CN109689267A - Method and apparatus for constructing metal object by solid free fo manufacture by two welding guns - Google Patents

Abstract

Provide a kind of system and method for manufacturing by solid free fo to manufacture object, the object especially titanium and titanium alloy object, wherein, increase deposition rate by using two individual heat sources, one heat source is for the deposition region on heated substrate, and a heat source is for heating and melting metal material, such as wire or powdered metal materials.

Description

For the side of metal object to be constructed by solid free fo manufacture by two welding guns Method and equipment

Related application

Entitled " the method for being manufactured by solid free fo to construct metal object submitted on September 27th, 2013 And equipment " U.S. Patent Application Serial Number 14/008,307, be international filing date be on March 30th, 2012 it is entitled " use In the method and apparatus for constructing metal object by solid free fo manufacture " international patent application no PCT/NO2012/ 000033 American National stage, this application require to submit on March 31st, 2011 entitled " for by solid free fo system Make the method and apparatus to construct metal object " GB Patent Application No. GB 1105433.5 priority, it is above-mentioned it is each specially The full content of the theme of benefit application is by being incorporated herein.

Technical field

The present invention relates to one kind for manufacturing object (especially titanium and titanium alloy object by solid free fo manufacture Body) method and apparatus.

Background technique

The nanostructured metal component made of titanium or titanium alloy by blank usually by being cast, forging or being processed into.This The shortcomings that a little technologies, is largely long using expensive titanium metal material and manufacture delivery time.

(SFFF) can be manufactured by referred to as rapid prototyping manufacturing, quick manufacture, Layered manufacturing, solid free fo, add It adds and makes, adds the manufacturing technology of production and 3D printing to manufacture fully dense physical objects.The technology uses area of computer aided (CAD) software is designed to construct the dummy model of object to be manufactured first, it is generally horizontal fixed to be then converted into dummy model To thin parallel slices or layer.May then pass through by liquid, paste, powder or other can layered, smearable or fluid shape The continuous layer of feed stock material setting-out of formula (such as molten metal, such as the welding wire from fusing) or be pre-formed into is similar to The sheet material of the shape of virtual level manufactures physical objects until forming whole object.These layers can fuse together solid to be formed Body densification object.

Solid free fo manufacture is a kind of flexible technology, allows to form substantially any shape with relatively fast productivity The object of shape, this usually requires to differ from a few houres to several days for each object.Therefore, which is suitable for the formation of prototype It produces, and is may be scaled up to be produced in enormous quantities with small lot.

Layered Manufacturing Technology can be extended to include the deposition of the piece of building material, that is, each of dummy model of object Structure sheaf is divided into a pack, they form the layer when placed side by side.This allows through the virtual hierarchy mould according to object Type will be entire until being formed in welded wire to substrate and to every layer of repetition process in forming every layer of continuous strip Physical objects form metal object.The precision of welding technique is generally too coarse, is subjected to so that cannot directly be formed and be had The object of size.Therefore, it is formed by object and is typically considered the green object for needing to be processed to acceptable size precision Or preformed member.

The manufacture of electron beam free forming is well known in the art (for example, with reference to Taminger et al. (at 2002 8 What on the moon 5 to 7 was delivered in the 13rd solid free fo manufacture seminar that Austin, TX is held " passes through electricity The characteristic of 2219 aluminium of beamlet free forming manufacture "；In the collection of thesis (2002) of The University of Texas at Austin； Taminger et al. is (in the annual automotive composite material meeting of September 9 to 10 thirds in Michigan in 2003 Collection of thesis " electron beam free forming manufacture: quick metal deposition process " plastic engineering Shi Xiehui (2003)；And Taminger and Hafley (" the electron beam free forming manufacture for the manufacture of cost-benefit near-net shape ", NATO/ RTOAVT-139 carries out the specialists meeting (Amsterdam, the Netherlands, 2006) of cost-effectiveness manufacture about processing by net shape (NATO), the 9-25 pages)).Taminger and Hafley (2006) describe it is a kind of for directly from combine electron beam freely at The method and apparatus that shape makes the computer-aided design data manufacture structural metal element of (EBF).Structure member passes through welding It is constructed on the pantostrat of metal welding wire, metal welding wire is welded by the thermal energy provided by electron beam.EBF technique is related to metal Silk is supplied in the preheated zone or molten bath for being formed and being maintained in high vacuum environment by focusing electron beam.By making electron beam gun Movably hingedly and pass through four axes motion control along one or more axis (X, Y, Z and rotation) with the actuator of supporting substrate System adjusts the position of electron beam gun and supporting substrate to obtain the positioning of electron beam and welding wire.It is said that the technique is in materials'use Aspect almost 100% effectively, in loss efficient up to 95%.This method can be used for reguline metal deposition and it is finer in detail Thin deposition, and compared with traditional metal parts processing method, this method requires to the shortening time of delivery and reduces material Have with processing cost and significantly affects.

The known heat provided using plasma arc for welding metal material.This method can in atmospheric pressure or It uses, and therefore allows using simpler and cheaper process equipment under higher pressure.Method as a kind of is referred to as gas Body tungsten arc welding (GTAW, also be indicated as Wolfram Inert Gas (TIG) welding), in the method, in non-expendable tungsten electrode and Plasma transferred arc power is formed between welding region.Gas of the plasma arc usually by being supplied by plasma torch It protects, the gas of plasma torch supply forms protection cap around electric arc.TIG weld may include by wire or Metal powder is supplied in molten bath or plasma arc using as filler.

By solid free fo manufacture (SFFF) constructed using tig torch object be it is known (for example, with reference to The U.S. Patent Publication No. 2010/0193480 of Adams), in the method, the continuous metal raw material with low ductility Layer is applied on substrate.Plasma stream is generated by using the gas of arc electrodes excitation flowing, arc electrodes tool It is provided with to the variable amplitude electric current of the arc electrodes.Before the deposition, plasma stream is directed into scheduled target area To preheat scheduled target area.Electric current is adjusted, and raw material (such as wire) is introduced into plasma stream to incite somebody to action Fused raw material is deposited in scheduled target area.Electric current is adjusted, and makes fused raw material Slow cooling at elevated temperatures, it should Raised temperature usually above raw material brittleness to tough transition temperature, in cooling stage, so that generating material stress Possibility minimizes.

Withers et al. (U.S. Patent Publication No. 2006/185473) is also described to be replaced traditionally using using tig torch In the expensive laser of SFFF technique, the titanium charging with relatively low cost passes through the side to significantly reduce the cost of raw material Formula combines titanium charging and alloy compositions.Withers et al. is taught, and it is pure lower than the non-alloyed commercialization of alloy wire that cost can be used Titanium silk (CP titanium silk), and by combining CP titanium silk and powder alloying components in welding torch melt or other high-power energy beams, CP titanium silk can be used in combination in situ with powder alloying components in SFFF technique.Wither et al. is taught that, titanium sponge Material can mix with alloying element and be formed wire, can in SFFF technique with plasma welding torch or other high powers Energy beam is used in combination to generate near net-shaped titanium part.

Abbott et al. (WO 2006/133034,2006), which is described, manufactures complexity three using laser/electric arc hybrid technique Tie up the direct metal deposition technique of shape comprising substrate is provided and uses laser emission and electric arc on substrate from raw metal The step of depositing the first melting metal layer.Electric arc can use raw metal to mention as electrode by gas metal arc welding torch For.Abbott et al., which teaches being used in combination for laser emission and gas metal arc welding, can stablize electric arc and it is said that can mention For higher processing speed.Abbott et al. using by wire guiding devices guide and from wire guiding devices draw from Power pole.The metal of consutrode is end melted, and by the way that end to be located on saltation point come depositing molten metal.With In fusing consutrode institute's calorific requirement can by the electric arc that is expanded between the tip of electrode and workpiece/deposition substrate and It is provided by laser irradiation deposition region.Referred to as gas shield is welded by the consutrode of electric arc heated by melting Metal arc welding (GMAW), wherein be also referred to as Metallic Inert Gas using non-active gas to form electric arc and protect Shield weldering (MIG welding).

The titanium or titanium alloy for being heated to 400 DEG C or more may be aoxidized when contacting with oxygen.Therefore, it is necessary to Protection manufactures the weld seam to be formed and heated object against the influence of oxygen in ambient air by being layered free forming.

Guldberg (WO2011/019287) teaches a solution for this problem, and it is logical that it discloses one kind Cross in the closed reactor chamber of ambient air by SFFF manufacture object (especially titanium and titanium alloy object) it is heavy to improve The method of product rate.By keeping settling chamber fully not oxygenous, it is no longer necessary to be avoided using safeguard measure by ambient air Oxidation of the oxygen to new welding region allows welding process with the progress of higher speed, because can permit welding region tool There is risk of the higher temperature without having weld seam excessive oxidation.For example, when producing the object of titanium or titanium alloy, it is no longer necessary to Welding region is cooled to 400 DEG C or less to avoid oxidation.

The solution of deposition rate is improved from another kind known to Keicher et al. (U.S. Patent number 6,268,584), Disclose a kind of deposition head assembly comprising following characteristics: a row exports powder jet, is used to generate to the meeting of deposition region Poly powder stream；Medium pore allows multiple beams to focus in deposition substrate；And the coaxial air-flow for each powder jet, It concentrates the powder stream from these nozzles, in order to provide the longer operating distance between nozzle and deposition head assembly.Compared with Long operating distance for ensure molten metal particle it is non-cohesive during processing be vital on depositing device.Specifically Ground, Keicher et al. describe a kind of manifold system designed in deposition head assembly, which can be simultaneously using not Only a laser beam is to be used for deposition process.Depositing head assembly further includes for initiatively concentrating the powder stream from each aperture To improve the device of material use efficiency.

Abbott et al. (WO 2006/133034) is described for the another of the problem related to the reaction property of molten titanium A solution, which depict the combinations of using gas metal arc and laser welding.If gas metal arc technology has Dry disadvantage, this severely limits their applications in deposition titanium.These disadvantages include the unstability, excessive of metal transfer Splash high heat input that is poorly controlled with sedimentary shape, and causing slice to deform during deposition.Moreover, because The drift of the cathode protection occurred during deposition, it is impossible to improve productivity.The solution of these problems is directed to according to Abbott et al. Certainly scheme is related to direct metal deposition technique comprising provides substrate and metal is deposited to from raw metal to the step on substrate Suddenly.Electric arc is generated between raw metal and substrate, and electric arc is exposed to laser emission to form molten metal on substrate Pond.Cooling molten metal pond on substrate to form the first solid metallic layer.

Problem to be solved is that material is deposited on the speed on substrate to form workpiece.Can increase the temperature of wire with Preheated metallic silk melts it with faster rate.However, higher temperature will lead to spraying transfer or splashing or uncontrolled Molten metal be added in pool of molten metal from the electrode of fusing, so as to cause it is bad deposition and not can control sedimentary Shape.The excessive temperature in preheated zone or molten bath also result in deposition during thin layer deformation.

Therefore, this field needs a kind of economic means that direct metal deposition is carried out with increased metal deposition rates.? A kind of method of capacity and output for improving Process of Direct Metal Deposition product is also needed in the field.

Summary of the invention

It is an object of the present invention to provide a kind of for constructing the device of metal object by SFFF.

It is a further object to provide a kind of methods for the fast hierarchical manufacture object in titanium or titanium alloy.

The present invention solves the demand of the method for improved, economic execution direct metal deposition.The present invention is into one Step solves the production without deformation Process of Direct Metal Deposition component for improving with sedimentary boundaries that are smooth, clearly limiting The demand of the method for ability and yield.

The present invention is based on following understanding: can increase deposition rate by using double welding gun system, which can To include first welding gun in target deposition region for example in pre- hot substrate and for heating and melting wire Two welding guns.The various combinations of the first welding gun and the second welding gun can be used.First welding gun may include laser aid for preheating Target deposition region on substrate, and the second welding gun may include plasma arc (PAW) welding torch, such as plasma transferred Electric arc (PTA) welding torch, for wire to be heated to and is melted to the target deposition region on substrate.First welding gun may include PAW welding torch, such as PTA welding torch are with the target deposition region in pre- hot substrate, and the second welding gun may include laser aid For wire to be heated to and is melted to the target deposition region on substrate.First welding gun may include first laser device with Target deposition region in pre- hot substrate, and the second welding gun may include second laser device for heating wire And it is melted on the target deposition region on substrate.First welding gun may include that laser aid is heavy with the target in pre- hot substrate Product region, and the second welding gun may include coaxial powder supply nozzle laser system for heating and being melted to metal powder On target deposition region on substrate.First welding gun may include electron beam device with the target deposition area in pre- hot substrate Domain, and the second welding gun may include laser aid for wire to be heated to and is melted to the target deposition region on substrate On.First welding gun may include laser aid with the target deposition region in pre- hot substrate, and the second welding gun may include electricity Wire for being heated and being melted to the target deposition region on substrate by beamlet device.First welding gun may include the first electricity Beamlet device is with the target deposition region in pre- hot substrate, and the second welding gun may include the second electron beam device to be used for Wire is heated and on the target deposition region that is melted on substrate.

The present invention provides a kind of system for being manufactured by solid free fo to construct metal object, the system packets It includes: the first welding gun, for preheating the substrate at metal material position to be deposited；Second welding gun, for melting source metal At the metal material drop on the preheated zone for being deposited on substrate；Make the actuator support that substrate is mobile relative at least the first welding gun Disk, or the actuator arm for keeping the first welding gun mobile, or any group of the actuator arm or these actuators that keep the second welding gun mobile It closes；And control system, CAD (CAD) model of object to be formed can be read, and use CAD model Carry out position and the movement of regulating system, with for positioning and moving substrate and operating welding gun, so that by by the company of metal material Continuous deposit is fused on substrate to construct physical objects.

The pre- hot substrate of first welding gun enables it to receive molten metal silk at molten metal material position to be deposited Molten drop.In some embodiments, at least part substrate can be melted by the first welding gun, so that substrate has more acceptance.? In some embodiments, the first welding gun applies enough heats to form preheating in the substrate at metal material position to be deposited Region.In some embodiments, the second welding gun applies enough heats in the substrate at metal material position to be deposited Form molten bath.It may be noted that although the present invention describes use relevant to wire, can be used any can be guided With fusing with the conductivity structure of deposition materials, any suitably sized and shape consutrode can be used for example.

First welding gun can promote the fusion between substrate and molten metal material by deepening the fusing in substrate.The One welding gun can help ensure that the abundant fusing of over hot melting metal material, and molten metal material oneself may not be able to be realized Sufficiently fusing.

The system may include: PAW welding torch, such as PTA welding torch, as the first welding gun；And laser aid, as second Welding gun.In such a system, PAW welding torch may be electrically connected to DC power supply, so that the electrode of PAW welding torch becomes cathode, and And wire becomes anode.

Second welding gun is also designed to contribute thermal energy in preheated zone.Moreover, the first welding gun and the second welding gun can positions In on the opposite side of substrate.

