CN110216286A - 一种离心力辅助铺平粉末的激光熔覆装置与方法 - Google Patents

一种离心力辅助铺平粉末的激光熔覆装置与方法 Download PDF

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CN110216286A
CN110216286A CN201910552202.XA CN201910552202A CN110216286A CN 110216286 A CN110216286 A CN 110216286A CN 201910552202 A CN201910552202 A CN 201910552202A CN 110216286 A CN110216286 A CN 110216286A
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任旭东
孙禺州
童照鹏
刘怀乐
焦加飞
胡文景
陈嘉男
顾嘉阳
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Abstract

本发明涉及一种离心力辅助铺平粉末的激光熔覆装置与方法,包括控制系统、旋转系统和激光增材制造系统。本发明首先将基体放入一个圆形的池内,再通过一个升降台固定在粉末池上。粉末池上部有一个可以向四周展开的顶盖。顶盖最开始为闭合状态,可以覆盖住基体。随后,升降台微调直到基体上部到粉末池顶盖的高度差为一层熔覆层的厚度,再向粉末池内加入过量粉末。随后,粉末池开始旋转,当转速达到一定数值后,粉末由于离心力会向粉末池边缘移动,直至填满所有空隙。粉末铺平后,盖板向上抬起,然后向四周展开,激光增材制造系统将基体上的粉末熔化,熔化后的粉末冷却后便与基体结合成为了新的基体。如此往复,便可以快速进行激光增材制造。

