CN111356576A - Dmlm构建平台和表面平坦化 - Google Patents

Dmlm构建平台和表面平坦化 Download PDF

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CN111356576A
CN111356576A CN201880072027.8A CN201880072027A CN111356576A CN 111356576 A CN111356576 A CN 111356576A CN 201880072027 A CN201880072027 A CN 201880072027A CN 111356576 A CN111356576 A CN 111356576A
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build
recessed
build surface
powder
filling
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贾斯汀·曼拉克
麦肯齐·赖安·雷丁
扎卡里·大卫·费尔德曼
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General Electric Co
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General Electric Co
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Abstract

提供了一种通过增材制造制造物体的方法。该方法包括：测量用于构建物体的构建表面；确定构建表面的哪些区域凹陷；以及在构建表面的凹陷区域之一处开始物体的构建。初始构建包括以下步骤：在建筑表面的一个凹陷区域沉积给定的粉末层，在该凹陷区域熔融该给定的粉末层，并在该凹陷区域沉积后续的粉末层。重复这些步骤，直到构建表面位于整个构建表面统一的层上为止。

Description

DMLM构建平台和表面平坦化
技术领域
本公开大体上涉及用于执行增材制造处理的增材制造(AM)装置和方法。更具体地，本公开涉及使得能够连续地同时制造大的环形物体或多个较小的物体(例如但不限于飞行器发动机的部件)的连续过程的装置和方法。
相关申请的交叉引用
参考以下同时提交的相关申请，其全部内容通过引用合并于本文：
2017年11月8日提交的题为“构建表面映射的装置和方法”的美国专利申请号[]，代理人案卷号为037216.00128。
背景技术
与减材制造方法相反，增材制造处理通常涉及一种或多种材料的堆积，以制成净形或近净形(NNS)的物体。尽管“增材制造”是行业标准术语(ASTM F2792)，但是AM包含以各种名称已知的各种制造和原型技术，包括自由形式制造，3D打印，快速原型/工具等。AM技术能够由多种材料制造复杂的部件。通常，可以从计算机辅助设计(CAD)模型中制造独立物体。特定类型的AM处理使用照射发射引导设备，其引导能量束(例如，电子束或激光束)来烧结或熔化粉末材料，从而创建粉末材料颗粒结合在一起的固体三维物体。例如使用了不同的材料系统，例如工程塑料，热塑性弹性体，金属和陶瓷。激光烧结或熔化是用于快速制造功能原型和工具的显著AM处理。应用包括直接制造复杂的工件，熔模铸造的模型，用于注塑成型和压铸的金属模具以及用于砂型铸造的模具和型芯。制作原型物体以增强设计周期中概念的交流和测试是AM处理的其他常见用法。
选择性激光烧结，直接激光烧结，选择性激光熔化和直接激光熔化是常用的工业术语，用于指通过使用激光束烧结或熔化细粉来生产三维(3D)物体。例如，通过引用并入本文的美国专利4,863,538和美国专利5,460,758描述了常规的激光烧结技术。更准确地，烧结需要在低于粉末材料的熔点的温度下熔融(凝聚)粉末颗粒，而熔化则需要使粉末颗粒完全熔化以形成固体均质块。与激光烧结或激光熔化相关的物理过程包括热传递到粉末材料，然后烧结或熔化粉末材料。尽管激光烧结和熔化处理可以应用于多种粉末材料，但是生产路线的科学和技术方面，例如烧结或熔化速率以及处理参数对层制造过程中微观结构演变的影响尚未被很好地理解。这种制造方法伴随着多种模式的热，质量和动量传递以及化学反应，使过程变得非常复杂。