It additionally provides for manufacturing the method to manufacture the three-dimension object of metal material by solid free fo, wherein The object is made and being fused to the successive sedimentation object of metal material on substrate together, this method comprises: using the first weldering Rifle carrys out at least part on the surface of pre- hot substrate, such as at metal material position to be deposited；Added using the second welding gun Heat simultaneously melts metal material molten metal material is deposited on the preheated zone of substrate；And make substrate with predetermined pattern It is mobile relative to the position of the first welding gun and the second welding gun, so that the successive sedimentation object of molten metal material solidifies and forms three-dimensional Object.

Method provided herein can be used PAW welding torch (such as PTA welding torch) as the first welding gun and use laser aid As the second welding gun.Method provided herein can be used laser aid as the first welding gun and use PAW welding torch as second Welding gun.In such a system, PAW welding torch may be electrically connected to DC power supply, so that the electrode of PAW welding torch becomes cathode, and And wire becomes anode.

First laser device can be used as the first welding gun in method provided herein, and use second laser device as Second welding gun.Method provided herein can be used laser aid as the first welding gun, and be swashed using coaxial powder supply nozzle Photosystem is as the second welding gun.Method provided herein can be used electron beam device and be filled as the first welding gun, and using laser It sets as the second welding gun.Method provided herein can be used laser aid and be made as the first welding gun, and using electron beam device For the second welding gun.Electron beam device can be used as the first welding gun in method provided herein, and uses laser aid as Two welding guns.The first electron beam device can be used as the first welding gun in method provided herein, and uses the second electron beam device As the second welding gun.

Supplementary features and advantage of the invention will be set forth in the description that follows, and partly from the description show and It is clear to, or can be learnt by practicing the present invention.The objectives and other advantages of the invention will by printed instructions and its The structure that particularly points out in claim and attached drawing is achieved and obtained.

It should be appreciated that foregoing general description and the following detailed description are all exemplary and illustrative, and purports Further explanation to claimed invention is being provided.

Detailed description of the invention

(it is included to provide a further understanding of the present invention and is incorporated and constitutes one of this specification attached drawing Point) the embodiment of the present invention is shown, and be used to explain the principle of the present invention together with specification.For clarity, attached drawing It is not drawn on scale, and some components is omitted.

In the accompanying drawings:

The duplication (" electron beam for the manufacture of cost-benefit near-net shape that Fig. 1 is Fig. 1 of Taminger and Hafley Free forming manufacture ", NATO/RTOAVT-139 carries out the specialists meeting (lotus of cost-effectiveness manufacture about processing by net shape Blue Amsterdam, 2006) (NATO), and the 9-25 pages), the figure shows the signals of the principle of solid free fo manufacture Figure.

Fig. 2 is the duplication of Fig. 1 of US 2006/0185473, and it illustrates plasma transferred arc power solid free fos The schematic diagram of the principle of manufacture.

Fig. 3 is to show the schematic diagram of the sectional view of equipment according to the second aspect of the invention.

Fig. 4 is to show the schematic diagram of the sectional view of the second embodiment of the invention including thermal pulse.

Fig. 5 is the schematic side elevation of the embodiment of double welding gun system provided herein comprising is used for pre- hot substrate Target deposition region laser aid, and for wire being heated and is melted on the target deposition region on substrate Plasma transferred arc.

Fig. 6 is the schematic side elevation of the embodiment of double welding gun system provided herein, which includes being used for pre- hot radical The plasma transferred arc power in the target deposition region on material, and for being heated wire and being melted to the target on substrate Laser aid on deposition region.

Fig. 7 is the schematic side elevation of the embodiment of double welding gun system provided herein, which includes being used for pre- hot radical The laser aid in the target deposition region on material, and for wire to be heated to and is melted to the target deposition region on substrate On laser aid.

Fig. 8 is the schematic side elevation of the embodiment of double welding gun system provided herein comprising is used for pre- hot substrate Target deposition region laser aid, and for by swashing in METAL HEATING PROCESS and the target deposition region that is melted on substrate Light blows powder system.

Fig. 9 is the schematic side elevation of the embodiment of double welding gun system provided herein, which includes being used for pre- hot radical The electron beam device in the target deposition region on material, and for wire to be heated to and is melted to the target deposition area on substrate Laser aid on domain.

Figure 10 is the schematic side elevation of the embodiment of double welding gun system provided herein, which includes being used for pre- hot radical The laser aid in the target deposition region on material, and for wire to be heated to and is melted to the target deposition region on substrate On electron beam device.

Figure 11 is the schematic side elevation of the embodiment of double welding gun system provided herein, which includes being used for pre- hot radical First electron beam device in the target deposition region on material, and sink for wire to be heated to and is melted to the target on substrate The second electron beam device on product region.

Specific embodiment

A. it defines

Unless otherwise defined, otherwise all technical and scientific terms used herein has and skill of the art The identical meaning of the normally understood meaning of art personnel.Unless otherwise stated, what is referred in this paper entire disclosure is all Patent, patent application, disclosed application and publication, website and other public materials full content be incorporated by reference In this.If the term of this paper has multiple definition, the definition being subject in this section.It should be appreciated that in reference URL or other this In the case where the identifier of sample or address, such identifier be can change and the specific information on internet can make a return journey, But equivalent information can be found by searching for internet.Reference demonstrates the availability and open biography of these information It broadcasts.

As used herein, unless the context clearly indicates otherwise, otherwise singular " one ", "one" and "the" are also wrapped Include plural form.

As used herein, range and amount are represented by " about " specific value or range.It " about " further include exact amount.Therefore, " about 5% " means " about 5% " and also implies that " 5% "." about " mean to miss in the model experiment of application or specified purpose In poor range.

As used herein, term first, second, third, etc. can be used to describe various component, assembly units, region, layer herein And/or section, but these component, assembly units, region, layer and/or section should should not be limited by these terms.These terms can To be only used for distinguishing a component, assembly unit, region, layer or section and another region, layer or section.Unless civilized up and down It really points out, otherwise the term He other numerical terms of such as " first ", " second " used herein do not imply that order or sequence.Cause This, in the case where not departing from the introduction of example embodiment, first element, component, region, layer or section discussed below can be with Referred to as second element, component, region, layer or section.

As used herein, " optional " or " optionally " refer to the event then described or happen or do not occur, and And the description includes event or the example happened and the example not occurred.For example, the optional feature in system means this Component may exist or can be not present in system.

As used herein, " combination " refers to any association between two items or between more than two items.The association It can be space, or refer to common purpose and use two or more items.

As used herein, " plasma arc torch " or " PAW welding torch " refers to the weldering that can be used for plasma arc weldering Torch.Welding torch is designed to make gas that can be heated to high temperature to form plasma and become conductive, then plasma Electric arc is transmitted to workpiece, and the heat-flash of electric arc can melt metal and/or fuse together two metalworks.PAW weldering Torch may include the nozzle for shrinking electric arc, to increase the power density of electric arc.Plasma gas is usually argon gas.Deng from Daughter gas can supply along electrode and ionize and accelerate near cathode.Electric arc can be directed toward workpiece and compare free combustion Electric arc (such as in tig torch) is more stable.PAW welding torch is generally also provided with for providing the outer nozzle of protective gas.Protect gas Body can be argon gas, helium or combinations thereof, and protective gas helps to minimize the oxidation of molten metal.In PAW welding torch, Electric current usually may be up to about 400A, and voltage usually can be in about 25V to (but may be up to about 14kW) between 35V.The present invention is not It is related to the PAW welding torch of any particular options or type.The dress that can be used as any known of PTA welding torch or be contemplated that can be used It sets.Exemplary PAW welding torch is plasma transferred arc power (PTA) welding torch.

Term " plasma transferred arc power welding torch " used interchangeably herein or " PTA welding torch " are to refer to pass through electric arc Inert gas flow is heated and is actuated to plasma and the plasma gas flow including electric arc is then displaced through hole by electric discharge Any device for the plume that mouth (such as nozzle) is shunk with formation, the plume extend aperture and the heat-flash of electric arc are transmitted to mesh Mark region.Electrode and target area may be electrically connected to DC power supply, so that the electrode of PTA welding torch becomes cathode and target area Become anode.This will ensure that the plasma plume including electric arc flows to the heat that the small surface area delivery head of target area is concentrated Stream, while admirably controlling the size extended from the region that PTA welding torch is supplied with heat flux.Plasma transferred arc power, which has, to be mentioned The advantages of for stable and consistent electric arc, the electric arc have seldom drift and to the good of the length variation between cathode and anode Good tolerance.Therefore, PTA welding torch is not only suitable for pre- hot surface, and answers in formation preheated zone or some of molten bath in the substrate In, it is also applied for heating and melts wire feed.PTA welding torch can advantageously have the electrode made of tungsten and be made of copper Nozzle.However, the present invention is not related to the PTA welding torch of any particular options or type.It can be used and can be used as PTA welding torch Device that is any known or being contemplated that.

Terms used herein " power density " refer to the quantity of power that unit area is distributed to from laser beam or electron beam.

As used herein, " SFFF " refers to that solid free fo manufactures.

Term " metal material " as used herein, which refers to, can be formed as wire and manufacture in solid free fo The metal or metal alloy to form any of of three-dimension object or be contemplated that is used in technique.The example packet of suitable material Titanium and titanium alloy are included but are not limited to, such as i.e. Ti-6Al-4V alloy.

Terms used herein " metalloid material " refer to the metal material and refer to metal material gold having the same Category or metal alloy.

Terms used herein " keeping substrate " refer to target base plate, free using SFFF or solid in the target base plate Forming Technique deposition is with the additional materials for keeping substrate identical or different to form workpiece.In the exemplary embodiment, it protects Holding substrate is plate.In alternative embodiments, keeping substrate can be forged part.In alternative embodiments, keep substrate can Think the object for staying on deposition additional materials.In the exemplary embodiment, keep substrate that can become a part of workpiece. Material for keeping substrate can be metal or metal alloy.In the exemplary embodiment, keep substrate by supplying with wire It is made to the identical metal of material.

Terms used herein " substrate " refer to the target that three-dimension object is formed for receiving molten metal material.When heavy When the first metal material layer of product, substrate will be holding substrate.When one or more layers metal material, which is deposited on, to be kept on substrate, base Material will deposit new metal material layer for for the upper layer of deposited metal material.As used herein, term " workpiece " refers to use The metallic object of solid free fo manufacture production.

Term " Computer Aided Design Model " used interchangeably herein or " CAD model " refer to object to be formed Virtual three-dimensional expression that is any known or being contemplated that, can be in the control system of equipment according to the second aspect of the invention It uses: adjusting the position and movement for keeping substrate, and with integrated wire-feed motor operation welding torch, so that by by the company of metal material Continuous deposit is kept on substrate with causing the pattern form for constructing physical objects according to the virtual three-dimensional model of object to be fused to To construct physical objects.This can be for example by being divided into one group of virtual parallel layer and then will be each for virtual three-dimensional model first Parallel layers are divided into one group of virtual quasi- one-dimensional workpiece and are obtained by the virtual vector hierarchical mode of formation threedimensional model.So Afterwards, physical objects can be formed by engagement control system, according to the first layer of the virtual vector hierarchical mode of object Pattern a series of quasi- one-dimensional metal material pieces are deposited and are fused on supporting substrate.Then, by according to the void of object A series of one-dimensional weldable material part of standards is deposited and is fused to previous sedimentary by the pattern of the second layer of quasi- vector quantization hierarchical mode On, the sequence of the second layer of Lai Chongfu object.For each pantostrat of the virtual vector hierarchical mode of object, repeat continuous Layer by layer deposition and alloying process, until formed whole object.However, the present invention is not related to for running according to the present invention set Any specific CAD model and/or computer software of standby control system, and the present invention be not related to yet it is any certain types of Control system.Can be used can be constructed any known of metal three-dimension object or be contemplated that by solid free fo manufacture Control system (CAD model, computer-aided manufacturing (CAM) system or software, computer software, computer hardware and actuating Device etc.), as long as the control system is adjusted to operate a first PTA welding torch respectively to form preheated zone or molten bath and operation 2nd PTA welding torch is the feed wire of metal material to be melted in molten bath.

B. double welding gun system

It has been determined that molten metal can be increased to the deposition rate of Forming Workpiece using double welding gun system, welded in this pair In gun system, the pre- hot substrate of the first welding gun is to form preheated zone, and the second welding gun is for heating metal and by metal molten Onto the preheated zone of substrate.As used herein, term " welding gun " or abbreviation " rifle " are used interchangeably, and mean any heating Device or the device or heating source that can be generated heat.The non-limiting example of welding gun or rifle include PAW welding torch (including PTA welding torch), Laser beam emitting device (" laser aid ") and electron beam launcher (" electron beam device ").First rifle may insure substrate or work Part and the fusion between the molten metal generated on metal (such as wire or metal powder) is acted on by the second rifle.First rifle It can deepen molten metal to be melted in the preheated zone of substrate.Overheat from molten metal drop can keep the pre- of substrate Molten bath near thermal region.The preheating of substrate can produce preferably wetting, better deposition profile and increased deposition rate. More round and broader deposition profile can be obtained by pre- hot substrate about deposition profile.Improved profile, which can produce, to be had Towards the profile of the advantageous angle of substrate, this can promote fusion and previous metal deposit with substrate.Improved fusion produces The raw manufactured goods with improved integrality.

Each welding gun includes heating device.Each welding gun can be controlled individually, and each welding gun can be conditioned with Generate individual temperature effect.The advantages of this equipment, is that the metal being applied on the preheated zone to be melted to substrate is former The amount of the thermal energy of material can be greater than the amount for the thermal energy being applied on substrate, so that substrate be avoided to overheat.

In the exemplary embodiment, a heating device as welding gun can be used for pre- hot substrate and optionally form molten Pond, and another heating device for being used as another welding gun can be individually used for fusing wire or consutrode.Implement in substitution In example, the heating device of the welding gun as fusing wire or consutrode be can also be used for from wire or comsumable melt Molten metal position to be deposited at further heated substrate.It can to the additional heating in the region having been warmed up or even molten bath To allow the region to be deposited to metal to carry out better temperature control, to further realize with preheated zone or molten bath Benefit.

In the exemplary embodiment, the heating device of the welding gun as fusing wire or consutrode can weld for PAW Torch (such as PTA welding torch), wherein welding torch is also connected to DC power supply identical with substrate.Therefore, for melting wire Meanwhile welding torch can also become cathode, while substrate becomes anode, add via another so that pulse heat flux is transmitted to Substrate regions in thermal or rifle preheating and the region that wire melts on it and therefore metal is deposited.

Similarly, other kinds of heating device or rifle be can be used to realize to the preheated zone or molten bath in substrate This additional heating.For example, wire can be directed a laser to when using laser aid as the welding gun for melting wire Direct it towards with substrate rather than only wire.Any known device for redirecting laser can be used for guiding laser or separation Laser simultaneously directs it towards substrate, while still melting wire.In the exemplary embodiment, one or more reflecting mirrors can be used Separate or at least part of reflection laser so that laser light strikes wire and substrate rather than only hit wire.It uses Electron beam device can be used for realizing the purpose as welding gun.For example, electron beam can be led to wire to melt metal Silk and be led to substrate also to provide additional heat to preheated zone or molten bath.Any of guidance electronics can be used The method of beam.