Description

一种离心力辅助铺平粉末的激光熔覆装置与方法
技术领域
本发明属于激光增材制造领域,尤其涉及一种离心力辅助铺平粉末的激光熔覆装置与方法。
背景技术
当前激光熔覆可以应用在快速原型制造领域,称作利用激光熔敷技术快速制造零件的技术LENS (Laser Engineered Net Shaping) 、DLF (Direct Laser Fabrication) 、DMD (Direct Metal Deposition)、LC (Laser Consolidation) 。其原理为:利用金属粉末的逐层烧结叠加,快速制造出模型。目前快速原型制造技术研究比较多的方向主要集中在所使用的熔覆材料上,应用广泛的激光熔覆材料主要有:镍基、钴基、铁基合金、碳化钨复合材料,陶瓷等材料。其中,又以镍基材料应用最多,与钴基材料相比,其成本更低廉。
当前针对激光熔覆进行激光增材制造的装置及方法的专利还比较少,是激光熔覆应用在快速原型制造领域比较有潜力的重要技术。
发明内容
本发明的目的在于提供一种离心力辅助铺平粉末的激光熔覆装置与方法,使得激光熔覆进行激光增材制造的成本得以降低,生产效率得到提高。
为实现上述发明目的,本发明采取的技术方案为:一种离心力辅助铺平粉末的激光熔覆装置,包括粉末池,所述粉末池内设有升降台,所述升降台上固定有基体,所述升降台和所述基体沉浸在所述粉末池内的金属粉末内,所述粉末池的上方设置有激光加工系统和激光测距仪。
上述方案中,所述粉末池的开口处设置有顶盖,所述顶盖通过滑轨可移动的安装在所述粉末池的开口处,所述粉末池固定在旋转装置上,所述旋转装置安装在工作台上。
上述方案中,所述旋转装置、所述升降台、所述激光加工系统和所述激光测距仪均与控制系统相连。
上述方案中,所述升降台的数量为多个。
上述方案中,所述激光加工系统包括激光发生器,所述激光发生器发出的激光通过扩束镜扩展成平行激光束,平行激光束经过反光镜和透镜聚焦到覆盖在基体上方的金属粉末上。
本发明还提供一种离心力辅助铺平粉末的激光熔覆装置的加工方法,包含以下步骤:
A.将基体打磨、清洗和吹干,并对其进行预热;
B.将基体固定至升降台上,并通过激光测距仪间接测量顶盖到基体的表面距离,再控制升降平台微调使基体表面与粉末池顶盖的高度差为一个熔覆层的距离;
C.顶盖闭合,将金属粉末倒入粉末池顶盖的开口处,旋转装置开始旋转,随着旋转,粉末由于离心力会向粉末池边缘移动,直至填满所有空隙;
D.旋转停止后,顶盖向上升起一段距离,随后向两边打开,激光测距仪间接测量粉末厚度,若其达到预期要求则进入下一步,若没有达到预期要求,则重复步骤C,直至其达标;
E.随后,进行一个工位的激光增材加工,直至此工位加工完毕;
F.粉末池旋转90°进行下一个工位的加工,直至四个工位都加工完成;
G.升降台下降一个熔覆层的厚度,重复步骤C-F, 直至激光增材制造完成;
H.将所得构件进行热等静压处理,以消除其残余应力和微裂纹等缺陷。
上述方案中,激光加工系统的功率为800W-2000W,为避免材料被氧化,整个过程在氩气氛围中进行,同轴保护气压力速率为5L/min; 光斑直径为2mm。
上述方案中,热等静压工艺参数为:温度1100 ℃,持续时间3.5小时,压力为170MPa。
本发明的有益效果:(1)传统的刮板铺粉方法为了达到精度要求,往往对铺粉设备的精度要求很高,从而造成设备成本上升,并降低生产效率。而本方案所使用的旋转式铺粉方案,则具有铺粉设备精度要求更低,生产效率更高的特点。(2)粉末经过旋转后,粉末颗粒分布的均匀性大大提高,使得到的构件结构均匀性大大提高。且粉末之间的空隙由于离心力而减少,进一步减少了缩的构件的空隙以及裂纹,大大提高了构件的力学性能。(3)取消了刮板,铺粉精度不再受限于刮板的制造精度,铺粉精度大大提高。(4)本装置一次铺粉可以对四个或更多零件进行熔覆,大大提高了生产效率。(5)整个系统组成一个闭环系统,且通过激光测距仪,可以动态控制粉末的厚度,使得到的构件拥有更优良的性能。
附图说明
图1为本发明装置的结构原理图。
图2为本发明粉末池顶盖闭合时的俯视图。
图3为本发明粉末池顶盖打开后的俯视图。
图4为本发明粉末池初始状态的剖视图。
图5为本发明粉末池顶盖闭合后的剖视图。
图6为本发明粉末池添加粉末后的剖视图。
图7为本发明粉末池旋转铺粉后的剖视图。
图8为本发明粉末池旋转铺粉后顶盖升起后的剖视图。
图9为本发明粉末池旋转铺粉后顶盖打开后的剖视图。
图10为本发明激光熔覆增材制造过程的剖视图。
图11为本发明一个工位激光熔覆增材制造完成后的剖视图。
图12为本发明所有工位激光熔覆增材制造完成后的剖视图。
图13为本发明粉末池中升降平台下降一段距离后的剖视图。
图中:1.激光发生器;2.扩束镜;3.平行激光束;4.反光镜;5.激光测距仪;6.透镜;7.基体;8.升降台;9.顶盖;10.滑轨;11.金属粉末;12.粉末池;13.旋转装置;14.工作台;15.控制系统。
具体实施方式
为了便于理解本发明,下面结合附图和具体实施方式对本发明作进一步详细描述。
本实施例提供的一种离心力辅助铺平粉末的激光熔覆装置包括激光发生器1,扩束镜2,扩束镜2用来将入射激光扩展成平行激光束3。平行激光束3经过反光镜4和透镜6聚焦到覆盖在基材上的金属粉末11上,将其熔化。基体7固定在升降台8上,升降台8则固定在粉末池12的底壁上。粉末池12顶部有可以开合的顶盖9,通过滑轨10固定在粉末池的开口处。在铺平粉末时顶盖9闭合,进行激光熔覆时顶盖9打开。粉末池12通过旋转装置13固定在工作台14上。激光束按照预先规划的路径在粉末上扫过,完成激光增材制造的过程。所述升降平台8和旋转装置13,以及激光测距仪5和激光发生器1均与控制系统相连15,并由其控制。一个粉末池12内可以安装多个升降台8,以安装多个基体7,从而达到一次铺粉对多个基体进行熔覆的目的,进一步提高生产效率。
本实施例涉及的一种离心力辅助铺平粉末的激光熔覆装置的加工方法,包含以下步骤:将基体打磨、清洗和吹干,并对其进行预热;将基体固定至升降台上,并通过激光测距仪间接测量顶盖到基体的表面距离,再控制升降平台微调使基体表面与粉末池顶盖的高度差为一个熔覆层的距离,如图4。顶盖闭合,如图5。将金属粉末倒入粉末池顶盖的开口处,入图6。旋转装置开始旋转,随着旋转,粉末由于离心力会向粉末池边缘移动,直至填满所有空隙,如图7。旋转停止后,顶盖向上升起一段距离,如图8。随后向两边打开,如图9。激光测距仪间接测量粉末厚度,若其达到预期要求则进入下一步,若没有达到预期要求,则重复步骤C,直至其达标。随后,进行一个工位的激光增材加工,直至此工位加工完毕,如图10、图11。粉末池旋转90°进行下一个工位的加工,直至四个工位都加工完成,如图12。升降台下降一个熔覆层的厚度,如图13。重复步骤C-F, 直至激光增材制造完成。将所得构件进行热等静压处理,以消除其残余应力和微裂纹等缺陷。热等静压工艺参数为:温度1100 ℃,持续时间3.5小时,压力为170 MPa。
在本实施例中,依靠离心力来铺粉方式,在保证了铺粉精度的前提下,大大提高了铺粉效率。而对于铺粉设备的精度要求也大大降低,从而降低了制造成本。同时,由于离心力的作用,粉末分布得更加均匀,粉末之间的间隙减少,大大提高了构件的均匀性以及减少孔隙裂纹。本发明可以提高生产效率,降低生产成本,提高构件均匀性以及力学性能。