图1是示出用于直接金属激光烧结(“DMLS”)或直接金属激光熔化(DMLM)的示例性常规系统100的截面图的图。装置100通过使用由源120(可以是例如产生激光束的激光器，也可以是当电流流过时发出电子的丝)生成的能量束136烧结或熔化粉末材料(未示出)，以逐层的方式构建物体，例如部件122。由能量束熔化的粉末由贮存器126提供，并使用沿方向134行进的重涂覆臂116在粉末床112上均匀铺展，以将粉末保持在水平118，将多余的粉末材料去除并从粉末水平118上方延伸到废料容器128。能量束136在诸如振镜扫描仪132的照射发射引导设备的控制下烧结或熔化正在建造的物体的横截面层。振镜扫描仪132可以包括例如多个可移动镜或扫描透镜。扫描激光的速度是关键的可控过程参数，影响激光功率施加到特定点的时间。典型的激光扫描速度为每秒10到100毫米。降低构建平台114，并将另一层粉末铺在粉末床和正在构建的物体上，然后通过激光器120进行粉末的连续熔化/烧结。粉末层通常为例如10至100微米。重复该处理，直到部件122完全由熔化/烧结的粉末材料制成。
激光器120可以由包括处理器和存储器的计算机系统控制。该计算机系统可以确定每个层的扫描图案，并根据扫描图案控制激光器120以照射粉末材料。在部件122的制造完成之后，可以将各种后处理程序应用于部件122。后处理程序包括通过吹扫或抽真空除去多余的粉末。其他后期处理过程包括压力释放处理。另外，可以使用热和化学后处理程序完成部件122。
图2是常规粉末床204的图。本领域技术人员可以理解，粉末床204可以例如与图1所示的传统的用于DMLM的装置的粉末床112类似地构建。尽管未示出传统装置的其他机械部件，但是图2示出了在其上构建物体202的构建平台208。当构建物体202时，一层粉末铺展在粉末床204上，随后通过激光器120相继熔化/烧结粉末(见图1)。重复该过程，直到部件(物体202)完全由熔化/烧结的粉末材料制成。
但是，在构建或生长过程中，某些粉末床增材制造的部件会断裂或扭曲，因为粉末床由于部件的收缩而在生长的部件上施加了过大的压力。滞留在生长的部件内或部件与粉末箱壁之间的粉末会在部件上施加过大的压力，从而导致部件断裂和变形。另外，滞留在粉末腔室底板和生长的部件之间的粉末限制了部件在冷却时收缩的能力，这可能导致部件断裂和变形。
因此，仍然需要生长大的无断裂的未变形部件，并控制粉末床中制造的零件上的粉末床载荷。
发明内容
以下提供本公开的一个或多个方面的简化概述，以便提供对这些方面的基本理解。该概述不是所有预期方面的详尽概述，并且既不旨在标识所有方面的关键或重要元件，也不旨在描绘任何或所有方面的范围。其目的是以简化形式呈现一个或多个方面的一些概念，作为稍后呈现的更详细描述的序言。
本发明的前述和/或其他方面可以通过使用通过增材制造制造物体的方法来实现。一方面，该方法包括测量构建表面的形貌并识别相对于期望的基本平坦表面凹陷的区域，并填充凹陷区域以减少构建表面的形貌变化。填充凹陷区域包括：(a)在构建表面的凹陷区域上沉积给定的粉末层；(b)在构建表面的一个凹陷区域熔融给定的粉末层；(c)在构建表面的凹陷区域上沉积随后的粉末层；及(d)重复步骤(a)-(c)，直到完成凹陷区域的填充。
本发明的前述和/或其他方面可以通过一种用于制造物体的增材制造装置来实现。该装置包括构建单元，该构建单元至少包括粉末分配器，熔融机构和重涂覆器。该装置还包括构建表面和测量单元，该测量单元用于测量构建表面的形貌并识别相对于期望的基本平坦表面凹陷的区域。
本发明的前述和/或方面也可以通过计算机可读存储介质实现，该计算机可读存储介质中包含程序，该程序在由处理器执行时执行通过增材制造制造物体的方法。一方面，该方法包括测量构建表面的形貌并识别相对于期望的基本平坦表面凹陷的区域，并填充凹陷区域以减少构建表面的形貌变化。填充凹陷区域包括：(a)在构建表面的凹陷区域上沉积给定的粉末层；(b)在构建表面的一个凹陷区域熔融给定的粉末层；(c)在构建表面的凹陷区域上沉积随后的粉末层；及(d)重复步骤(a)-(c)，直到完成凹陷区域的填充。