One or more actuators can be used to realize the positioning of substrate He any one or more welding guns.Exemplary In embodiment, it can be used and shelve the actuator pallet of the substrate to relocate or moving substrate.Actuator pallet can be with Moving substrate in any direction.In the exemplary embodiment, actuator pallet can be set on rail system or guide track system And it can be along any desired direction moving substrate.Alternatively, mechanical arm or robots arm can be used to operate actuating Device pallet.Hydraulic system can be used also to operate in actuator.Similarly, one or more actuators can be used to move one A or multiple welding guns.For example, each welding gun in one or more welding guns can be attached to the actuator arm of independent control, such as Robots arm or mechanical arm.Hydraulic system can be used also to operate in actuator.It can also realize using for actuator arm Other kinds of mechanism, such as guide track system or rail system.In the exemplary embodiment using two or more welding guns, Each welding gun can independently move.In the alternate embodiment using two or more welding guns, two or more welding guns Position can be fixed relative to each other, and one or more actuator arm two or more mobile welding guns simultaneously.In example Property embodiment in, actuator pallet be used unique actuator, one or more welding guns are maintained at during deposition Fixed position.In alternative embodiments, moving substrate in the both direction of actuator pallet only in a plane, and one or Only (such as plane movable within perpendicular to actuator pallet) is one or more mobile in one direction for multiple actuator arms A welding gun.Opposite situation is also such, wherein one or more actuator arms planar in both directions move one or Multiple welding guns, while actuator pallet is along single direction moving substrate.In alternative embodiments, substrate is maintained at during deposition Fixed position, and one or more actuator arms are for mobile one or more welding guns.In another alternate embodiment, cause Dynamic device pallet and one or more actuator arms are all used for moving substrate and one or more welding guns.

Control system including such as computer-aided manufacturing (CAM) system or software can be used for operating and adjusting one or The engagement of multiple actuators, the actuator can constantly position with any one of moving substrate, one or more welding gun or A combination thereof, so that preheated zone or molten bath are located at the predetermined deposition region provided by the CAD model of object to be formed.

Control system may include computer processor or central processing unit (CPU), display cpu, one or more electricity Source, power connector, as the signaling module of input and/or output, the integrated shielding of analog signal, storage device, circuit board, Memory chip or other storage mediums, the non-transitory with the computer-readable program being included in is computer-readable deposits Storage media or any combination thereof.Computer-readable program may include software appropriate, for partially or even wholly automatic Any of change system or combination.Computer-readable program may include for monitoring and/or adjustment parameter (such as temperature, pressure Power, the location of workpiece, deposition rate or any combination thereof) appropriate software.Exemplary control system includes but is not limited to come westerly The SIMATIC-S7-1500 of Men Zi joint-stock company (Munich, Germany), can be from Bosch Rexroth AG (German Meine River side Luo Er) obtain IndraMotion MTX system and can from limited partnership, SIGMATEK joint-stock company (Austria orchid Prey Xi Cihaosen) the SIGMATEK C-IPC compact industrial computer system obtained.

It may be noted that although the embodiment as described herein of the illustrated examples according to Fig. 3 into Figure 11 is shown, wherein two A welding gun is located at the same side of substrate, and but the invention is not restricted to this.In the exemplary embodiment, for realizing pre- in substrate The welding gun of thermal region is alternatively located at the side opposite with the welding gun for melting wire of substrate.

System comprising two PTA welding torches

In the exemplary embodiment, the three of metal material is manufactured by solid free fo manufacture the present invention relates to a kind of The method for tieing up object, wherein the object is made by being fused the successive sedimentation object of metal material on keeping substrate together, The feature of this method be include:

Substrate is kept made of use metal material as with the object type to made of, and

Each successive sedimentation object obtains in the following manner:

I) it is preheated using the first plasma transferred arc power (PTA) and optionally at metal material position to be deposited Molten bath is formed in the substrate,

Ii the metal material to be deposited of wire form) is supplied to the position above preheated zone or molten bath,

Iii wire) is heated and melts using the second plasma transferred arc power (PTA), so that molten metal material Dripped on preheated zone or molten bath and iv) make that substrate is kept to move relative to the position of the first and second PTA with predetermined pattern It is dynamic, so that the successive sedimentation object of molten metal material solidifies and forms three-dimension object.In second aspect, the present invention relates to a kind of use In the equipment for the three-dimension object for manufacturing metal material by solid free fo manufacture, wherein the equipment includes:

Welding gun, the welding gun have the integrated wire-feed motor of supply metal material silk,

Make the actuator pallet or make first heater movement that substrate is mobile relative at least first heater Any combination of actuator arm or the actuator arm for keeping secondary heating mechanism mobile or these actuators, and

Control system, the control system can read CAD (CAD) model of object to be formed and The position and movement of the system are adjusted using CAD model to be used to position and move holding substrate, and operate and there is integrated send The welding torch of silk machine, so that physical objects keep constructing on substrate by the way that the successive sedimentation object of metal material to be fused to, it is special Sign is,

Substrate metal material as with the object type to made of is kept to be made,

Welding torch includes:

I) the first plasma transferred arc power (PTA) welding torch, is electrically connected to substrate, and

Ii) the second plasma transferred arc power (PTA) welding torch is electrically connected to the supply silk of metal material,

Control system can it is individually operated and adjust the first PTA welding torch, at metal material position to be deposited in base Preheated zone or molten bath are formed and kept in material, and

Control system can be individually operated and adjusts wire-feed motor and the 2nd PTA welding torch, drip molten metal material It falls on the position on preheated zone or molten bath and melts supplied metal material.

Carry out pre- hot substrate using the first PTA welding torch individually controlled or forms molten bath and welded using individual 2nd PTA Torch come melt the advantages of supply silk of metal material provides for can increase the heat for the feeder for being supplied to wire and with confession The heat of substrate should be given unrelated, allow to increase " the spray splashed into the heat flux of supply charging without formation generation The risk of mist electric arc ".Therefore, can be in the case where overheating substrate, and in no splashing or formed excessive pre- Therefore thermal region or molten bath simultaneously loosely control the risk of consolidation of deposition materials in the case that, sinking for molten metal charging is improved Product rate.This feature by connect DC power supply make the electrode of the first PTA welding torch become negative polarity and substrate become anode Property is to limit the arc discharge between the electrode and substrate by the first PTA welding torch come the circuit of transfer charge and by by The electrode of two PTA welding torches is connected to the cathode of DC power supply and the supply silk of metal material is connected to anode to be passed through with being formed Arc discharge between the electrode of 2nd PTA welding torch and the supply silk of metal material is carried out the circuit of transfer charge and is obtained.

First PTA welding torch and the 2nd PTA welding torch can advantageously have individual power supply and be supplied to accordingly for adjusting The device of the power of welding torch.The temperature of the deposition region for monitoring substrate can be advantageously comprised for the device of regulation power Device and width and positioning for adjusting electric arc device, such as magnetic arc arrangement for deflecting.In addition, for pre- hot substrate and can The first PTA welding torch that selection of land forms molten bath in the substrate can advantageously generate wide arc, such as by gas tungsten-arc welding torch (GTAW Welding torch is also expressed as tig torch in the literature) simply to preheat or form molten bath in the wider region of substrate surface.

The delivery rate (wire speed) of the supply silk of metal material and positioning can be according to being supplied to the 2nd PTA welding torch The effect of power controlled and adjusted, to ensure that wire is predetermined above the preheated zone or molten bath reached in substrate It is heated continuously and melts when position.This can (GMAW be welded by using the traditional gas metal arc welding torch as wire-feed motor Torch, also referred to as MIG welding torch) it obtains, without forming electric arc in MIG welding torch.This embodiment of wire-feed motor has the advantage that For the DC power supply and also highly precisely positioning metal silk that wire can be electrically connected to the 2nd PTA welding torch.Metal material The supply silk of material can have the achievable size of any reality, 1.0mm, 1.6mm, 2.4mm etc..

Applied metal material will be depended on to the supply effect of the first PTA welding torch and the 2nd PTA welding torch, supply silk Diameter, the heat resistance of substrate, deposition rate etc..Therefore, the present invention is independent of any specific power supply window, but can apply Generate any potential difference actually to work and electric current of the feature operation of the first PTA welding torch and the 2nd PTA welding torch.Technical staff These parameters will be found by test and error checking.The experiment that the applicant carries out shows to supply when for the first PTA welding torch Should about 150A and when supplying about 250A for the 2nd PTA welding torch, be 1.6mm by using made of 5 grades of titanium alloys diameter Wire can have the three-dimensional article of mechanical performance similar with traditional titanium object with 3.7 to 3.8kg/h deposition rate manufacture Body.It is believed that in the atmosphere of effective protection, in such as reaction chamber disclosed in WO2011/0198287, according to the present invention First aspect and second aspect by execute SFFF deposition can obtain the up to deposition rate of 10kg/h.The applicant carries out Another experiment confirm this point, wherein wire diameter be 2.4mm, 5 grades of titaniums, when for the first PTA welding torch supply about The electric current of 250A and for the 2nd PTA welding torch supply about 300A electric current when, deposition rate 9.7kg/h.

As an alternative, the present invention can also include the device for generating thermal pulse in preheated zone or molten bath, To break the growth tendency for crystallizing dendrite at this location.Due to improved grain structure, this feature, which allows to be formed to have, to be increased The metal object of strong mechanical property.Thermal pulse can be obtained by using third dc generator, the third dc generator It conveys pulse direct current current potential and the cathode of dc generator is connected to the electrode of the 2nd PTA welding torch and anode is connected to base Material is with the pulse arc discharge that is formed between the electrode and substrate by the 2nd PTA welding torch come the circuit of transfer charge.2nd PTA Arc discharge between the electrode and substrate of welding torch will be switched on and off according to the pulse direct current current potential of application, and be consequently formed into Enter the pulse heat flux in the preheated zone or molten bath in substrate.The frequency of pulse can be up to several kHz or higher (i.e. in 1Hz In the range of 10kHz).

The first example embodiment of equipment according to a second aspect of the present invention is schematically shown in Fig. 3.The diagram The holding substrate 1 made of the Ti-6Al-4V alloy that shape is rectangle cuboid is gone out, will have been manufactured by solid free fo The three-dimension object made of identical Ti-6Al-4V alloy is formed on the holding substrate 1.The figure shows the initial of deposition process Part, in this process, the first welding rod 2 of Ti-6Al-4V alloy are just deposited.

The wire 3 made of Ti-6Al-4V alloy is without interruption by wire-feed motor 4, which is positioned to wire 3 So that its distal end is located at 5 top of preheated zone or molten bath kept at the deposition region on substrate 1.Wire 3 is given by scheming The speed of middle upward arrow instruction, corresponds to heating and the melting rate of distal end, so that the drop 6 of molten metal silk constantly supplies Preheated zone or molten bath 5 should be arrived.

First plasma transferred arc power 7 is formed by PTA welding torch 8, which is electrically connected to DC power supply 9, so that The electrode 10 of PTA welding torch becomes cathode and substrate 1 is kept to become anode.Plasma transferred arc power 7 is continuous and is drawn Lead with heat and optionally be melted at deposition region substrate (in the stage of SFFF technique, substrate be keep substrate), make Preheated zone or molten bath 5 must be obtained.The effect of DC power supply 9 is adjusted to keep that there is constant ruler by control system (not shown) Very little and range preheated zone or molten bath 5.PTA welding torch 8 is that gas tungsten-arc welds (GTAW) welding torch, is deflected equipped with magnetic arc Device (not shown) is to control size and the position of electric arc 8.Second plasma transferred arc power 11 is formed by PTA welding torch 12, the PTA Welding torch is electrically connected to DC power supply 13, so that the electrode 14 of PTA welding torch 12 becomes cathode and supplying silk 3 becomes anode.Plasma Body transferred arc 11 is continuous and is guided to heat and melt the distal end of wire 3.Adjust the effect of DC power supply 13 To keep heating and melting rate according to the feed speed of wire, so that the formation of drop 6 is timed to keep fusing metal Silk continuously drips on preheated zone or molten bath 5.The effect and wire 3 supplied by DC power supply 13 leave the supply of wire-feed motor 4 Speed by control system consistently regulation and control so that with provide the rate of the predetermined deposition rate of Ti-6Al-4V alloy to 5 molten metal feed silk of preheated zone or molten bath.Control system is simultaneously engaged with to operate and adjust connecing for actuator (not shown) It closes, actuator consistently positions and mobile holding substrate 1, so that preheated zone or molten bath are located at the CAD by object to be formed At the predetermined saltation point that model provides.In this stage of SFFF technique, keep moving shown in the following arrow of substrate 1.

Second example embodiment of the invention be include in preheated zone or molten bath 5 formed thermal pulse additional dress The upper surface of set the first example embodiment provided.The device for being used to form thermal pulse is DC power supply 15, is electrically connected to second PTA welding torch 12, so that electrode 14 becomes cathode and substrate 1 is kept to become anode.Additionally, there are for pulsing by DC power supply The device 16 of the power of 15 conveyings, so that electric arc 11 is other than heating and melting wire 3, also with identical with the pulse power Frequency enters preheated zone or molten bath 5, and therefore conveys pulse heat flux to molten bath.Device 16 can be adjusted by control system, And pulse arc discharge is provided into preheated zone or molten bath with the frequency of 1kHz.

System comprising laser aid and PAW welding torch

In the alternate embodiment of double welding gun system provided herein, which may include as the heating dress for welding gun The laser aid set and the PAW welding torch as the heating device for another welding gun, such as PTA welding torch.In some configurations, swash Target deposition region in the pre- hot substrate of electro-optical device is to form preheated zone, and PAW welding torch heats and melt wire, thus Generate the molten metal drop fallen into the preheated zone in target deposition region.In some configurations, in the pre- hot substrate of PAW welding torch Target deposition region to form preheated zone, and laser aid heats and melts wire, to generate, to fall into target heavy Molten metal drop in the preheated zone in product region.

In the first configuration, laser aid, which can be arranged, is directed to the target area of substrate for laser energy to be formed Preheated zone, and PAW welding torch can be arranged and plasma transferred arc power is directed on the preheated zone of substrate On the end of the wire of side.The end of the thermal energy fusing wire of PAW welding torch falls on the last in wire of substrate to be formed Hold the molten metal drop of the wire on the preheated zone of lower section.It is melted in substrate, is swashed by deepening molten metal drop Electro-optical device can promote the fusion between substrate and the molten metal material being deposited thereon.The electric arc of PAW welding torch can also be Thermal energy is nearby contributed in the preheated zone in target deposition region, to facilitate the thermal energy provided by laser beam.For example, PAW welding torch It may be coupled to DC power supply identical with substrate, be accordingly changed into cathode, and substrate becomes anode, and thus by pulse heat flux It is transported to substrate.Overheat from molten metal drop can assist in keeping the molten bath near the preheated zone of substrate.This is System may include wire feedway to provide wire.Wire feedway can be positioned in laser and PAW welding torch Between, or may be oriented such that it than laser closer to PAW welding torch.

The system can also include positioning device, which can be located in wire by laser in the substrate Above the preheated zone of formation.The end of wire can also be suitably put into plasma transferred arc power by positioning device, It melts it suitably, and to melt the drop to be formed by the plasma transferred arc power and fall on substrate below Preheated zone on.

