CN107735197A - 附带表面再处理的基于粉末床的增材制造方法和适用于该方法的设备 - Google Patents

附带表面再处理的基于粉末床的增材制造方法和适用于该方法的设备 Download PDF

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CN107735197A
CN107735197A CN201680039213.2A CN201680039213A CN107735197A CN 107735197 A CN107735197 A CN 107735197A CN 201680039213 A CN201680039213 A CN 201680039213A CN 107735197 A CN107735197 A CN 107735197A
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D.雷兹尼克
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Siemens AG
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Abstract

本发明涉及一种基于粉末床的增材制造方法，所述方法可以在一个用于增材制造方法的设备(1)中实施。本发明还涉及这种设备。按照本发明规定，在设备中设有用于烧蚀介质的涂施装置(26)、例如印刷头。通过该涂施装置可以与构件(25)的增材制造交替地实施激光喷丸，借此有利地也在构件的内表面(27)进行再处理，以便产生压应力。为此设有脉冲激光器(28)，所述脉冲激光器与用于增材制造工艺的能量源(20)(激光器)可以交替地运行，其中，通过脉冲激光器(28)使由涂施装置(26)涂覆的烧蚀介质蒸发，以便产生压应力。

Description

附带表面再处理的基于粉末床的增材制造方法和适用于该方 法的设备
本发明涉及一种基于粉末床的增材制造方法，其中，在构造过程中通过使粉末床中的颗粒一层一层地局部熔融而产生构件。此外，通过激光喷丸实施所述构件的表面的再处理，其中，通过激光喷丸在所述构件内的表面上产生压应力。
本发明还涉及一种用于基于粉末床的增材制造方法的设备。所述设备具有粉末床容纳装置，其中，粉末床容纳装置是一种在其中可以产生粉末床的装置。为此，在设备内设有用于粉末的计量装置，其中，粉末床容纳装置还具有构造平台，在构造平台上放置被增材制造的构件并且可以一层一层地降低。为了在设备内制造构件还设有能量源，处于所述粉末床容纳装置内的粉末床通过所述能量源能够被局部熔化。能量源优选是用于产生激光束的激光器或者用于产生电子束的电子源。由此，可以实施选择性激光熔融、选择性激光烧结或选择性电子束熔融。
根据US 2014/0034626 A1已知，通过激光烧结制成的构件在其表面上优选形成张应力。这是因为在选择性激光熔融时(并且也在选择性电子束熔融时)通过激光器使粉末床内非常小的体积熔融。当从当前的熔融池移走激光器时，熔融的区域就会以大约105℃/s的冷却率冷却并且相应地收缩。这解释了所述张应力如何形成的。之前在下面制造的构件的层相应地承受压力，因为这些层承受所述在表面上的张应力。
但是，构件的表面上的张应力在机械结构中是不利的，因为腐蚀侵入或裂缝由于机械应力可以快速地扩张到构件的内部。因此根据US2014/0034626 A1建议，对通过激光熔融制成的构件实施再处理，借此将在表面上存在的张应力转变为压应力。这可以通过热处理(低应力灼烧)借助热力等静压挤压或者也借助表面的机械处理、喷丸(peening)实现。为了进行表面喷丸，在US 2014/0034626 A1中建议一种喷丸处理或激光喷丸(laserpeening)。根据DE 10 2009 051 551 A1建议，激光喷丸不仅用于制成构件的再处理，还在制造期间进行，方法是，在制造出一层之后为了使用激光喷丸而中断构造过程。
激光喷丸(也称激光冲击喷丸)是一种已知的方法，其例如在US5,674,328中以详细描述。在待处理的表面上涂覆液态或固态的烧蚀介质，其随后通过激光脉冲被剥除。这个过程也称为激光烧蚀。因为激光是脉冲式的，通过烧蚀介质的突然蒸发产生冲击波，该冲击波也从表面开始扩散到构件的内部中，并且在那里导致锻压过程。材料的局部变形产生压应力，由此甚至可以减低张应力。