根据以下详细描述，附图和权利要求，其他特征和方面将是显而易见的。
附图说明
结合到本说明书中并构成本说明书的一部分的附图示出了本公开的一个或多个示例方面，并且与详细描述一起用于解释其原理和实施方式。
图1是使用粉末床的用于DMLM的常规装置的示意图；
图2是传统粉末床箱的图；
图3是根据本发明实施例的大型增材制造装置的图；
图4是根据本发明实施例的构建单元的侧视图；
图5是根据本发明实施例的分配粉末的构建单元的侧视图；
图6是根据本发明实施例的构建单元的立体图；
图7A至图7C是根据本发明的实施例的构建表面的图；及
图8是示出根据本发明的实施例的初始构建过程的框图。
具体实施方式
下面结合附图阐述的详细描述旨在作为各种配置的描述，并且不旨在代表可以实践本文描述的概念的唯一配置。详细描述包括特定细节，以提供对各种概念的透彻理解。然而，对于本领域技术人员将显而易见的是，可以在没有这些具体细节的情况下实践这些概念。例如，本发明提供了一种用于增材制造金属部件或物体的优选方法，并且优选地，这些部件或物体用于喷气飞行器发动机的制造中。特别地，根据本发明可以有利地制造喷气发动机的大的环形部件。然而，可以使用本文描述的装置和方法来制备飞行器的其他部件和其他非飞行器部件。
本发明的示例性实施例包括一种装置，方法和系统，该装置，方法和系统被构造为使用扫描设备相对于期望的起始构建平面来映射平台，表面拓扑。根据一个方面，可以提供系统软件，该系统软件使用扫描信息来建立构建基础和建立具有必要覆盖区域的构建计划所需的底层，该覆盖区域对于开始零件构建的初始层是必需的。这样，本发明可以提供一种装置，方法和系统，其包括用于生成集成到机器软件或系统中的平坦构建表面的软件，而不是传统的构建支持或补偿的软件。该软件可以被构造为自动生成并将用于构建表面准备的必要构建策略和构建表面准备序列附加到部件或物体的机器构建序列中。
图3是根据本发明实施例的大型增材制造装置300的图。在图3中，装置300包括定位机构301(例如，台架)，构建单元302，该构建单元302包括照射发射引导设备303，层流区域307以及正在构建的物体309下方的构建板(未显示)。最大构建区域可以由定位机构301限定，而不是如传统系统那样由粉末床限定，并且进行特定构建的构建区域可以受限于构建封套308，其可以与物体一起动态地构建。定位机构或台架301具有x横梁304，该x横梁在x方向上移动构建单元302。可能存在两个z横梁305A和305B，它们使构建单元302和x横梁304在z方向上移动。x横梁304和构建单元302可以通过在y方向上移动构建单元302的机构306来附接。构建单元302可以包括传感器330，将会在下面图6中详细讨论。传感器330可以在图3中被示出在构建单元302的底部，但是可以被定位在设备300上的各种其他位置。尽管图3中的实施例将台架示出为定位机构，但是本发明不限于此，并且可以利用其他多维定位系统，例如，三角机器人，缆线机器人或机器人臂。照射发射引导设备303可以通过第二定位系统(未示出)独立地在构建单元302内部移动。
图4是根据本发明实施例的构建单元的侧视图。图4示出了构建单元400，其包括照射发射引导设备401，具有加压出口部分403A和真空入口部分403B的气流设备403，该气流设备403向气流区域404提供气流，以及重涂覆器405。可以在气流区域404上方设置包含惰性环境419的外壳418。重涂覆器405可包括具有后板407和前板408的料斗406。重涂覆器405还可包括至少一个致动元件409，至少一个闸板410，重涂覆器刀片411，致动器412和重涂覆器臂413。可以将重涂覆器安装到安装板420。图4示出了传感器430(以下图6中详细描述)，其定位在安装板420一侧，但是传感器430可以定位在装置400的各种其他位置。