Wire can be or containing aluminium, chromium, copper, iron, hafnium, tin, manganese, molybdenum, nickel, niobium, silicon, tantalum, titanium, vanadium, tungsten or zirconium or Its compound or alloy.In some embodiments, wire contains titanium or titanium alloy.Wire can be or containing such a Titanium alloy, the titanium alloy contain the combination of one of titanium and aluminium, vanadium, tin, zirconium, molybdenum, niobium, chromium, tungsten, silicon and manganese or combinations thereof. For example, exemplary titanium alloy includes Ti-6A1-4V, Ti-6Al-6V-2Sn, Ti-6Al-2Sn-4Zr-6Mo, Ti-45Al-2Nb- 2Cr, Ti-47Al-2Nb-2Cr, Ti-47Al-2W-0.5Si, Ti-47Al-2Nb-lMn-0.5W-0.5Mo-0.2Si and Ti- 48Al-2Nb-0.7Cr-0.3Si.Wire can containing aluminium, iron, cobalt, copper, nickel, carbon, titanium, tantalum, tungsten, niobium, gold, silver, palladium, platinum, Zirconium, their alloy and their combination.When wire is the form of silk thread, wire can have any desired shape Cross section.Typical cross section is circular cross section.The diameter of wire can be up to about 10mm, and can be in about 0.8mm To about 5mm.Wire can have the achievable size of any reality, such as 1.0mm, 1.6mm, 2.4mm etc..Gold The delivery rate and positioning for belonging to silk can be controlled and be adjusted according to effect of the power supply to welding torch, to ensure that wire is arrived at it It is heated continuously and melts when up to predetermined position above the preheated zone or molten bath in substrate.

Laser aid can produce the laser beam of enough energy, to transfer thermal energy to substrate with the region of pre- hot substrate. Preheating is carried out to substrate via the energy from laser beam and promotes substrate and molten metal by deepening the fusing in substrate Fusion between material.In some embodiments, at least part substrate can be by the energy of the laser beam from laser aid Fusing.In some embodiments, enough heats are applied by the laser beam of laser aid, with the position to be deposited in metal material It sets place and forms preheated zone or molten bath in the substrate.The example of suitable laser aid may include ytterbium (Yb) laser, Yb optical fiber Laser, Yb fiber coupled diode lasers, Yb: the ytterbium that amorphous laser, diode pumping Yb:YAG laser, neodymium adulterate Aluminium garnet (Nd:YAG) laser, CO₂Laser, CO laser, Nd: amorphous laser, neodymium doping ortho-vanadic acid ytterbium (Nd: YVO) laser, Cr: ruby laser, diode laser, diode-pumped laser, excimer laser, gas swash Light device, semiconductor laser, solid-state laser, dye laser, x-ray laser, free electron laser, ion laser Device, gas mixture laser, chemical laser and combinations thereof.Preferred laser includes Yb laser, especially Yb optical fiber Laser.In numerous applications, compared with other optical maser wavelengths, wavelength used in Yb optical fiber laser can be less anti- It penetrates.

PAW welding torch can be that can generate electric arc to heat and melt any configuration of wire, such as PTA welding torch, gas Body protects metal arc welding (GMAW), and electric arc (Metallic Inert Gas welding or MIG weldering are generated especially with non-active gas It connects).Wire is melted in the plasma generated by welding torch using electric arc, and molten metal silk is deposited on workpiece On preheated zone or molten bath on, to add and be formed near net-shaped metallic object.

The titanium or titanium alloy for being heated to 400 DEG C or more may be aoxidized when contacting with oxygen.Therefore, it is necessary to Influence of the weld seam and heated object that protection is formed by Layered manufacturing against oxygen in ambient air.One solution of the problem Certainly scheme be depositing system is surrounded with the closed chamber of ambient air in, and it can be made fully not oxygenous.? Exemplary chamber is described in International Patent Application Publication WO2011/019287 (Guldberg).For welding under an inert gas The welding purging room connect is also commercially available (for example, Massachusetts Salisbury LC technical solution company), and The system that design or engineering design can be easy to carry out to adapt to any size or configuration.By using fully not oxygenous Settling chamber, such as replace environmental gas with argon gas or other inert gases, the speed of welding process can be improved, this is because It can permit welding region and reach risk of the higher temperature without having weld seam excessive oxidation.For example, being closed in production titanium or titanium When the object of gold, it is no longer necessary to which welding region is cooled to 400 DEG C or less to avoid oxidation.

Without using in the not no alternative configuration of the settling chamber of oxygen, double welding gun system protective gas can be used rather than Chamber avoids aoxidizing.In such a system, protective gas (such as Ar) is directed to around wire and PTA welding torch by nozzle Region.For example, inert gas can be guided by nozzle, which is arranged in the surrounding them of welding torch.Nozzle can incite somebody to action Inert gas is directed near melting weldpool.Gas is by preheated zone or molten bath and isolated from atmosphere, to prevent block.? Ireland et al. (U.S. Patent No. 7,220,935)；Comon et al. (U.S. Patent No. 9,145,832)；And Exemplary system is described in Cooper et al. (U.S. Patent Application Publication No. US 2010/0276396).

A kind of exemplary embodiment of configuration is shown in FIG. 9, wherein the target deposition in the pre- hot substrate of laser aid Region is to form preheated zone, and PTA welding torch heats and melts wire.In an illustrated embodiment, it is produced by SFFF Shape is the substrate 200 of rectangle cuboid.The figure shows the initial parts of deposition process, and in this process, the first welding rod 220 is just It is deposited.Double welding gun system shown in Fig. 9 includes: laser aid 410, which is positioned such that its laser generated Beam 420 is directed into target area with hot substrate 200 pre- at target area；And PTA welding torch 110, the PTA welding torch are positioned To melt wire above target area, to form the molten metal drop fallen into preheated zone 210.

The wire 150 made of forming the material of workpiece SFFF is continuously fed with to be generated by PTA welding torch 110 Plasma transferred arc power 130.Wire 150 is supplied by wire feeder 140 and is positioned such that wire 150 End be located at 210 top of preheated zone at the deposition region on substrate 200 or molten bath.Wire 150 can be given court To the speed (as illustrated by arrow 170) of plasma transferred arc power 130.The speed of wire 150 can be chosen such that metal It is pre- that the heating of the distal end of silk 150 and melting rate are continuously supplied to the molten metal drop 160 of molten metal silk 150 Thermal region or molten bath 210.Wire 150 can be supplied to the plasma transferred electricity generated by PTA welding torch 110 at any angle In arc 130, and it is not limited to angle shown in Fig. 9.

Plasma transferred arc power 130 is formed by PTA welding torch 110.As shown, PTA welding torch 110 is electrically connected to power supply 310, so that torch electrode 120 becomes cathode, and wire 150 becomes anode.Power supply can be AC power source or direct current Source.Plasma transferred arc power 130 is continuous and is guided to heat and melt the distal end of wire 150.Adjust direct current The effect of power supply 310 is to keep heating and melting rate according to the feed speed of wire 150, so that molten metal drop 160 Formation be timed with keep fusing wire continuously drip in preheated zone or molten bath 210.The effect supplied by DC power supply 310 Fruit and wire 150 leave the feed speed of wire feeder 140 by control system consistently regulation and control, so that with will Metal or metal alloy is provided to be melted to the rate of the predetermined deposition rate on substrate 200 to preheated zone or the supply of molten bath 210 Wire 150.Control system can be simultaneously engaged with to operate and adjust the engagement of actuator (not shown), and the actuator is consistently fixed Position and moving substrate 200 are made a reservation for sink so that preheated zone or molten bath 210 are located at by what the CAD model of object to be formed provided At plot point.In this stage of SFFF technique, substrate 200 moves as indicated by the arrow 240.

Fig. 9 further depicts optional electrical configurations, can generate thermal pulse in preheated zone or molten bath 210.Institute Show in embodiment, DC power supply 320 is electrically connected to PTA welding torch 110, so that torch electrode 120 becomes cathode, and substrate 200 Become anode.In addition, the pulse frequency generator 330 for the power conveyed by DC power supply 330 of pulsing is positioned in circuit In, so that plasma transferred arc power 130 will also be with frequency identical with the pulse power other than heating and melting wire 150 Rate enters in preheated zone or molten bath 210, and pulse heat flux is therefore transported to preheated zone or molten bath 210.Pulse frequency Generator 330 can be adjusted by control system.In some embodiments, optional electrical configurations with 1 to about 200Hz frequency to Pulse arc discharge is provided in preheated zone or molten bath 210, but the frequency for being up to about 1kHz can be used.Two power supplys 310 With 320 can be pulse or only one power supply 310 or 320 can be pulse.For example, wire fusion current can Think pulse, perhaps to the electric current of workpiece can for pulse or wire fusion current and to the electric current of workpiece can be with For pulse.When two power supplys 310 and 320 are all pulse, pulse frequency can be identical or different.Pulse frequency can be single Solely selection is up to 1kHz.Pulse frequency can in the range of about 1 to 200Hz or in the range of about 1 to 100Hz or about 10 to It is individually selected in the range of 100Hz or in the range of about 5 to 50Hz.

Using the pre- hot substrate of laser aid and forms preheated zone and melt the confession of metal material using PTA welding torch Provide advantages in that the heat that can increase supplied to the supply of wire to silk, and with the heat supplied to substrate without It closes, makes it possible to increase the heat flux into supplying material, the risk of " the spraying electric arc " that splashes is generated without being formed.It can be with Selection is applied to the fusing power of wire with quality of match input (to be added to the molten metal drop of the wire of workpiece Amount) to ensure the stably fused and/or all burnt of wire.Laser aid, which can permit, is placed into target area for thermal energy orientation Domain.Therefore, can be in the case where overheating substrate, and in no splashing or form excessive preheated zone or melt Therefore pond simultaneously loses the risk of the control to the consolidation of deposition materials in the case that, the deposition rate of molten metal charging is improved.

Laser aid may also be configured such that can be along X or Y-direction scanning laser beam to cover only than laser beam The broader region of focus.Sweep spacing can be about 0.001 to about 0.1 inch.It can change by adjusting laser beam by laser The pre-arcing characterisitics of the target area of device heating.For example, the power or laser beam device of adjustable laser beam can be matched Be set to allow laser beam relative to the mobile perhaps adjustable laser beam of workpiece surface direction of closing and angle or These any combination can be modified to adjust the preheating of target area.Appoint caused by being reflected due to laser beam by workpiece surface What loss in efficiency can also be compensated by adjusting direction of closing and the angle of laser beam.

By moving laser beam relative to workpiece surface along predefined paths, the region heated by laser beam layer can be in base It is limited on plate with two dimension, the width of layer is determined by the diameter of laser beam hits substrate.Laser beam can along moving for predefined paths To carry out under the control of the computer.It adjusts pulse shape and/or the duration provides a kind of control during laser beam is mobile The method of the specific power of the laser of offer.Laser beam can also be conveyed with pulse.Traditional Focused Optical system can also be used for adjusting Save the focusing of laser beam on the surface of the workpiece.

Laser aid 410 can be installed into can be under control of the computer in the X-Y plane for being parallel to substrate surface It is mobile, and vertically moved in orthogonal to that Z-direction.Therefore, laser beam 420 may be directed in X-Y plane Any point, and be vertically guided to adapt to the region of the different height in the workpiece and workpiece of different height.Such as Fig. 9 institute Show, transverse direction is the direction of arrow 240, during which is in manufacture layer 220.When use laser aid as welding gun When forming preheated zone or molten bath, reflecting mirror can be used also to guide laser and be used to preheat or melt on substrate to limit Region.

In different configurations, PAW welding torch can be arranged the target that plasma transferred arc power is directed to substrate Region is to form preheated zone, and laser aid can be positioned so that and laser beam is directed to above substrate preheated zone Wire end on.Laser beam thermal energy fusing wire end, thus formed fall on substrate in wire end The molten metal drop of wire on the preheated zone of lower section.PAW welding torch preheating target region, and can be molten by deepening Melt molten drop and is melted in substrate the fusion promoted between substrate and molten metal material.The laser beam of laser aid may be used also For contributing thermal energy in the preheated zone or molten bath in the substrate at target deposition region, to facilitate the offer of PAW welding torch Thermal energy.Overheat from molten metal drop can assist in keeping the molten bath near the preheated zone of substrate.The system can Including wire feedway, for wire to be provided to the desired locations below laser beam.Wire feedway can To be positioned between laser and PAW welding torch, or it may be oriented such that it is filled than PAW welding torch closer to laser It sets.

The system can also include positioning device, which can be located in wire by PAW welding torch in substrate Above the preheated zone of middle formation.The end of wire can also be suitably put into laser beam by positioning device, so that metal Silk suitably melts, and makes the preheating that substrate below is fallen on by the drop of the molten metal of fusing wire formation On region.

Wire can be or containing aluminium, chromium, copper, iron, hafnium, tin, manganese, molybdenum, nickel, niobium, silicon, tantalum, titanium, vanadium, tungsten or zirconium or Its compound or alloy.In some embodiments, wire contains titanium or titanium alloy.Wire can be or containing such a Titanium alloy, the titanium alloy contain the combination of one of titanium and aluminium, vanadium, tin, zirconium, molybdenum, niobium, chromium, tungsten, silicon and manganese or combinations thereof. For example, exemplary titanium alloy includes Ti-6A1-4V, Ti-6Al-6V-2Sn, Ti-6Al-2Sn-4Zr-6Mo, Ti-45Al-2Nb- 2Cr, Ti-47Al-2Nb-2Cr, Ti-47Al-2W-0.5Si, Ti-47Al-2Nb-lMn-0.5W-0.5Mo-0.2Si and Ti- 48Al-2Nb-0.7Cr-0.3Si.Wire can containing aluminium, iron, cobalt, copper, nickel, carbon, titanium, tantalum, tungsten, niobium, gold, silver, palladium, platinum, Zirconium, their alloy and their combination.Wire can be for any configuration and with the cross section of any desired shape. Wire can have circular cross section.The diameter of wire can be in the range of about 0.8mm to about 5mm.Wire can have Any achievable cross sectional dimensions of reality, such as 1.0mm, 1.6mm, 2.4mm etc..The delivery rate of wire and positioning can be by Computer control, fusing when ensuring predetermined position of the wire above the preheated zone or molten bath in its arrival substrate.

Laser aid can produce the laser beam of enough energy, with transfer thermal energy to wire with melt the wire with Form molten metal drop.The example of suitable laser aid may include ytterbium (Yb) laser, Yb optical fiber laser, Yb optical fiber Coupled diode laser, Yb: amorphous laser, diode pumping Yb:YAG laser, neodymium doping YBAG ytterbium aluminum garnet (Nd: YAG) laser, CO2 laser, CO laser, Nd: amorphous laser, neodymium doping ortho-vanadic acid ytterbium (Nd:YVO) laser, Cr: ruby laser, diode laser, diode-pumped laser, excimer laser, gas laser, semiconductor Laser, solid-state laser, dye laser, x-ray laser, free electron laser, ion laser, admixture of gas Laser, chemical laser and combinations thereof.Preferred laser includes Yb laser, especially Yb optical fiber laser.In many In, compared with other optical maser wavelengths, wavelength used in Yb optical fiber laser can less reflect.