但是，借助激光喷丸的再处理的前提是，构件的表面在通过激光熔融制成之后对于激光是可到达的。但是，通过激光熔融和其它增材制造方法优选制成具有非常复杂的几何结构的构件。在此，也产生空腔和内表面，它们可能在构件制成之后无法被激光达到。
本发明所要解决的技术问题是，提供一种用于构件的基于粉末床的增材制造方法，通过该方法也可制造具有复杂几何形状的表面的构件，邻近表面处被施加压应力，其中，使产生压应力的耗费尽可能地低。此外，本发明所要解决的技术问题还在于，提供一种制造设备，由此可以实施这种改进的增材制造方法。
所述技术问题按照本发明通过前述的制造方法由此解决，即，为了实施所述构件的表面的再处理，在制造出一层后中断构造过程。随后，对所述构件的表面的已构造的部分实施激光喷丸，其中，所述构件按照本发明为了再加工保留在用于基于粉末床的增材制造方法的设备的粉末床内。所以接下来可以有利地为了制造下一层再次进行构造过程。因此按照本发明规定，基于粉末床的增材制造过程至少一次被中断，以便通过激光喷丸进行再处理。这具有的优点是，通过激光喷丸也可以对一些构件区域进行再处理，这些构件区域在制成构件之后无法再到达(例如空腔)。为了能够在用于增材制造方法的设备内进行激光喷丸，必须对制造设备进行相应的改造。为了通过激光喷丸进行处理，需要脉冲激光器。此外，烧蚀介质必须涂覆在正在产生的构件的待再处理的构件区域内，为此按照本发明，在制造设备中设有涂施装置。
由此，所述技术问题也通过一种改造的、用于基于粉末床的增材制造方法的设备被解决，其中，在所述设备内相对于设置用于熔化粉末床的能量源附加地集成有脉冲激光器，所述脉冲激光器能够指向所述粉末床容纳装置并且由此也指向正在产生的构件的已制成的部分。随后，通过所述脉冲激光器能够实施激光喷丸，其中，在该处理之前必须借助涂施装置在待再处理的构件区域上涂覆烧蚀介质。脉冲激光器的功率必须如此定量，使得其足够实施激光喷丸。
用于烧蚀介质的涂施装置可以有利地是用于液态的烧蚀介质的印刷头。在此，有利地使用在增材制造方法、如3D打印中已应用的部件。涂施装置可以集成在用于激光熔化的设备中并且允许液态烧蚀介质的涂覆。烧蚀介质可以作为液膜用于激光喷丸。另外的可行性是，液态的烧蚀介质在实施激光喷丸之前被干燥(溶液的蒸发)或硬化。液态的烧蚀介质也可以包含颗粒形式的固体。
另外有利的可行性是，烧蚀介质以薄膜的形式使用。薄膜可以通过卷材形式的涂施装置设置在设备内。烧蚀介质则可以简单地在正在产生的构件的表面上展开。特别有利的是，所述薄膜具有条带的形状。这种条带必须足够宽，使得其上或者可以施加一条激光脉冲的轨迹或者可以多条激光脉冲的轨迹彼此相邻地施加。在此，烧蚀介质可以有利地非常充分地被利用，而不会产生大的薄膜边角料。薄膜条带必须在更大的(也就是比条带宽度更宽的)待处理面上重复地展开并且横向于其纵向延伸段在待处理的面上移动，用于激光脉冲在待处理的面上产生相邻的轨迹。
根据按照本发明的方法的设计方案规定，为了再处理而多次中断构造过程，并且所述表面的已构造的部分被如此再处理，使得被再处理的部分直接邻接所述表面的先前已被再处理的部分。以这种方式可以有利地实现对构件的内表面的覆盖整个表面的再处理。用于再处理的策略在了解CAD模型的情况下可以容易地计算，因为本来为了通过增材制造方法制造构件就要使用CAD模型。
有利的是，再处理局限在所述表面的在构件制成之后无法再到达以实施再处理的部分上。为了累进地实施再处理必须始终再次中断增材的制造方法，从而产生耗费，而所述耗费可以由此保持尽可能地小。外侧的、也就是可到达的表面也可以在整个构件制成之后以已知的方式实施再处理，其例如也通过激光喷丸实施，但是也可通过另外的在所述的现有技术中已知的工艺实施再处理。
在本发明的另外的设计方案中，每次在再处理之前，将没有被熔融的颗粒从所述表面的预设用于再处理的部分上清除。这例如可以通过粉末颗粒的局部的抽吸实现。烧蚀介质在待再处理的表面上的涂覆有利地不会由于残留的颗粒被干扰。此外可行的是，实施构件部分的再处理，这些部分之前在增材制造方法的多个依次的步骤中产生。这具有的优点是，用于增材制造构件的过程只需很少地中断。但只要所产生的构件的内表面还可到达，就必须对于构件区域实施再处理。换句话说，在内表面由于构件体积的封闭无法再到达之前，必须对其实施再处理。