Claims (8)

1.一种离心力辅助铺平粉末的激光熔覆装置,其特征在于,包括粉末池(12),所述粉末池(12)内设有升降台(8),所述升降台(8)上固定有基体(7),所述升降台(8)和所述基体(7)沉浸在所述粉末池(12)内的金属粉末(11)内,所述粉末池(7)的上方设置有激光加工系统和激光测距仪(3)。
2.根据权利要求1所述的一种离心力辅助铺平粉末的激光熔覆装置,其特征在于 ,所述粉末池(12)的开口处设置有顶盖(9),所述顶盖(9) 通过滑轨(10)可移动的安装在所述粉末池(12)的开口处,所述粉末池(12)固定在旋转装置(13)上,所述旋转装置(13)安装在工作台(14)上。
3.根据权利要求2所述的一种离心力辅助铺平粉末的激光熔覆装置,其特征在于 ,所述旋转装置(13)、所述升降台(8)、所述激光加工系统和所述激光测距仪(3)均与控制系统(15)相连。
4.根据权利要求1或2或3所述的一种离心力辅助铺平粉末的激光熔覆装置,其特征在于 ,所述升降台(8)的数量为多个。
5.根据权利要求1或2或3所述的一种离心力辅助铺平粉末的激光熔覆装置,其特征在于 , 所述激光加工系统包括激光发生器(1),所述激光发生器(1)发出的激光通过扩束镜(2)扩展成平行激光束(3),平行激光束(3)经过反光镜(4)和透镜(6)聚焦到覆盖在基体(7)上方的金属粉末上。
6.一种离心力辅助铺平粉末的激光熔覆装置的加工方法,其特征在于,包含以下步骤:
S1:将基体打磨、清洗和吹干,并对其进行预热;
S2:将基体固定至升降台上,并通过激光测距仪间接测量顶盖到基体的表面距离,再控制升降平台微调使基体表面与粉末池顶盖的高度差为一个熔覆层的距离;
S3:顶盖闭合,将金属粉末倒入粉末池顶盖的开口处,旋转装置开始旋转,随着旋转,粉末由于离心力会向粉末池边缘移动,直至填满所有空隙;
S4:旋转停止后,顶盖向上升起一段距离,随后向两边打开,激光测距仪间接测量粉末厚度,若其达到预期要求则进入下一步,若没有达到预期要求,则重复步骤C,直至其达标;
S5:随后,进行一个工位的激光增材加工,直至此工位加工完毕;
S6:粉末池旋转90°进行下一个工位的加工,直至四个工位都加工完成;
S7:升降台下降一个熔覆层的厚度,重复步骤C-F, 直至激光增材制造完成;
S8:将所得构件进行热等静压处理,以消除其残余应力和微裂纹等缺陷。
7.根据权利要求6所述的一种离心力辅助铺平粉末的激光熔覆装置的加工方法,其特征在于,激光加工系统的功率为800W-2000W,为避免材料被氧化,整个过程在氩气氛围中进行,同轴保护气压力速率为5L/min; 光斑直径为2mm。
8.根据权利要求6所述的一种离心力辅助铺平粉末的激光熔覆装置的加工方法,其特征在于,热等静压工艺参数为:温度1100 ℃,持续时间3.5小时,压力为170 MPa。
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