The PAW welding torch of target area for pre- heated work pieces can be that can generate electric arc to heat workpiece surface at least A part and any configuration that the molten metal drop from molten metal silk can be received.Exemplary PAW welding torch can Including PTA welding torch or for the welding torch of gas-shielded metal-arc welding (GMAW), electricity is generated especially with non-active gas Arc (Metallic Inert Gas welding or MIG welding).The target area of workpiece is preheated by welding torch using the plasma that electric arc generates. Molten metal silk is as in the preheated zone or molten bath on molten metal droplet deposition to workpiece, to add and form near net Shape workpiece.

When using PAW welding torch (such as PTA welding torch), the electric arc of plasma transferred arc power can control to limit preheating Or the region of fusing.Magnetic field can be used to adjust electric arc.Furthermore, it is also possible to by using mechanical and/or hydraulic actuator or Any actuator moves PAW welding torch to limit the region for preheating or melting in the substrate as described herein.

As described above, being heated to 400 DEG C or more of titanium or titanium alloy may aoxidize when contacting with oxygen. In order to protect the weld seam formed by Layered manufacturing and heating object from the influence of the oxygen in ambient air, can be used pair Ambient air is closed and can make its fully not oxygenous chamber.In International Patent Application Publication WO2011/019287 (Guldberg) exemplary chamber is described in.Welding for welding under an inert gas purges the also commercially available (example in room Such as, Massachusetts Salisbury LC technical solution company), and can be easy to carry out design or engineering design with The system for adapting to any size or configuration.By using fully not oxygenous settling chamber, such as with argon gas or other inertia Gas replaces environmental gas, the speed of welding process can be improved, this is because can permit welding region reaches higher temperature The risk spent without having weld seam excessive oxidation.

Alternatively, protective gas can be used in double gun systems rather than chamber avoids aoxidizing.In such system In, protective gas (such as Ar) is directed to the region around target area and PTA welding torch by nozzle.For example, can be by indifferent gas By nozzle, which is arranged in the surrounding them of welding torch for body guidance.Nozzle inert gas can be directed to target area and It melts near weldpool.Gas is by preheated zone or molten bath and isolated from atmosphere, to prevent block.In Ireland et al. (United States Patent (USP) No. 7,220,935)；Comon et al. (U.S. Patent No. 9,145,832)；And (U.S. Patent application is public by Cooper et al. Open US 2010/0276396) in describe exemplary system.

A kind of exemplary embodiment of configuration is shown in FIG. 10, wherein the target deposition in the pre- hot substrate of PTA welding torch The laser beam heats from laser aid and wire is melted to form preheated zone in region.In an illustrated embodiment, The substrate 200 of rectangle cuboid is configured to by SFFF production.The figure shows the initial parts of deposition process, in this process, First welding rod 220 is just deposited.Double welding gun system shown in Figure 10 includes: PTA welding torch 110, which is oriented to make It obtains plasma transferred arc power 130 that it is generated and is directed into target area with hot substrate 200 pre- at target area；And swash Electro-optical device 410, the laser aid are positioned in above target area to melt wire, fall on preheated zone or molten to be formed Molten metal drop on pond 210.

The wire 155 made of forming the material of workpiece SFFF is continuously fed with to be produced by laser aid 410 Raw laser beam 420.Wire 155 is supplied by wire feeder 145 and is positioned such that the end position of wire 155 Above preheated zone or molten bath 210 at the deposition region on substrate 200.Wire 155 can be given towards laser beam 420 speed (as illustrated by arrow 170).The speed of wire 155 might be chosen such that the heating of the distal end of wire 155 The molten metal drop 165 of molten metal silk 155 is made to be continuously supplied to preheated zone or molten bath 210 with melting rate.

The laser beam 420 of laser aid 410 is directed into the distal end of wire 155 to melt wire and form melting gold Belong to drop 165.The amount of the adjustable thermal energy provided by laser beam 420 according to the feed speed of wire 155 to keep heating And melting rate, so that the formation of molten metal drop 165 is timed to keep fusing wire 155 continuously to drip to preheated zone Or on molten bath 210.The feed speed that laser beam 420 and wire 155 leave wire feeder 145 can be by control system (example Such as, computer) consistently regulation and control, so as to provide metal or metal alloy to the speed of the predetermined deposition on substrate 200 The rate of rate melts wire 155 to preheated zone or the supply of molten bath 210.Wire can be supplied to laser beam at any angle In, and it is not limited to angle shown in Figure 10.Control system is simultaneously engaged with to operate and adjust connecing for actuator (not shown) It closes, which consistently positions and moving substrate 200, so that preheated zone or molten bath 210 are located at by object to be formed At the predetermined saltation point that CAD model provides.

As previously mentioned, in the exemplary embodiment, laser beam can also be manipulated to not be only channeled to wire 155, and it is directed into the region in the substrate below the fusing wire of drippage.In this way, laser beam can be with For further being heated to the region having been warmed up or molten bath that are generated by PTA welding torch 110.

Plasma transferred arc power 130 is formed by PTA welding torch 110.As shown, PTA welding torch 110 may be electrically connected to electricity Source 320, so that torch electrode 120 becomes cathode, and workpiece 200 becomes anode.Power supply can be AC power source or direct current Source.Plasma transferred arc power 130 can be continuous and be guided to heat the target area on workpiece surface at least A part.The preheating of target surface can make it easier to receive the molten metal drop 165 from molten metal silk 155.Mesh The preheating on mark surface can melt a part of workpiece surface at target area.The effect of adjustable DC power supply 310, with Heating and/or melting rate are kept according to the target velocity of wire 155, so that target area is preheated and receives molten metal Drop 165.The feed speed that the effect and wire 155 supplied by DC power supply 310 leave wire feeder 145 can be by Control system consistently regulation and control, so that metal or metal alloy to be provided to the predetermined deposition rate on substrate 200 Rate to preheated zone or molten bath 210 supply fusing wire 150.In this stage of SFFF technique, substrate 200 such as arrow It is moved shown in 240.

Figure 10 further depicts optional electrical configurations, can generate thermal pulse in preheated zone or molten bath 210.Institute Show in embodiment, DC power supply 320 may be electrically connected to PTA welding torch 110, so that torch electrode 120 becomes cathode, and substrate 200 become anode.In addition, the pulse frequency generator 330 for the power conveyed by DC power supply 330 of pulsing is positioned in electricity Lu Zhong, so that plasma transferred arc power 130 is in addition to heating a part with the target area optionally melted on workpiece surface Except pulse heat flux is also transported to target area.Pulse frequency generator 330 can be adjusted by control system.In some realities It applies in example, optional electrical configurations provide pulse arc discharge with 1 to about 200Hz frequency, but can be used and be up to about The frequency of 1kHz.In some applications, pulse frequency can in the range of about 1 to 100Hz or about 10 to 100Hz model In enclosing, or in the range of about 5 to 50Hz.

Carry out pre- hot substrate using PTA welding torch and forms preheated zone and melt the supply of metal material using laser beam Wire offers the advantage that the heat that can increase supplied to the feeder of wire, and with the heat that is supplied to substrate It is unrelated.The fusing power for being applied to wire be can choose with quality of match input (to be added to the melting of the wire of workpiece The amount of molten drop) to ensure the stably fused and/or all burnt of wire.Therefore, substrate can not be made to overheat simultaneously In the case of, and in no splashing or form excessive preheated zone or molten bath and therefore lose the control to the consolidation of deposition materials In the case where the risk of system, the deposition rate of molten metal charging is improved.

System comprising two laser aids

In some configurations of double welding gun system provided herein, which may include that two laser aids are used as two The heating device of a welding gun.In one configuration, the target deposition region in the pre- hot substrate of laser aid, and another laser system System heats and melts wire, to form the drop dropped on preheated zone or molten bath on target deposit.Another In kind configuration, the target deposition region in the pre- hot substrate of laser aid, and laser blows powder welding gun system heating powder metal And it is melted on the preheated zone on target deposit or molten bath.

In one configuration, first laser device can be arranged the target area that first laser beam is directed to substrate To form preheated zone, and second laser device can be positioned so that and second laser beam is directed to positioned at the preheating zone of substrate On the end of wire above domain.The end of the thermal energy fusing wire of the laser beam of second laser device, falls to be formed To the molten metal drop of the wire on the preheated zone below wire end of substrate.As combined other embodiments institute It discusses, can also be used in the substrate at target deposition region for melting the laser beam of second laser device of wire Thermal energy is contributed in preheated zone or molten bath, thus the thermal energy that the laser beam for facilitating first laser device provides.First laser dress The laser beam preheating target region set, and can be melted in substrate by intensification molten metal drop to promote substrate and melt Melt the fusion between metal material.Overheat from molten metal drop can assist in keeping near the preheated zone of substrate Molten bath.The system may include wire feedway, below the laser beam for wire to be provided to second laser device Desired locations.Wire feedway can be between first laser device and second laser device, or can be determined Position is at making it than first laser device closer to second laser device.

The system can also include positioning device, which can be located in wire is existed by first laser device Above the preheated zone formed in substrate.The end of wire suitably can also be put into second laser device by positioning device In laser beam, so that wire suitably melts and the drop of the molten metal formed by fusing wire is made to fall on it On the preheated zone of the substrate of lower section.

Wire can be or containing aluminium, chromium, copper, iron, hafnium, tin, manganese, molybdenum, nickel, niobium, silicon, tantalum, titanium, vanadium, tungsten or zirconium or Its compound or alloy.In some embodiments, wire contains titanium or titanium alloy.Wire can be or containing such a Titanium alloy, the titanium alloy contain the combination of one of titanium and aluminium, vanadium, tin, zirconium, molybdenum, niobium, chromium, tungsten, silicon and manganese or combinations thereof. For example, exemplary titanium alloy includes Ti-6A1-4V, Ti-6Al-6V-2Sn, Ti-6Al-2Sn-4Zr-6Mo, Ti-45Al-2Nb- 2Cr, Ti-47Al-2Nb-2Cr, Ti-47Al-2W-0.5Si, Ti-47Al-2Nb-lMn-0.5W-0.5Mo-0.2Si and Ti- 48Al-2Nb-0.7Cr-0.3Si.Wire can containing aluminium, iron, cobalt, copper, nickel, carbon, titanium, tantalum, tungsten, niobium, gold, silver, palladium, platinum, Zirconium, their alloy and their combination.Wire can be any configuration.Wire can have circular cross section.Metal The diameter of silk can be in the range of about 0.8mm to about 5mm.Wire can have the achievable cross sectional dimensions of any reality, Such as 1.0mm, 1.6mm, 2.4mm etc..The delivery rate of wire and positioning can be controlled by computer, to ensure wire when it It is melted when reaching the predetermined position above preheated zone or molten bath in substrate.

First laser device can produce the laser beam of enough energy to transfer thermal energy to the target area of workpiece to add Heat and at least part for optionally melting the surface, enable target area to receive the metal from molten metal silk Molten metal drop.Second laser device can produce the laser beam of enough energy, to transfer thermal energy to wire with molten Change the wire to form molten metal drop.The example of suitable laser aid may include ytterbium (Yb) laser, Yb optical fiber Laser, Yb fiber coupled diode lasers, Yb: the ytterbium that amorphous laser, diode pumping Yb:YAG laser, neodymium adulterate Aluminium garnet (Nd:YAG) laser, CO2 laser, CO laser, Nd: amorphous laser, neodymium doping ortho-vanadic acid ytterbium (Nd: YVO) laser, Cr: ruby laser, diode laser, diode-pumped laser, excimer laser, gas swash Light device, semiconductor laser, solid-state laser, dye laser, x-ray laser, free electron laser, ion laser Device, gas mixture laser, chemical laser and combinations thereof.Preferred laser includes Yb laser, especially Yb optical fiber Laser.In numerous applications, compared with other optical maser wavelengths, wavelength used in Yb optical fiber laser can be less anti- It penetrates.In some configurations, first laser device includes the laser of material identical as second laser device.For example, two laser Device can include Yb laser.In some configurations, the laser of first laser device has and second laser device The different material of laser.

The laser beam that first laser device may be configured so that it is generated can be along X or Y-direction in workpiece surface Upper scanning, to cover only region more broader than the focus of laser beam.Sweep spacing can be about 0.001 to about 0.1 inch.Pass through Adjusting laser aid can change the pre-arcing characterisitics of target area of the laser beam heats by first laser device.For example, can be with The power or laser beam device for adjusting laser beam may be configured so that laser beam can be mobile relative to workpiece surface, Perhaps the direction of closing of adjustable laser beam and angle or these any combination can be modified to adjust target area Preheating.Any loss in efficiency can also be by adjusting the close square of laser beam caused by being reflected due to laser by workpiece surface To compensating with angle.

By moving the laser beam of first laser device relative to workpiece surface along predefined paths, heated by laser beam layer Region can be limited on substrate with two dimension, the width of layer determines by the diameter of laser beam hits substrate.Laser beam is along pre- The movement for determining path can carry out under the control of the computer.It adjusts pulse shape and/or the duration provides one kind in laser The method of the specific power for the laser that control is provided by first laser device during beam moves through workpiece surface.First laser device Laser beam can also be conveyed with pulse.Traditional Focused Optical system can also be used for adjusting laser beam on the surface of the workpiece poly- It is burnt.

First laser device can be installed into can be under control of the computer in the X-Y plane for being parallel to substrate surface It is mobile, and can vertically be moved in orthogonal to that Z-direction.Therefore, the laser beam of first laser device can be guided Any point into X-Y plane, and be vertically guided to adapt to the different height in the workpiece and workpiece of different height Region.

A kind of exemplary embodiment of configuration is shown in FIG. 11, wherein the pre- hot radical of laser beam from laser aid The laser beam heats from another laser aid and metal is melted to form preheated zone for target deposition region on material Silk.In an illustrated embodiment, the substrate 200 for being configured to rectangle cuboid is produced by solid free fo manufacture.The figure The initial part of deposition process is shown, in this process, the first welding rod 220 is just deposited.Double welding gun system shown in Figure 11 System includes: first laser device 410, and the laser beam 420 which is positioned such that it is generated is directed into mesh Region is marked with hot substrate 200 pre- at target area；And second laser device 430, the second laser device are positioned in mesh Overlying regions are marked to melt wire 155, to form the molten metal drop 165 fallen on preheated zone or molten bath 210.

Swashed manufacturing to form wire 155 made of the material of workpiece and be continuously fed with free forming by second The laser beam 435 that electro-optical device 430 generates.Wire 155 is supplied by wire feeder 145 and is positioned such that wire 155 end is located at 210 top of preheated zone or molten bath at the deposition region on substrate 200.Wire 155 is given direction The speed (as illustrated by arrow 170) of laser beam 435.The speed of wire 155 might be chosen such that the distal end of wire 155 Heating and melting rate make the molten metal drop 165 of molten metal silk 155 be continuously supplied to preheated zone or molten Pond 210.