图4还示出了可以通过例如增材制造或Mig/Tig焊接构建的构建封套414，正在形成的物体415，以及容纳在用于形成物体415的料斗405中的粉末416。在该特定实施例中，致动器412可以致动致动元件409以将闸板410拉离前板408。在替代实施例中，致动器412可以是例如气动致动器，并且致动元件409可以是双向阀。在又一个实施例中，致动器412可以是例如音圈，并且致动元件409可以是弹簧。还可以在前板408和后板407之间设置料斗间隙417，当相应的闸板通过致动元件从粉末闸板拉开时，该料斗间隙417允许粉末流动。粉末416，后板407，前板408和闸板410可以全部是相同的材料。替代地，后板407，前板408和闸板410可以全部是相同的材料，并且该材料可以是与粉末材料兼容的一种材料，例如钴铬合金。在本发明的本示例性实施例中，在气流区域404中的气流在y方向上流动，但是不限于此。重涂覆器刀片411可具有沿x方向的宽度。在该视图中，当θ2近似为0时，照射发射束的方向限定了z方向。气流区域404中的气流可以基本上是层流的。照射发射引导设备401可以通过第二定位系统(未示出)独立地移动。该图示示出了处于关闭位置的闸板410。
图5是根据本发明实施例的分配粉末的构建单元的侧视图。图5示出了处于打开位置(如元件510所示)的闸板410(图4)和致动元件509。可以沉积料斗中的粉末以制成新的粉末层521，该新的粉末层521被重涂覆器刀片511抹平以形成基本上均匀的粉末层522。图5示出了位于料斗一侧的传感器530(下面在图6中详细讨论)，但是传感器530可以位于装置500上的各种其他位置。
图6是根据本发明的实施例的构建单元602的立体图。如图6所示，构建单元602可以包括能够追踪要在其上打印的构建表面606的传感器604。传感器604可以如图6所示附接到构建单元602。尽管未在图6中示出，构建表面606可以包括多个框架。图6示出了弯曲的表面606。例如，当在构建表面上进行构建时，即使经过研磨，典型构建表面的初始曲率也是不可避免的。根据本发明的一方面，构建单元602可以配置有传感器604，以追踪框架并在构建表面606上标出高低位置。传感器604可以是类似于但不限于可伸缩探针或激光雷达的扫描设备。例如，类似于雷达的这种设备典型地可以通过利用脉冲激光照射目标物并且利用传感器测量反射的脉冲，提供测量距目标的距离的测绘方法。然后，例如，可以使用激光返回时间和波长的差异来进行目标的数字3D表示。
可以提供控制器(未示出)，该控制器包括处理器，以确定由传感器604读取的高低位置。根据一方面，物体(未示出)的构建可以在构建表面606上的最低位置处开始。即，构建表面606的最低位置可以首先由构建单元602打印和重涂覆。例如，在打印和重涂覆构建表面606上的相邻框架之前，在最低位置上的打印和重涂覆过程可以重复几次。可以重复最低位置的构建，直到构建表面606上的所有框架都位于第一统一层。然后，控制器可以配置为在构建表面606处于第一统一层时自动开始物体的完整构建。
图7A至图7C是根据本发明的实施例的构建表面702的侧视立体图。图7A示出了具有稍低且凹陷的区域704的构建表面702。根据一方面，可以在凹陷区域704处开始构建。如图7B中所示，构建单元(未示出)可以通过将粉末706沉积在凹陷的下部区域704的位置中而在凹陷区域704处开始打印和重涂覆。图7C示出了凹陷的下部区域704，该下部区域704由多层粉末706构建至统一层708，基本上在构建表面702的整个表面区域。
图8是示出根据本发明的实施例的初始构建过程的框图。在802处，可以查询部件构建文件以建立构建的覆盖区域。也就是说，例如，控制器可以查询文件以确定构建表面的最低位置以开始构建。在804处，可以提供传感器以扫描构建表面并在建立的覆盖区域内创建构建表面的拓扑映射。本领域技术人员可以理解，传统的使用重涂覆器臂的粉末床缺乏在构建表面中使用拓扑结构的能力。
根据一个方面，可以基于所建立的覆盖区域或最低位置内的拓扑结构来创建计算机辅助设计(CAD)文件。由于部件或物体的完整构建可以从构建表面的统一层开始，因此在806处，控制器可以建立覆盖区域表面拓扑结构的最小和最大Z高度。在808处，通过建立覆盖区域表面拓扑结构的最小和最大Z高度，拓扑映射可以用于自动生成覆盖区域中具有反向拓扑结构和高度(Zmax-Zmin)的部件的构建文件。在810处，例如，可以在现有部件构建文件的开始处附加拓扑补偿构建(参见802)。在替代实施例中，根据构建表面的拓扑结构，可以生成z基准构建文件以及拓扑补偿，该z基准构建文件提供了构建实际部件底部开始位置的参考。在812处，可以使用部件构建文件开始和构建部件。
