相应设置为多个,每个储气罐21通过一气管20与一通气孔232连接,并且每个储气罐21中的气体种类不同,每个气管20上均安装有流量阀22,以控制通过喷头23的气体流量。
[0028] 优选地,所述激光通孔231处设置有保护镜3,能有效防止飞肩从激光通孔231内穿过而损坏激光头11。
[0029] 按照本发明的另一个方面,还提供了一种利用所述的3D打印系统进行3D打印的方法,包括以下步骤:
[0030] 1)在计算机上建立零件三维模型,然后将所述零件三维模型转成STL格式文件并导入到选择性激光熔化成形设备中;
[0031] 2)根据零件的服役条件确定零件的改性信息,将改性信息和零件三维形状信息整合,再将零件三维模型进行分层切片并规划每一层的加工路径,其中每一层的加工路径包括激光头11的移动路径和喷头23内的通气信息,然后将这些信息数据输入计算机;其中,改性信息包括零件的改性部位及改性部位的性能要求,通气信息包括喷头23内的气体的启闭、流量和种类;
[0032] 3)按照步骤2)规划的加工路径执行3D打印,完成零件的成形。
[0033] 参照图2,本发明的3D打印系统可以实现喷头23和激光头11同步移动,当加工需要改性的部位时,打开储气罐21开关,并通过调节流量阀22来输入适量的气体G,高能量激光束12将粉层Μ熔化,形成如图2所示的微小熔池4,在熔池4高温的作用下,通入的气体G会与液态金属Μ发生反应M+G — MG,生成的MG分布在金属Μ的基体中,可以实现指定区域金属的改性;当加工不需要改性的部位时,关闭储气罐开关,停止输入气体G,在激光束12单独作用下完成这一层的加工。
[0034] 与现有激光3D打印技术相比,该方法不仅可以制造复杂结构的零部件,并且可以实现零件中任何区域的改性,包括渗氮/渗碳增强、氧化物弥散增强等,在实现结构复杂化的同时也可以实现零件的性能设计。
[0035] 与传统激光3D打印技术相比,本发明创新地提出基于可控气体与金属粉末气相扩散/反应的激光3D打印方法,可以实现多种金属零件不同部位在线改性和复杂结构的一体化成形。具体特点有:
[0036] 1)激光3D打印过程中,按照所需改性部位的信息规划出通气设备2移动路径,喷头23与激光头11同步移动,并按设定的量通入所需气体,实现需要改性部位的气相扩散/反应。不需要改性的部位,激光头11移动,但喷头23内不通入气体,实现加工。
[0037] 2)该方法采用分层制造的原理,根据零件三维形状信息和需要改性位置信息进行分层切片并规划每一层的加工路径,每一层的加工路径包括激光头11移动路径信息和喷头23内的通气信息。其中通气信息包括气流量、气体种类。
[0038] 3)通气设备2具有多个气路,每个气路具有独立控制的流量阀22,具有调控流量的功能。
[0039] 4)通入喷头23内的气体可为N2、C0、CH4、C02、02的一种或多种混合,但不局限于以上种类的气体。
[0040] 5)整个激光3D打印过程在真空室中进行,真空度为10 2Pa以下。
[0041] 参照图3〜图5,此零件为具有复杂冷却水道的模具,该零件无法用传统机加工方法进行制造,特别适合激光3D打印。此模具需要较高的表面硬度和耐磨性,传统模具钢材料在3D打印时极易出现热应力、裂纹等缺陷,影响使用寿命。因此选用塑形好的316L不锈钢进行制造,同时使用气相扩散方法进行表面硬化,获得外硬内韧的零件,加工制造周期短、成本低。
[0042] 首先,获取模具表面和流道表面信息,建立厚度为l_2mm的硬化区域,图4和图5中剖面线部分即为硬化区域,将该信息和零件三维结构信息整合。通过软件进行切片,图4和图5分别为图3模具零件不同截面的切片图,获得喷头23和激光头11运动路径和通气信息数据,将这些信息数据输入计算机。
[0043] 然后,启动激光3D打印装备、气源和气路装置。根据切片信息,激光头11和喷头23同步移动,根据通气信息,在需要通气的位置通入定量的N2,即在加工切片剖面线部分时,通入气体,在激光和气体的作用下完成该部分的加工;在加工空白部分位置时,不需要通气,关闭气路,完成整个截面的加工。
[0044] 最后,在已成形的平面上铺置一层新的粉层M,再进行下一层加工,直至完成整个三维零件的制造。
[0045] 本领域的技术人员容易理解,以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。
Claims (4)
1.一种气相扩散/反应的激光金属3D打印系统,包括选择性激光选区成形设备(1)和通气设备(2),其特征在于激光与气体的同步移动装置,所述通气设备(2)包括储气罐(21)、气管(20)和喷头(23),所述气管(20)安装在所述储气罐(21)上,所述喷头(23)固定安装在所述激光选区熔化成形设备(1)的激光头(11)上,并且所述喷头(23)上设置有上下贯通的激光通孔(231),以使所述激光头(11)发射的激光束(12)从所述激光通孔(231)处穿过所述喷头(23);此外,所述喷头(23)上还设置有上下贯通的通气孔(232),以使所述气管(20)中流动的气体从所述通气孔(232)处穿过所述喷头(23),进而使气体喷到零件上需要进行化学热处理的部位。
2.根据权利要求1所述的一种气相扩散/反应的激光金属3D打印系统,其特征在于,所述储气罐(21)的数量可以为多个,所述气管(20)和通气孔(232)的数量也可以相应设置为多个,每个储气罐(21)通过一气管(20)与一通气孔(232)连接,并且每个储气罐(21)中的气体种类不同,另外,每个气管(20)上均安装有流量阀(22)。
3.根据权利要求1所述的一种气相扩散/反应的激光金属3D打印系统,其特征在于,所述激光通孔(231)处设置有保护镜(3)。
4.一种利用权利要求1〜3中任一权利要求所述的3D打印系统进行3D打印的方法,其特征在于,包括以下步骤: 1)在计算机上建立零件三维模型,然后将所述零件三维模型转成STL格式文件并导入到激光选区熔化成形设备中; 2)根据零件的服役条件确定零件的改性信息,再将零件三维模型进行分层切片并规划每一层的加工路径,然后输入计算机;其中每一层的加工路径包括激光头(11)的移动路径和喷头(23)内的通气信息,改性信息包括零件的改性部位及改性部位的性能要求,通气信息包括喷头(23)内的气体的启闭、流量和种类; 3)按照步骤2)规划的加工路径执行3D打印,完成零件的成形。
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