用于激光喷丸的烧蚀介质可以有利地以薄膜的形式粘贴在构件上。在此，薄膜如前所述可以从卷材上展开。另外的可行性是，薄膜段以适合的方式被切割并且借助涂施装置直接施加在待再处理的构件区域上。作为涂施装置例如可以使用操作系统，例如通常用于电子器件组装的操作系统，尤其是抽吸体，其通过负压暂时固定所切割下的薄膜段，并且放置在构件的待再处理的表面上。
还有利的是，在完成激光喷丸之后，在为了制造下一层而再次进行构造过程之前，将在激光喷丸时未使用的剩余的烧蚀介质从所述构件的表面上清除。这例如可以通过抽吸实现并且其具有的优点是，构件的下一层在其制造过程中不会由于烧蚀介质而被污染。特别有利的是，未使用的烧蚀介质通过也用于熔融颗粒的那个能量源被清除。借助激光束或电子束可以使烧蚀介质蒸发，其中，该能量不是脉冲式地施加，从而不会导致不希望的激光喷丸。所述未使用的烧蚀介质材料被持续地去除。
以下结合附图阐述本发明的另外的细节。相同的或相应的附图元素分别标以相同的附图标记，并且只有在各个附图之间存在差别时才多次阐述。在附图中：
图1和2示出按照本发明的用于基于粉末床的增材制造方法的设备的实施例的剖面示意图，和
图3至9示意性地示出按照本发明的基于粉末床的增材制造方法的实施例的所选择步骤。
根据图1的制造设备具有处理室11，在处理室中设有粉末床容纳装置12。该粉末床容纳装置具有结构平台13，该结构平台被侧壁14围绕并且可以通过气缸15下降。由此产生一个凹形的空腔，在空腔中可以产生粉末床16。
为了产生粉末床而使用刮板17，所述刮板可以将来自粉末存储器中的粉末分布在粉末床16上。所述方法在这方面是已知的并且对此不再详细描述。刮板17可以在导轨19上沿导轨运动。
在图1中还示出，借助激光器作为能量源20可以产生激光束21。该激光束21通过光学耦合器22和转向镜23穿过窗户24被导引至处理室11内，并且在那里扫过粉末床16的表面，在此应形成构件25。作为将激光用作能量源20的替代，也可以使用用于电子束的发生装置(未示出)。
通过导轨19，印刷头26也可以在粉末床16的表面上运动，以便在那里涂覆液态的烧蚀介质，用于构件25的表面27的后续处理。为此，印刷头26下降到构件25的待再处理的区域，并且在那里涂施液态的烧蚀介质。随后，激活脉冲激光器28，借助脉冲激光器28可以实施再处理。在此，还使用光学耦合器22和转向镜23(参见图2)。
在图2中示出用于薄膜29形式的烧蚀介质的另外的涂施方法。薄膜从存储卷材30上展开并且剩余的薄膜29卷绕在另外的卷材31上。在此涉及所谓的卷对卷过程。还可看到刮板17，其中，刮板17在导轨19上的运动方向垂直于薄膜29从存储卷材30至卷材31的运动方向地定向。由此，刮板17和薄膜29可以交替地下降到粉末床16上。
通过脉冲激光器28产生脉冲激光束32，该脉冲激光束在构件25的内表面27上实施激光喷丸。在此，在相应的位置33上薄膜29的材料蒸发，这引发已述的激光喷丸过程。
在图3至9中示例性地示出按照本发明的方法的可能的流程。在此，分别仅示出制造设备的在相关的制造步骤中需要的部分。粉末床也没有示出其围绕的结构平台13或侧壁14，其中，在图3至9使用的制造设备的结构可以根据图1构造。
在图3中示出，如何制造粉末床的第一层34a。借助激光束21在该层34a中制造构件25的第一层。在第一层34中产生的构件用阴影示出。
在图4中示出，如何在粉末床上施加第二层34b并且在此如何借助激光器21部分熔融。在此，产生构件25的另一部分，其之后形成构件25的侧壁。
在图5中示出，如何从构件内存在的凹穴35中借助抽吸装置36清除粉末床的粉末。
在图6中示出，如何借助印刷头26在构件25的表面27上涂覆液态的烧蚀介质37。该烧蚀介质37可以随后借助热辐射器38被硬化(可选的步骤)。
在图7中示出，如何借助脉冲激光器28产生脉冲激光束32并且在表面27上使烧蚀介质37发生蒸发。在此，在表面27上的一些区域内产生压应力，这些区域之前根据方法流程产生了张应力。
在图8中示出，如何借助刮板17产生粉末床内的第三层34c。在此，还再次填充了凹穴35(参见图5)。
在图9中示出，如何再次针对第三层34c采用选择性激光熔化方法并且继续产生构件25的壁。通过重复步骤6和7，所产生的垂直的壁可以通过实施激光喷丸(未示出)一层一层地消除张应力。