The laser beam 435 of second laser device 430 is directed into the distal end of wire 155 to melt wire and be formed molten Melt molten drop 165.The amount of the adjustable thermal energy provided by the laser beam 435 of second laser device 430 is according to wire 155 feed speed keeps heating and melting rate, so that the formation of molten metal drop 165 is timed to keep fusing metal Silk 155 continuously drips in preheated zone or molten bath 210.Laser beam 420 and wire 155 leave the confession of wire feeder 145 To speed by control system (for example, computer) consistently regulation and control, so as to provide metal or metal alloy to base The rate of predetermined deposition rate on material 200 melts wire 155 to preheated zone or the supply of molten bath 210.Wire can be with Any angle is supplied in laser beam, and is not limited to angle shown in Figure 11.Control system can simultaneously engage with operate and The engagement of actuator (not shown) is adjusted, which consistently positions and moving substrate 200, so that preheated zone or molten bath 210 are located at the predetermined saltation point provided by the CAD model of object to be formed.

First laser device 410 can be installed into can be flat in the X-Y for being parallel to substrate surface under control of the computer It moves, and can vertically be moved in orthogonal to that Z-direction in face.Therefore, the laser beam 420 of first laser device 410 It may be directed to any point in the X-Y plane on workpiece surface, and be vertically guided to adapt to the work of different height The region of different height in part and workpiece.As shown in figure 11, transverse direction is the direction of arrow 240, which is in manufacture During layer 220.

In different configurations, laser aid is used as the first welding gun, and laser blows powder system as the second welding gun.Laser Device, which can be arranged, is directed to the target area of substrate for laser beam to form preheated zone, and laser blows powder system and adds Hot powder metal is simultaneously melted on the preheated zone on target deposit or molten bath.The laser beam of laser aid preheats mesh Region is marked, and can be melted in substrate by intensification molten metal drop to promote between substrate and molten metal material Fusion.Laser blow the laser of powder system thermal energy fusing metallic particles, thus formed fall on substrate in the case where laser blows powder system Molten metal drop on the preheated zone of side.Laser blow powder system can also be used in it is pre- in the substrate at target deposition region Thermal energy is contributed in thermal region or molten bath, to facilitate the thermal energy provided by the laser beam of laser aid.From molten metal bath The overheat of drop can assist in keeping the molten bath near the preheated zone of substrate.

It is blown in powder system in laser, metal powder is blown into the interaction zone between laser beam and workpiece.Powder Usually it is carried in laser path by carrier gas.In some embodiments, using coaxial powder supply nozzle.In United States Patent (USP) No. 6,774,338 (Baker et al.)；No. 6,608,281 (Ishide et al.)；No. 5,486,676 (Aleshin)；With And U.S. Patent Application Publication No. US2015/0328718 (Iwatani et al.)；No. US2005/0056628 (Hu)；And Coaxial powder that is can be used or modifying to use within the system is described in No. US2006/0065650 (Guo) The example of supply nozzle.

Coaxial supply nozzle streams metal powder in nozzle, so that it is directed to the focus of laser, powder is heated It extremely approaches the temperature of fusing or is heated to the temperature by powder particles fuse at molten drop, molten drop is deposited on workpiece Preheated zone or molten bath on.The laser for the laser aid for forming preheated zone or molten bath can be pulsed in cooling procedure, To change the micro-structure of adding layers, to mitigate any stress assigned by addition delaminating process.

Exemplary embodiment is shown in Fig. 8.In an illustrated embodiment, it is produced by solid free fo manufacture Shape is the substrate 200 of rectangle cuboid.The figure shows the initial parts of deposition process, and in this process, the first welding rod 220 is just It is deposited.Double welding gun system shown in fig. 8 includes: laser aid 410, which is positioned such that it is generated sharp Light beam 420 is directed into a part of target area with the surface of pre- hot substrate 200 at target area；And coaxial powder supplies To nozzle laser system 510, preheating target overlying regions are positioned in, are fallen on preheated zone or molten bath 210 to be formed Molten metal particles 520.

Powdered-metal is transported to coaxial powder supply nozzle laser system by powder conveying system (attached to be not shown in the figure) 510.Powdered-metal is to be formed to manufacture the composition of the metal for the material to form workpiece by free forming or contain upon melting The composition.Powder metal can be titanium or can be or containing such a titanium alloy, the titanium alloy contain titanium and aluminium, The combination of one of vanadium, tin, zirconium, molybdenum, niobium, chromium, tungsten, silicon and manganese or combinations thereof.For example, exemplary titanium alloy includes Ti- 6A1-4V、Ti-6Al-6V-2Sn、Ti-6Al-2Sn-4Zr-6Mo、Ti-45Al-2Nb-2Cr、Ti-47Al-2Nb-2Cr、Ti- 47Al-2W-0.5Si, Ti-47Al-2Nb-lMn-0.5W-0.5Mo-0.2Si and Ti-48Al-2Nb-0.7Cr-0.3Si.Powder Endization metal containing aluminium, iron, cobalt, copper, nickel, carbon, titanium, tantalum, tungsten, niobium, gold, silver, palladium, platinum, zirconium, they alloy and they Combination.

Powder can be continuously fed to the laser spot generated by blowing powder laser system 510, at the laser spot, it It is heated to its fusing point or be completely melt into and deposits to the preheated zone on substrate 200 or the molten metal on molten bath 210 520 Drop.Be provided to blow the powdered-metal of powder laser system 510 speed be selected such that heating and melting rate make heating The drop of powder or molten metal 520 is continuously supplied to preheated zone or molten bath 210.During cooling, laser aid 410 It can be pulse, to adjust the micro-structure of the transfer layer of molten metal.Two welding guns can be fixed in single frame, so as to Remain appropriately distance.

It as the double welding gun system of heating device may include control system including two laser systems, which can To operate and adjust the engagement of actuator (not shown), the actuator can consistently position with moving substrate 200 so that preheating Region or molten bath are located at the predetermined saltation point provided by the CAD model of object to be formed.In this stage of SFFF technique, Substrate 200 moves as indicated by the arrow 240.Actuator can be flat in the X-Y for being parallel to double welding gun system under control of the control system It moves, and can vertically be moved in orthogonal to that Z-direction in face.The laser spot of laser aid 410 is also moveable And it may be directed to any point in the X-Y plane on workpiece surface, and be vertically guided to adapt to two differences The workpiece of height and the region for also adapting to the different height in workpiece.Exemplary laser 410 is Yb optical fiber laser.

Including two laser aids as the double welding gun system of heating device can surround with the closed chamber of ambient air Interior, and the chamber can be made fully not oxygenous.At International Patent Application Publication WO2011/019287 (Guldberg) In describe exemplary chamber.Welding purging room for welding under an inert gas is also commercially available (for example, Massachusetts State Salisbury LC technical solution company), and design or engineering design can be easy to carry out to adapt to any ruler Very little or configuration system.By using fully not oxygenous settling chamber, ring such as is replaced with argon gas or other inert gases Border gas, can be improved the speed of welding process, this is because can permit welding region reaches higher temperature without having The risk of weld seam excessive oxidation.

Alternatively, the double welding gun system including two laser aids may be configured so that the encapsulating of protective gas is enclosed Around deposition processes region to avoid oxidation.In such a system, protective gas (such as argon gas) is directed to around same by nozzle The region of axis powder supply nozzle laser system 510 and preheated zone or molten bath 210.For example, inert gas can be guided to pass through Inert gas is directed to melting weldpool surrounding nearby by one or more nozzles in support 530.Gas is by preheating zone Domain or molten bath and isolated from atmosphere, to prevent block.Ireland et al. (U.S. Patent No. 7,220,935)；Comon et al. (beauty State's patent the 9,145,832nd)；And Cooper et al. (U.S. Patent Application Publication No. US 2010/0276396) description It can be used together with double welding gun system or the system suitable for being used together with double welding gun system.

Using the pre- hot substrate of laser aid and forms preheated zone and melt wire using another laser aid Or metallic particles offer the advantage that can increase heat supplied to wire or metallic particles and with supplied to substrate Heat is unrelated.The fusing power for being applied to wire or metallic particles be can choose with quality of match input (to be added to workpiece Molten metal drop amount) to ensure the stably fused of wire and/or all burnt or ensure the completely molten of metallic particles Change.Therefore, can in the case where overheating substrate, and do not formed excessive preheated zone or molten bath and because In the case that this loses the risk of the control to the consolidation of deposition materials, the deposition rate of molten metal charging is improved.

System comprising laser aid and electron beam device

In some configurations of double welding gun system provided herein, which may include the laser aid as a welding gun With the electron beam device as another welding gun.In some configurations, the target deposition region in the pre- hot substrate of electron beam device To form preheated zone, and laser aid heats and melts wire, to generate the preheating zone for falling into target deposition region Molten metal drop in domain.In some configurations, the target deposition region in the pre- hot substrate of laser aid is to form preheating zone Domain, and electron beam device heats and melts wire, to generate the melting fallen into the preheated zone in target deposition region Molten drop.

In one configuration, electron beam device, which is used as the first welding gun and can be arranged, is directed to substrate for electron beam Target area to form preheated zone, and laser aid is used as the second welding gun and can be positioned so that and guides laser beam On the end of wire above to the preheated zone for being located at substrate.The end of the thermal energy fusing wire of laser beam, thus shape At the molten metal drop for the wire on the preheated zone below wire end for falling on substrate.The electricity of electron beam device Beamlet preheating target region, and can be melted in substrate by intensification molten metal drop to promote substrate and molten metal Fusion between material.As in conjunction with discussing other embodiments, the laser beam of first laser device can also be used in heavy in target Thermal energy is contributed in the preheated zone or molten bath in substrate at product region, to facilitate the thermal energy provided by electron beam.It comes from The overheat of molten metal drop can assist in keeping the molten bath near the preheated zone of substrate.The system may include that wire supplies To device, for wire to be provided to the desired locations below laser beam.Wire feedway can be located at laser aid Between electron beam device, or it may be oriented such that it than electron beam device closer to laser aid.

Electron beam device, which can be arranged, is directed to the target area of substrate for electron beam to form preheated zone.Electronics Bundle device can produce the electron beam of enough energy to transfer thermal energy to the target area of workpiece to heat and optionally melt At least part for changing surface, enables target area to receive the molten metal drop of the metal from molten metal silk.Electricity Beamlet device is commercially available and in the art (for example, with reference to U.S. Patent No. 3,136,882 (Radtke, 1964)； 3rd, 187, No. 216 (Sciaky, 1965)；3rd, 535, No. 489 (Hinrichs, 1970)；No. 3,592,995 (Hinrichs, 1971)；3rd, 766, No. 355 (Kottkamp, 1973)；4th, 058, No. 697 (Sokolov et al., 1977)； 4th, 327, No. 273 (Kita et al., 1982)；4th, 677, No. 273 (Colegrove et al., 1987)；No. 4,698,546 (Maitland et al., 1987)；6th, 882, No. 095 (Avnery, 2005)；And Taminger and Hafley " for having The electron beam free forming manufacture of cost-efficient near-net shape manufacture ", NATO, 2006) in description.

Electron beam device may be configured so that the electron beam that it is generated can be along X or Y-direction on the surface of the workpiece Scanning, to cover only region more broader than the focus of electron beam.Sweep spacing can be about 0.001 to about 0.1 inch.Pass through tune Section electron beam device can change the pre-arcing characterisitics of the target area by electron beam heating.Electron beam device can be selected to make It contains electromagnetic coil to adjust electron beam.Electron beam device can provide the energy of the focusing electron flow form accelerated towards workpiece Amount.High voltage potential (for example, greater than about 15kV, such as in the range of about 15kV to about 150kV) can be used to accelerate electricity Son.One or more heater strips can be used and generate electronics in electron beam device.The power output of electron beam gun usually can be with It is controlled by limiting or being adjusted to the electron stream of workpiece.It is, for example, possible to use the beam powers for being up to about 30kW, but usually about In the range of 2.5kW to about 10kW or about 3kW to about 6kW.Beam current is generally greater than about 100 milliamperes, and can be in about 100 millis In the range of 600 milliamperes of An Zhiyue.Beam power is variable, and by using the input within the scope of about 100V to about 500V Voltage generates.The exemplary input voltage of about 110V can be by using about 100V to the input of about 600V (for example, 110V) Voltage exports.

It, can be in base by the region that electron beam heats by moving electron beam relative to workpiece surface along predefined paths It is limited on plate with two dimension, the width of layer is determined by the diameter that electron beam hits substrate.Electron beam can along moving for predefined paths To carry out under the control of the computer.It adjusts harness shape and/or the duration provides a kind of control by electron beam device in electronics The method that beam moves through the specific power provided during workpiece surface.Electron beam can also be conveyed with pulse.As further below It is discussed in detail, mechanical and/or hydraulic actuator can be used to move, to limit preheated zone in the substrate in electron beam device Or molten bath.Moreover, preheated zone or molten bath can also adjust electron beam by using electromagnetic coil to limit.

The laser beam of laser aid thermal energy fusing wire end, thus formed fall on substrate in wire end The molten metal drop of wire on the preheated zone of lower section.The laser beam of laser aid can also be in target deposition region Thermal energy is nearby contributed in preheated zone, to facilitate the thermal energy provided by the electron beam of electron beam device.From molten metal bath The overheat of drop can assist in keeping the molten bath near the preheated zone of substrate.The system may include wire feedway, with For wire to be provided to the desired locations below the laser beam of laser aid.Wire feedway can be located at laser and fill It sets between electron beam device, or may be oriented such that it than electron beam device closer to laser aid.

The system can also include positioning device, which can be located in wire by electron beam device in base Above the preheated zone formed in material.The end of wire can also be suitably put into the laser beam of laser aid by positioning device In, so that wire suitably melts, and the drop of the molten metal formed by fusing wire is fallen below Substrate preheated zone on.

Wire can be or containing aluminium, chromium, copper, iron, hafnium, tin, manganese, molybdenum, nickel, niobium, silicon, tantalum, titanium, vanadium, tungsten or zirconium or Its compound or alloy.In some embodiments, wire contains titanium or titanium alloy.Wire can be or containing such a Titanium alloy, the titanium alloy contain the combination of one of titanium and aluminium, vanadium, tin, zirconium, molybdenum, niobium, chromium, tungsten, silicon and manganese or combinations thereof. For example, exemplary titanium alloy includes Ti-6A1-4V, Ti-6Al-6V-2Sn, Ti-6Al-2Sn-4Zr-6Mo, Ti-45Al-2Nb- 2Cr, Ti-47Al-2Nb-2Cr, Ti-47Al-2W-0.5Si, Ti-47Al-2Nb-lMn-0.5W-0.5Mo-0.2Si and Ti- 48Al-2Nb-0.7Cr-0.3Si.Wire can containing aluminium, iron, cobalt, copper, nickel, carbon, titanium, tantalum, tungsten, niobium, gold, silver, palladium, platinum, Zirconium, their alloy and their combination.In some applications, wire is free of aluminium.Wire can have any cross section Shape.Wire can have circular cross section.The diameter of wire can be up to about 10mm.The diameter of wire can be about In the range of 0.8mm to about 5mm.Wire can have an achievable cross sectional dimensions of any reality, such as 1.0mm, 1.6mm, 2.4mm waiting.The delivery rate of wire and positioning can be controlled by computer, to ensure that wire reaches the preheating in substrate when it It is melted when predetermined position above region or molten bath.