如上所述，本发明提供例如一种方法，装置和系统，该方法，装置和系统能够对弯曲的构建表面进行实时校正。这样，可以实现在部件或物体的构建开始时的均匀性。另外，利用扫描设备标出构建表面的凹陷区域，本发明可以反馈用于初始打印。因此，可以减少与用于理想的初始构建表面的表面研磨板相关的时间和成本。
本发明能够将不平坦的构建平台变成平坦的水平。同样，本发明能够在构建物体的过程中将构建表面恢复到平坦状态。
该书面描述使用示例来公开本发明，包括优选实施例，并且还使本领域技术人员能够实践本发明，包括制造和使用任何设备或系统以及执行任何结合的方法。本发明的专利范围由权利要求书限定，并且可以包括本领域技术人员想到的其他示例。如果这样的其他示例具有与权利要求的字面语言没有不同的结构元件，或者如果它们包括与权利要求的字面语言没有实质性差异的等效结构元件，则它们旨在权利要求的范围内。本领域普通技术人员可以根据本申请的原理，混合和匹配来自所描述的各个实施例的各方面以及每个此类方面的其他已知等效物，以构造其他实施例和技术。

Claims (13)

1.一种通过增材制造制造物体的方法，其特征在于，包括：
测量构建表面的形貌并识别相对于期望的基本平坦表面凹陷的区域；以及
填充凹陷区域以减少所述构建表面的所述形貌的变化，其中填充所述凹陷区域包括：
(a)在所述构建表面的凹陷区域上沉积给定的粉末层；
(b)在所述构建表面的一个凹陷区域熔融所述给定的粉末层；
(c)在所述构建表面的凹陷区域上沉积随后的粉末层；以及
(d)重复步骤(a)-(c)，直到完成所述凹陷区域的所述填充。
2.根据权利要求1所述的方法，其特征在于，进一步包括：
(e)在步骤(d)之后构建所述物体。
3.根据权利要求2所述的方法，其特征在于，进一步包括将所测量的形貌的反向3D表示附加到所述物体的CAD文件以产生定制CAD文件，并使用所述定制CAD文件引导所述凹陷区域的所述填充和构建所述物体。
4.根据权利要求1所述的方法，其特征在于，其中所述测量是利用激光雷达或可伸缩探针完成的。
5.根据权利要求1所述的方法，其特征在于，其中所述熔融是使用照射或粘合剂喷射进行的。
6.一种用于构建物体的增材制造装置，其特征在于，包括：
构建单元，所述构建单元包括至少粉末分配器，熔融机构和重涂覆器；
构建表面；和
测量单元，所述测量单元用于测量所述构建表面的形貌并识别相对于期望的基本平坦表面凹陷的区域。
7.根据权利要求6所述的装置，其特征在于，其中所述熔融机构是粘合剂射流或照射源。
8.根据权利要求6所述的装置，其特征在于，其中所述测量单元包括激光雷达或可伸缩探针。
9.一种计算机可读存储介质，其中包含程序，所述程序在由处理器执行时执行通过增材制造制造物体的方法，其特征在于，所述方法包括：
测量构建表面的形貌并识别相对于期望的基本平坦表面凹陷的区域；以及
填充所述凹陷区域以减少所述构建表面的所述形貌的变化，其中填充所述凹陷区域包括：
(a)在所述构建表面的凹陷区域上沉积给定的粉末层；
(b)在所述构建表面的一个凹陷区域熔融所述给定的粉末层；
(c)在所述构建表面的凹陷区域上沉积随后的粉末层；以及
(d)重复步骤(a)-(c)，直到完成所述凹陷区域的所述填充。
10.根据权利要求9所述的方法，其特征在于，进一步包括：
(e)在步骤(d)之后构建所述物体。
11.根据权利要求10所述的方法，其特征在于，进一步包括将所测量的形貌的反向3D表示附加到所述物体的CAD文件以产生定制CAD文件，并使用所述定制CAD文件引导所述凹陷区域的所述填充和构建所述物体。
12.根据权利要求9所述的方法，其特征在于，其中所述测量是利用激光雷达或可伸缩探针完成的。
13.根据权利要求9所述的方法，其特征在于，其中所述熔融是使用照射或粘合剂喷射进行的。
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