Claims (13)

1.一种基于粉末床的增材制造方法，
-其中，在构造过程中通过使粉末床(16)中的颗粒一层一层地局部熔融而产生构件(25)，并且
-通过激光喷丸实施所述构件的表面(27)的再处理，其中，在所述构件(25)内的表面(27)上产生压应力，
其中，
-为了实施所述构件(25)的表面(27)的再处理，在制造出一层后中断构造过程，
-对所述构件(25)的表面(27)的已构造的部分实施激光喷丸，并且
-为了制造下一层再次进行构造过程，
其特征在于，在设备中设有用于烧蚀介质的涂施装置(26、31)。
2.按照权利要求1所述的制造方法，其特征在于，为了再处理而多次中断构造过程，并且所述表面(27)的已构造的部分被如此再处理，使得被再处理的部分直接邻接所述表面(27)的先前已被再处理的部分。
3.按照前述权利要求之一所述的制造方法，其特征在于，再处理局限在所述表面(27)的、在构件(25)制成之后无法再到达以实施再处理的部分上。
4.按照前述权利要求之一所述的制造方法，其特征在于，每次在再处理之前，将没有被熔融的颗粒从所述表面(27)的预设用于再处理的部分上清除。
5.按照前述权利要求之一所述的制造方法，其特征在于，用于激光喷丸的烧蚀介质以薄膜(29)的形式被粘贴。
6.按照权利要求1至4之一所述的制造方法，其特征在于，用于激光喷丸的烧蚀介质以层(37)的形式被涂覆。
7.按照权利要求6所述的制造方法，其特征在于，通过印刷实施层(37)的涂覆。
8.按照权利要求1至4之一所述的制造方法，其特征在于，在完成激光喷丸之后，在为了制造下一层而再次进行构造过程之前，将在激光喷丸时未使用的剩余的烧蚀介质从所述构件(25)的表面(27)上清除。
9.按照权利要求8所述的制造方法，其特征在于，未使用的烧蚀介质通过能量源(20)被清除，所述能量源(20)也用于熔融颗粒。
10.一种用于基于粉末床的增材制造方法的设备，其具有
-粉末床容纳装置(12)，
-能量源，处于所述粉末床容纳装置(12)内的粉末床通过所述能量源能够被局部熔化，和
-相对于所述能量源(20)附加的脉冲激光器，所述脉冲激光器能够指向所述粉末床容纳装置(12)，并且通过所述脉冲激光器能够实施激光喷丸，
其特征在于，在设备中设有用于烧蚀介质的涂施装置(26、31)。
11.按照权利要求10所述的设备，其特征在于，所述涂施装置(26、31)具有用于液态的烧蚀介质的印刷头(26)。
12.按照权利要求10所述的设备，其特征在于，所述涂施装置具有用于薄膜(29)形式的烧蚀介质的存储卷材(31)。
13.按照权利要求12所述的设备，其特征在于，所述薄膜(29)具有条带的形状。
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CN110116207A (zh) * 2019-05-14 2019-08-13 中国航发北京航空材料研究院 激光选区熔化增材制造构件的强化装置和方法
CN113382820A (zh) * 2019-06-11 2021-09-10 三菱重工工作机械株式会社 三维层叠方法及三维形状物

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