Laser aid can produce the laser beam of enough energy, with transfer thermal energy to wire with melt the wire with Form molten metal drop.The example of suitable laser aid may include ytterbium (Yb) laser, Yb optical fiber laser, Yb optical fiber Coupled diode laser, Yb: amorphous laser, diode pumping Yb:YAG laser, neodymium doping YBAG ytterbium aluminum garnet (Nd: YAG) laser, CO2 laser, CO laser, Nd: amorphous laser, neodymium doping ortho-vanadic acid ytterbium (Nd:YVO) laser, Cr: ruby laser, diode laser, diode-pumped laser, excimer laser, gas laser, semiconductor Laser, solid-state laser, dye laser, x-ray laser, free electron laser, ion laser, admixture of gas Laser, chemical laser and combinations thereof.Preferred laser includes Yb laser, especially Yb optical fiber laser.In many In, compared with other optical maser wavelengths, wavelength used in Yb optical fiber laser can less reflect.

Exemplary configuration is shown in FIG. 9.In the configuration shown in, forming is produced by solid free fo manufacture For the substrate 200 of rectangle cuboid.The figure shows the initial parts of deposition process, in this process, the first welding rod 220 just quilt Deposition.Double welding gun system shown in Fig. 9 includes: electron beam device 610, which is positioned such that it was generated Electron beam 620 is directed into a part of target area with the surface of pre- hot substrate 200 at target area；And laser dress 410 are set, which generates the laser beam 420 that can heat and melt wire 155.

The laser beam 420 of laser aid 410 may be directed to the distal end of wire 155 to melt wire and be formed molten Melt molten drop 165.The amount of the adjustable thermal energy provided by the laser beam 420 of laser aid 410 is according to wire 155 Feed speed keeps heating and melting rate, so that the formation of molten metal drop 165 is timed to keep melting wire 155 Continuously drip on preheated zone or molten bath 210.Laser beam 420 and wire 155 leave the feed speed of wire feeder 145 It can be by control system (for example, computer) consistently regulation and control, so as to provide metal or metal alloy to substrate 200 On predetermined deposition rate rate to preheated zone or molten bath 210 supply fusing wire 155.Wire can be with any angle Degree is supplied in laser beam, and is not limited to angle shown in Fig. 9.Control system is simultaneously engaged with to operate and adjust actuator The engagement of (not shown), the actuator consistently position and moving substrate 200 so that preheated zone or molten bath 210 be located at by At the predetermined saltation point that the CAD model of the object of formation provides.

Electron beam device 610 can be installed into can be under control of the computer in the X-Y plane for being parallel to substrate surface Interior movement, and can vertically be moved in orthogonal to that Z-direction.Therefore, the electron beam 620 of electron beam device 610 can be with Any point being directed into the X-Y plane on workpiece surface, and be vertically guided with adapt to the workpiece of different height and The region of different height in workpiece.As shown in figure 9, transverse direction is the direction of arrow 240, which is in manufacture layer 220 During.

In alternative configuration, laser aid, which is used as the first welding gun and can be arranged, is directed to substrate for laser beam Target area is to form preheated zone, and electron beam device is used as the second welding gun and can be positioned so that and guides electron beam On the end of wire above to the preheated zone for being located at substrate.The end of the thermal energy fusing wire of electron beam, thus shape At the molten metal drop for the wire on the preheated zone below wire end for falling on substrate.The laser of laser aid Beam preheating target region, and can be melted in substrate by intensification molten metal drop to promote substrate and molten metal material Fusion between material.In this embodiment, as discussed about other embodiments, the electron beam of electron beam device can also be used in Thermal energy is contributed in the preheated zone or molten bath in the substrate at target deposition region, to facilitate the heat provided by laser beam Energy.Overheat from molten metal drop can assist in keeping the molten bath near the preheated zone of substrate.The system may include Wire feedway, for wire to be provided to the desired locations below electron beam.Wire feedway can position Between electron beam device and laser aid, or it may be oriented such that it than laser aid closer to electron beam device.

Exemplary embodiment is shown in Figure 10.In an illustrated embodiment, it is produced by solid free fo manufacture It is configured to the substrate 200 of rectangle cuboid.The figure shows the initial parts of deposition process, in this process, the first welding rod 220 Just it is deposited.Double welding gun system shown in Figure 10 includes: the laser aid 410 for generating laser beam 420, which is guided A part to target area with the surface of pre- hot substrate 200 at target area；And electron beam device 710, it is positioned Wire 155 is heated and melted at the electron beam 720 for generating it.

The electron beam 720 of electron beam device 710 may be directed to the distal end of wire 155 to melt wire and be formed Molten metal drop 165.The amount of the adjustable thermal energy provided by the electron beam 720 of electron beam device 710 is according to wire 155 feed speed keeps heating and melting rate, so that the formation of molten metal drop 165 is timed to keep fusing metal Silk 155 continuously drips on preheated zone or molten bath 210.Electron beam 720 and wire 155 leave the confession of wire feeder 145 To speed by control system (for example, computer) consistently regulation and control, so as to provide metal or metal alloy to base The rate of predetermined deposition rate on material 200 melts wire 155 to preheated zone or the supply of molten bath 210.Wire can be with Any angle is supplied in electron beam, and is not limited to angle shown in Figure 10.Control system is simultaneously engaged with to operate and adjust The engagement of actuator (not shown) is saved, which consistently positions and moving substrate 200, so that preheated zone or molten bath 210 The predetermined saltation point provided positioned at the CAD model by object to be formed.

Laser aid 410 can be installed into can be under control of the computer in the X-Y plane for being parallel to substrate surface It is mobile, and can vertically be moved in orthogonal to that Z-direction.Therefore, the laser beam 420 of laser aid 410 can be drawn Any point in the X-Y plane on workpiece surface is led, and is vertically guided to adapt to the workpiece of different height and workpiece The region of interior different height.As shown in Figure 10, transverse direction is the direction of arrow 240, which is in the mistake of manufacture layer 220 Cheng Zhong.

In the double welding gun system provided herein including laser aid and electron beam device, wire can be or comprising Aluminium, chromium, copper, iron, hafnium, tin, manganese, molybdenum, nickel, niobium, silicon, tantalum, titanium, vanadium, tungsten or zirconium or its compound or alloy.In some embodiments In, wire contains titanium or titanium alloy.Wire can be or containing such a titanium alloy, the titanium alloy contain titanium and aluminium, The combination of one of vanadium, tin, zirconium, molybdenum, niobium, chromium, tungsten, silicon and manganese or combinations thereof.For example, exemplary titanium alloy includes Ti- 6A1-4V、Ti-6Al-6V-2Sn、Ti-6Al-2Sn-4Zr-6Mo、Ti-45Al-2Nb-2Cr、Ti-47Al-2Nb-2Cr、Ti- 47Al-2W-0.5Si, Ti-47Al-2Nb-lMn-0.5W-0.5Mo-0.2Si and Ti-48Al-2Nb-0.7Cr-0.3Si.Gold Belong to silk and contains aluminium, iron, cobalt, copper, nickel, carbon, titanium, tantalum, tungsten, niobium, gold, silver, palladium, platinum, zirconium, their alloy and their group It closes.Metal can be free of aluminium.Wire can have circular cross section.The diameter of wire can be in about 0.8mm to the model of about 5mm In enclosing.Wire can have the achievable cross sectional dimensions of any reality, such as 1.0mm, 1.6mm, 2.4mm etc..

In the double welding gun system provided herein including electron beam device, which includes shell, which defines Sealable chamber, the sealable chamber can be evacuated, and some or all of components can be located in the sealable chamber It is interior.At least part of one or more components (for example, control system, power supply or computer) can be located at the outer of the chamber Portion.Sealable chamber, which can be configured as, to be surrounded wire feeder, electron beam device, laser aid, workpiece and makes base The material actuator pallet mobile relative at least first heater, or the actuator arm for keeping first heater mobile, or make The mobile actuator arm or any combination thereof of secondary heating mechanism.Chamber can be evacuated to handle as needed.Chamber can For example to be evacuated using suitable vacuum pump or pumping system, so that the indoor pressure of chamber is about 1 × 10^-1To about 1 × 10^-7Support (torr) or in lower range.During deposition process, it may be desirable to by the indoor pressure reduction of chamber to less than about 0.1 support or Less than about 1 × 10^-2It holds in the palm or less than about 1 × 10^-6The pressure of support.

System comprising two electron beam devices

In some configurations of double welding gun system provided herein, which includes: to get one's things ready as the electronics of the first welding gun It sets, with the target deposition region in pre- hot substrate；And another electron beam device as the second welding gun, for heating Wire is simultaneously melted on preheated zone or molten bath.First electron beam device, which can be arranged, is directed to substrate for energy Target area to form molten bath.The pre- hot substrate of first electron beam enables it at molten metal material position to be deposited Receive molten metal silk molten drop.In some embodiments, at least part substrate is melted by the first electron beam device, so that base Material is easier to receive.In some embodiments, enough heats are applied by the first electron beam device, to wait sinking in metal material Preheated zone or molten bath are formed in substrate at long-pending position.First electron beam device can by deepen substrate in fusing come Promote the fusion between substrate and molten metal material.First electron beam device can help ensure that over hot melting metal material Abundant fusing, molten metal material may not be able to oneself realize sufficiently fusing.Preheated zone or molten bath can be monitored, such as Temperature and size, and it is based on information obtained, the power of adjustable electron beam device, so as to by preheated zone or molten bath It is maintained in desired parameter, such as in predetermined size.

The electron beam that first electron beam device may be configured so that it is generated can be along X or Y-direction in workpiece table It is scanned on face, to cover only region more broader than the focus of electron beam.Sweep spacing can be about 0.001 to about 0.1 inch.It is logical Overregulate the pre-arcing characterisitics for the target area that electron beam device can change by the electron beam heating of the first electron beam device.Electronics Bundle device can be selected to that it is made to contain electromagnetic coil to adjust electron beam.Electron beam device can be provided to be accelerated towards workpiece Focusing electron flow form energy.High voltage potential can be used (for example, greater than about 15kV, such as in about 15kV to about In the range of 150kV) accelerate electronics.One or more heater strips can be used and generate electronics in electron beam device.Electronics The power output of bundle device can usually be controlled by limiting or being adjusted to the electron stream of workpiece.It is, for example, possible to use up to The beam power of about 30kW, but usually in the range of about 2.5kW is to about 10kW or about 3kW to about 6kW.Beam current is usually big In about 100 milliamperes, and can be in the range of about 100 milliamperes to about 600 milliamperes.Beam power is variable, and can be led to It crosses using the input voltage within the scope of about 100V to about 500V and generates.Exemplary input voltage is about 110V.

Mechanical and/or hydraulic actuator also can be used to move, to limit preheated zone in the substrate in electron beam device Or molten bath.

By moving the electron beam of the first electron beam device relative to workpiece surface along predefined paths, by the first electron beam The region of the electron beam heating of device can be limited on substrate with two dimension, and width is true by the diameter that electron beam hits substrate It is fixed.Electron beam can carry out under the control of the computer along moving for predefined paths.It adjusts pulse shape and/or the duration provides A kind of method that the specific power provided during electron beam moves through workpiece surface by electron beam device is provided.Electron beam It can be conveyed with pulse.

Second electron beam device can be arranged the end for the wire being directed to electron beam above molten bath, make The end for obtaining the thermal energy fusing wire generated by the electron beam of the second electron beam device, falls under wire end to be formed The drop of molten metal on the preheated zone or molten bath of side.As in conjunction with discussing other embodiments, the second electron beam device The substrate that can also be used at target deposition region of electron beam in preheated zone or molten bath in contribute thermal energy, to facilitate The thermal energy provided by the first electron beam device.The system may include wire feedway, for wire to be provided to the Two electron beam devices.

Second electron beam device can have variable power output, can be conditioned substantially constant to provide to wire The amount of power or energy, the power or energy is to provide the amount of the substantially invariable melting rate of wire.By the second electronics The power or energy of bundle device conveying can be adjusted according to the composition of wire, allow wire with constant rate It supplies and is melted on the preheated zone on substrate or molten bath.First electron beam device and the second electron beam device can be independently It may include multiple electron beam guns including Single Electron beam rifle or every electron beam device.Double welding gun system may include one or Multiple detectors such as temperature sensor or are taken the photograph for example with for detecting the electronics generated by electron beam gun or for monitoring molten bath As head or the detector including camera, electrical phenomena testing agency or combinations thereof.

Electron beam device is commercially available and in the art (for example, with reference to U.S. Patent No. 3,136,882 (Radtke, 1964)；3rd, 187, No. 216 (Sciaky, 1965)；3rd, 535, No. 489 (Hinrichs, 1970)；3rd, 592, No. 995 (Hinrichs, 1971)；3rd, 766, No. 355 (Kottkamp, 1973)；No. 4,058,697 (Sokolov etc. People, 1977)；4th, 327, No. 273 (Kita et al., 1982)；4th, 677, No. 273 (Colegrove et al., 1987)；4th, 698, No. 546 (Maitland et al., 1987)；6th, 882, No. 095 (Avnery, 2005)；And Taminger and Hafley " electron beam free forming manufacture " for being manufactured with cost-benefit near-net shape, NATO, 2006) description.Electron beam Device can be selected to that it is made to contain electromagnetic coil to adjust electron beam.Electron beam gun can be provided towards workpiece or wire The energy of the focusing electron flow form of acceleration.Can be used high voltage potential (for example, greater than about 15kV, such as about 15kV extremely In the range of about 150kV) accelerate electronics.One or more heater strips can be used and generate electronics in electron beam device.Electricity The power output of beamlet device can usually be controlled by limiting or being adjusted to the electron stream of workpiece or wire.For example, can To use the beam power for being up to about 30kW, but usually in the range of about 2.5kW is to about 10kW or about 3kW to about 6kW.Beam current Generally greater than about 100 milliamperes, and can be in the range of about 100 milliamperes to about 600 milliamperes.Beam power is variable, and It is generated by using the input voltage within the scope of about 100V to about 500V.Exemplary input voltage is about 110V.

The system may also include positioning device, which can be located in wire is formed in the substrate by laser Above preheated zone or molten bath.The end of wire can also be suitably put into plasma transferred arc power by positioning device, It melts it suitably, and to be formed by the preheated zone or molten bath that drop is fallen below.

Wire can be or contain titanium.Wire can be or contain such a titanium alloy, which contains titanium With the combination of one of aluminium, vanadium, tin, zirconium, molybdenum, niobium, chromium, tungsten, silicon and manganese or combinations thereof.For example, exemplary titanium alloy includes Ti-6A1-4V、Ti-6Al-6V-2Sn、Ti-6Al-2Sn-4Zr-6Mo、Ti-45Al-2Nb-2Cr、Ti-47Al-2Nb-2Cr、 Ti-47Al-2W-0.5Si, Ti-47Al-2Nb-lMn-0.5W-0.5Mo-0.2Si and Ti-48Al-2Nb-0.7Cr-0.3Si. Wire containing aluminium, iron, cobalt, copper, nickel, carbon, titanium, tantalum, tungsten, niobium, gold, silver, palladium, platinum, zirconium, they alloy and they Combination.Wire can be free of aluminium.Wire can have any desired cross-sectional shape.Wire can have rounded cross section Face.The diameter of wire can be in the range of about 0.8mm to about 5mm.Wire can have the achievable ruler of any reality It is very little, such as 1.0mm, 1.6mm, 2.4mm etc..The delivery rate of wire and positioning can be according to the heat provided by electron beam device The effect of energy is controlled and is adjusted, to ensure pre-determined bit of the wire above the preheated zone or molten bath in its arrival substrate It is heated continuously and melts when setting.

The system may include shell, and shell restriction can be with rarefied sealable chamber, and some or all of components can To be located in the sealable chamber.At least part of one or more components (for example, control system, power supply or computer) can To be located at exterior thereto.Sealable chamber, which can be configured as, surrounds wire feeder, the first electron beam device, the second electronics Bundle device, workpiece and the actuator pallet for keeping substrate mobile relative at least first heater make first heater Mobile actuator arm or the actuator arm for keeping secondary heating mechanism mobile or any combination thereof.Chamber can be evacuated as needed For being handled.Chamber can be evacuated for example using suitable vacuum pump or pumping system, so that the indoor pressure of chamber is about 1 ×10^-1To about 1 × 10^-7In support or lower range.During deposition process, it may be desirable to extremely by the indoor pressure reduction of chamber Less than about 0.1 support or less than about 1 × 10^-2It holds in the palm or less than about 1 × 10^-6The pressure of support.

Exemplary embodiment is shown in Figure 11.In an illustrated embodiment, it is produced by solid free fo manufacture It is configured to the substrate 200 of rectangle cuboid.The figure shows the initial parts of deposition process, in this process, the first welding rod 220 Just it is deposited.Double welding gun system shown in Figure 11 includes the first electron beam device 610, which is oriented So that its electron beam 620 generated is directed into at least part on the surface of target area and heat target region.Some In, electron beam 620 can heat and optionally at least partially melt a part on the surface of target area, and can be with Facilitate at target area to generate preheated zone or molten bath 210 on substrate 200.Second electron beam device 710 generates electronics Beam 720, the electron beam are directed on the end of the wire above the preheated zone of substrate.The thermal energy of electron beam 720 The end of wire is melted, to form the melting for falling on the wire on the preheated zone below wire end of substrate Molten drop.The electron beam 620 of first electron beam device 610 can be melted in substrate to promote by intensification molten metal drop Into the fusion between substrate and molten metal material.The electron beam 720 of second electron beam device 710 can also be in target deposition area Thermal energy is nearby contributed in the preheated zone in domain, to facilitate the thermal energy provided by the electron beam 620 of the first electron beam device 610. Overheat from molten metal drop can assist in keeping the molten bath near the preheated zone of substrate.

Wire 155 can be supplied by wire feeder 145 and may be oriented such that the end of wire 155 Above the preheated zone or molten bath 210 at the deposition region on substrate 200.Wire 155 can be given towards electronics The speed of beam 720.The speed of wire 155 might be chosen such that the heating of the distal end of wire 155 and melting rate make The molten metal drop 165 for obtaining molten metal silk 155 is continuously supplied to preheated zone or molten bath 210.

Wire 155 is to be formed to manufacture the combination of the metal for the material to form workpiece by free forming or contain upon melting There is the combination of the metal.Wire 155 can be titanium or can be or containing such a titanium alloy, the titanium alloy contain titanium with The combination of one of aluminium, vanadium, tin, zirconium, molybdenum, niobium, chromium, tungsten, silicon and manganese or combinations thereof.For example, exemplary titanium alloy includes Ti- 6A1-4V、Ti-6Al-6V-2Sn、Ti-6Al-2Sn-4Zr-6Mo、Ti-45Al-2Nb-2Cr、Ti-47Al-2Nb-2Cr、Ti- 47Al-2W-0.5Si, Ti-47Al-2Nb-lMn-0.5W-0.5Mo-0.2Si and Ti-48Al-2Nb-0.7Cr-0.3Si.Gold Belong to silk and contains aluminium, iron, cobalt, copper, nickel, carbon, titanium, tantalum, tungsten, niobium, gold, silver, palladium, platinum, zirconium, their alloy and their group It closes.In some applications, wire does not include aluminium.

Wire 150 can be continuously fed to the electron beam 720 generated by the second electron beam system 710, in electron beam Place, it, which is heated to its fusing point or is completely melt into, deposits to the preheated zone on substrate 200 or the molten metal in molten bath 210 165 drop.Wire can be supplied in electron beam at any angle, and be not limited to angle shown in Figure 11.

Double welding gun system may include control system, which can operate and adjust connecing for actuator (not shown) It closes, which consistently positions and moving substrate 200, so that preheated zone or molten bath are located at the CAD by object to be formed At the predetermined saltation point that model provides.In this stage of SFFF technique, substrate 200 moves as indicated by the arrow 240.Actuator can It moves, and can be erected in orthogonal to that Z-direction in the X-Y plane for being parallel to double welding gun system under control of the control system It is directly mobile.The focus of each of electron beam device 710 and electron beam device 610 is also moveable.For example, changing electronics The focus of bundle device 610 can permit any point that electron beam 620 is directed into X-Y plane, and vertically adjusted with It adapts to two workpiece of different height and also adapts to the region of the different height in workpiece.Change the coke of electron beam device 710 Point can permit electron beam 720 be focused on can closer to or far from workpiece surface relocate wire on.In cooling Period, electron beam device 610 may be directed on cooling melting layer, to adjust the micro-structure of the transfer layer of molten metal.

First and second electron beam devices can advantageously have individual power supply and be supplied to each device for adjusting Power device.The system may include the sensor for the temperature for monitoring the deposition region of substrate, and electron beam Width and positioning can change on preheated zone or molten bath and/or the surface of wire.

In double welding gun system provided herein, carrys out pre- hot substrate using the first rifle containing heating device and form preheating Region and wire is melted using the second rifle containing heating device or metallic particles offers the advantage that and can increase It is unrelated with the heat of substrate is supplied to the supply of the heat of wire or metallic particles.It can choose and be applied to wire or gold The fusing power of metal particles is with quality of match input (to be added to the amount of the molten metal drop of workpiece) to ensure wire Stably fused and/or all burnt ensure that metallic particles is completely melt.It therefore, can be the case where overheating substrate simultaneously Under, and do not forming excessive preheated zone or molten bath and therefore losing the risk of control to the consolidation of deposition materials In the case of, improve the deposition rate of molten metal charging.

It will be apparent to one skilled in the art that without departing from the scope of the invention, it can be at this It carry out various modifications and changes in invention.Therefore, the present invention is directed to cover the range for falling into the following claims and their equivalents Interior modifications and variations of the invention.

Reference signs list

The following are the lists of appended drawing reference used in the description and the appended drawings.

110 PTA welding torches

120 torch electrodes

130 plasma transferred arc powers

140 wire feeders

145 wire feeders

150 wires

155 wires

160 molten metal drops

165 molten metal drops

170 speed arrows

200 substrates

210 preheated zones or molten bath

220 welding rods

240 direction arrows

310 power supplys

320 power supplys

330 pulse frequency generators

410 laser aids

420 laser beams

430 second laser devices

440 laser beams

510 blow powder laser aid

520 melt granules

530 supporting elements

610 first electron beam devices

620 electron beams

710 second electron beam devices

720 electron beams

Claims (34)

1. a kind of system for being manufactured by solid free fo to construct metal object, comprising:

First welding gun, a part on the surface for pre- hot substrate；

Second welding gun, the drop of the metal material for being fused into wire on the pre- hot surface for depositing to the substrate；With And

The deposition profile of object to be formed so that by according to the deposition profile by the successive sedimentation object of the metal material It is fused on the substrate and constructs the object,

Wherein, at least one of first welding gun and second welding gun include laser aid, and first welding gun It include one of PTA welding torch, laser or electron beam device with the other of second welding gun.

2. system according to claim 1 further includes the cause for keeping the substrate mobile relative at least described first welding gun Dynamic device pallet.

3. system according to any one of claim 1 to 2 further includes the actuator arm for keeping first welding gun mobile.

4. system according to any one of claim 1 to 3 further includes the actuator arm for keeping second welding gun mobile.

It further include computer-aided manufacturing (CAM) system or software 5. system according to any one of claim 1 to 4, The computer aided manufacture system or software responses guide the actuator pallet, described first to cause in the deposition profile The movement of dynamic device arm, second actuator arm or any combination thereof.

6. system according to any one of claim 1 to 5, wherein first welding gun includes PTA welding torch, and institute Stating the second welding gun includes laser aid.

7. according to claim 1 to system described in 5, wherein first welding gun includes laser aid, and described second welds Rifle is PTA welding torch, and the PTA welding torch is electrically connected to DC power supply, so that the electrode of the PTA welding torch becomes cathode and described Wire becomes anode.

8. system according to any one of claim 1 to 5, wherein first welding gun includes first laser device, and And second welding gun includes second laser device.

9. system according to any one of claim 1 to 5, wherein first welding gun includes the first electron beam device, And second welding gun includes laser aid.

10. system according to any one of claim 1 to 5, wherein first welding gun includes laser aid, and Second welding gun includes electron beam device.

11. system according to any one of claim 1 to 10, wherein second welding gun is designed to described pre- Thermal energy is contributed in thermal region.

12. a kind of system for being manufactured by solid free fo to construct metal object, comprising:

First welding gun, a part on the surface for pre- hot substrate；

Second welding gun, the drop of the metal material for being fused into source metal on the pre- hot surface for depositing to the substrate；With And

The deposition profile of object to be formed so that by according to the deposition profile by the successive sedimentation object of the metal material It is fused on the substrate and constructs the object,

Wherein, at least one of first welding gun and second welding gun include electron beam device.

13. system according to claim 12 further includes keeping the substrate mobile relative at least described first welding gun Actuator pallet.

14. system described in any one of 2 to 13 according to claim 1 further includes the actuator for keeping first welding gun mobile Arm.

15. system described in any one of 2 to 14 according to claim 1 further includes the actuator for keeping second welding gun mobile Arm.

16. system described in any one of 2 to 15 according to claim 1 further includes computer-aided manufacturing (CAM) system or soft Part, the computer aided manufacture system or software responses guide the actuator pallet, described in the deposition profile The movement of one actuator arm, second actuator arm or any combination thereof.

17. system described in any one of 2 to 16 according to claim 1, wherein first welding gun includes electron beam device, And second welding gun includes PAW welding torch.

18. system according to claim 17, wherein the PAW welding torch is PTA welding torch, and the PTA welding torch is electrically connected to DC power supply, so that the electrode of the PTA welding torch becomes cathode and the source metal is the wire for becoming anode.

19. system described in any one of 2 to 16 according to claim 1, wherein first welding gun includes PAW welding torch, and Second welding gun includes electron beam device.

20. system described in any one of 2 to 16 according to claim 1, wherein first welding gun includes that the first electronics is got one's things ready It sets, and second welding gun includes the second electron beam device.

21. system described in any one of 2 to 16 according to claim 1, wherein first welding gun includes electron beam device, And second welding gun includes coaxial powder supply nozzle laser system.

22. system described in any one of 2 to 21 according to claim 1, wherein second welding gun is designed to described pre- Thermal energy is contributed in thermal region.

23. according to claim 1 to system described in any one of 22, wherein first welding gun and second welding gun position In on the opposite side of the substrate.

24. a kind of method for being manufactured by solid free fo to manufacture the three-dimension object of metal material, wherein the object Body is made by the way that the successive sedimentation object of the metal material is fused to together on substrate, which comprises

Limit the deposition profile of the object；

At least part on the surface of the substrate is preheated using the first welding gun to form pre- hot surface；And

Wire is heated and melted using the second welding gun, so that molten metal material is deposited on the pre- hot surface, with The object is formed by fusing the successive sedimentation object of institute's molten metal material,

Wherein, at least one of first welding gun and second welding gun include laser aid, and first welding gun It include one of PTA welding torch, laser or electron beam device with the other of second welding gun.

25. according to the method for claim 24, further includes:

A) mobile actuator pallet is so that the substrate is mobile relative to first welding gun or second welding gun or the two； Or

B) mobile first actuator arm is so that first welding gun is moved relative to the substrate or second welding gun or the two It is dynamic；Or

C) mobile second actuator arm is so that second welding gun is moved relative to the substrate or first welding gun or the two It is dynamic；Or

D) any combination a), b) and c).

26. the method according to any one of claim 24 to 25, wherein the actuator pallet or first actuating The movement of any one of device arm or second actuator arm is taken turns by CAM system or software control and in response to the deposition Exterior feature, so that the successive sedimentation object of the molten metal material forms the three-dimension object in solidification.

27. the method according to claim 24 to 26, wherein first welding gun includes laser aid, and described Two welding guns are PTA welding torch, and the PTA welding torch is electrically connected to DC power supply so that the electrode of the PTA welding torch become cathode and The wire becomes anode.

28. the method according to any one of claim 24 to 26, in which:

First welding gun includes PTA welding torch, and second welding gun includes laser aid；Or

First welding gun includes first laser device, and second welding gun includes second laser device；Or

First welding gun includes the first electron beam device, and second welding gun includes laser aid；Or

First welding gun includes laser aid, and second welding gun includes electron beam device.

29. a kind of method for being manufactured by solid free fo to manufacture the three-dimension object of metal material, wherein the object Body is made by the way that the successive sedimentation object of the metal material is fused to together on substrate, which comprises

Limit the deposition profile of the object；

At least part on the surface of the substrate is preheated using the first welding gun to form pre- hot surface；And

Metal material is heated and melted using the second welding gun, so that molten metal material is deposited on the pre- hot surface, To form the object by the successive sedimentation object for fusing institute's molten metal material,

Wherein, at least one of first welding gun and second welding gun include electron beam device.

30. according to the method for claim 29, further includes:

A) mobile actuator pallet is so that the substrate is mobile relative to first welding gun or second welding gun or the two； Or

B) mobile first actuator arm is so that first welding gun is moved relative to the substrate or second welding gun or the two It is dynamic；Or

C) mobile second actuator arm is so that second welding gun is moved relative to the substrate or first welding gun or the two It is dynamic；Or

D) any combination a), b) and c).

31. the method according to claim 29 or 30, wherein the actuator pallet or first actuator arm or institute The movement of any one of second actuator arm is stated by CAM system or software control and in response to the deposition profile, so that The successive sedimentation object of the molten metal material forms the three-dimension object in solidification.

32. the method according to any one of claim 29 to 31, wherein second welding gun includes PAW welding torch, and First welding gun includes electron beam device.

33. according to the method for claim 32, wherein the PAW welding torch is PTA welding torch, and the PTA welding torch is electrically connected to DC power supply, so that the electrode of the PAW welding torch becomes cathode and the metal material is the wire for becoming anode.

34. the method according to any one of claim 29 to 31, in which:

First welding gun includes PAW welding torch, and second welding gun includes electron beam device；Or

First welding gun includes the first electron beam device, and second welding gun includes the second electron beam device；Or

First welding gun includes electron beam device, and second welding gun includes coaxial powder supply nozzle laser system.