CN112775441A - Light beam customization module and method and device for reducing selective laser melting pore defects - Google Patents

Light beam customization module and method and device for reducing selective laser melting pore defects Download PDF

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Publication number
CN112775441A
CN112775441A CN202011559628.7A CN202011559628A CN112775441A CN 112775441 A CN112775441 A CN 112775441A CN 202011559628 A CN202011559628 A CN 202011559628A CN 112775441 A CN112775441 A CN 112775441A
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laser
distribution
melting
shaping lens
selective laser
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谢德巧
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Nanjing University of Aeronautics and Astronautics
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Nanjing University of Aeronautics and Astronautics
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Laser Beam Processing (AREA)

Abstract

The invention discloses a method and a device for reducing internal pore defects of a metal part formed by selective laser melting by utilizing a customized beam, wherein a conventional circular Gaussian distributed laser beam is converted into the customized beam with spatial distribution meeting the requirement of melting powder, controllable temperature gradient and discontinuous time domain distribution by a beam customization module, and three energy modes can be realized: gaussian distribution, hollow distribution and rectangular uniform distribution. Aiming at a filling area melted in a selective laser area, hollow distribution light spots are used for quickly melting and solidifying metal powder, and the temperature gradient is reduced; aiming at the outer contour of selective laser melting, the Gaussian distribution is used for enhancing the melting effect of the edge and improving the surface roughness; and remelting the molten metal by using rectangular uniformly distributed laser, thereby obviously reducing the internal porosity of the part. The invention can reduce unsteady state flow of the molten pool, promote the powder at the edge of the molten pool to be completely melted, finally effectively reduce the pore defect of the part melted and formed by selective laser area, and obviously improve the mechanical property of the part.

Description

Light beam customization module and method and device for reducing selective laser melting pore defects
Technical Field
The invention relates to a light beam customization module and a method and a device for reducing internal pore defects of a metal part melted in a selective laser area, in particular to a light beam customization module and a method and a device for reducing internal pore defects of a metal part melted and formed in the selective laser area by utilizing a customized light beam, and belongs to the field of laser additive manufacturing.
Background
The Selective Laser Melting (SLM) technology is one of the main processes currently used for metal additive manufacturing, and due to the advantages of the Selective Laser Melting (SLM) technology in the aspects of forming complex structures, part precision, surface quality and the like, the Selective Laser Melting (SLM) technology is widely applied to multiple fields of aerospace complex parts, personalized biomedical devices and the like.
However, parts manufactured by the selective laser melting additive manufacturing technology often have internal porosity defects, which can reduce the mechanical properties, especially the fatigue strength. There are many studies on the problem of the pores in the SLM at home and abroad, and it is widely considered by scholars that the pores in the SLM mainly depend on the dynamic behavior of the molten pool, and the dynamic behavior of the molten pool is closely related to the energy distribution of the laser. At present, the Selective Laser Melting (SLM) generally adopts Gaussian heat source distribution, and the heat source form can cause higher energy density in a middle area (below a light spot) and lower energy density at the edge of a molten pool. The heat source distribution mode with weak outside and strong inside brings about two typical defect problems, one is that the energy of the laser spot center is often too high, the temperature of the molten pool center is too high, and the phenomenon of 'keyhole' is easily caused; secondly, the energy at the edge of the molten pool is low, the temperature gradient at the boundary of the molten channel is not high enough, and the material is not completely melted, so that the condition of poor fusion can be caused, namely, because the laser energy density at the edge of the molten pool is low, partial non-fused particles can be generated, the non-fused particles and the fused particles in the molten pool are adhered together, and the pore defect can also be generated. These porosity defects can affect the mechanical properties of the part, particularly fatigue strength. Therefore, to print high performance SLM structures, it is desirable to reduce void defects, especially large voids with dimensions above 200 microns.
Disclosure of Invention
The invention provides a light beam customization module and a method and a device for reducing internal pore defects of a metal part formed by selective laser melting by utilizing a customized light beam. The invention integrates three different energy distribution modes on the selective laser melting equipment by utilizing the beam customization module, realizes the accurate customization of laser energy by the cooperation of a space domain and a time domain, thereby avoiding the overhigh central temperature of a molten pool, improving the temperature gradient of the edge of the molten pool, and effectively reducing the defects of key holes or incomplete fusion and other holes by combining a remelting process, thereby improving the mechanical property of laser additive manufacturing parts.
The beam customization module of the present invention can achieve three energy modes: gaussian distribution, hollow distribution and rectangular uniform distribution. Aiming at a filling area melted in a laser selection area, hollow distribution light spots are used for quickly melting and solidifying metal powder, so that the temperature gradient is reduced, and the possibility of keyhole is reduced; aiming at the outer contour of selective laser melting, the Gaussian distribution is used for enhancing the melting effect of the edge and improving the surface roughness; and remelting the molten metal by using rectangular uniformly distributed laser, thereby obviously reducing the internal porosity of the part.
The invention adopts the following technical scheme for solving the technical problems:
the light beam customization module comprises a shaping lens fixing support, wherein a hollow distribution shaping lens is arranged at one end of the shaping lens fixing support, a rectangular uniformly-distributed shaping lens is arranged at the other end of the shaping lens fixing support, and a rotating shaft is arranged at the middle part of the shaping lens fixing support.
The device for reducing the selective laser melting pore defects comprises the beam customization module, the scanning galvanometer, the laser, the scraper, the forming cavity, the forming cylinder and the powder feeding cylinder, wherein the forming cylinder and the powder feeding cylinder are respectively arranged at the bottom of the forming cavity, metal powder in the powder feeding cylinder is scraped into the forming cylinder by the scraper and is paved, the laser, the beam customization module and the scanning galvanometer are sequentially connected, the scanning galvanometer is arranged on the forming cavity, and the scanning galvanometer is aligned to a formed part in the forming cylinder.
Further, the particle size of the metal powder is 15 to 53 μm, and the thickness of the metal powder layer in the forming cylinder is 30 μm.
The method for reducing the defect of the melting pore in the selective laser area comprises the following specific steps:
1) aiming at a filling area melted in a laser selection area, a shaping lens fixing support is adjusted through a rotating shaft, so that laser emitted by a laser penetrates through a hollow distribution shaping lens to form a hollow distributed laser beam, and metal powder in a model slice is melted through a scanning galvanometer;
2) aiming at the outer contour of selective laser melting, a shaping lens fixing support is adjusted through a rotating shaft, so that laser emitted by a laser does not pass through a hollow distribution shaping lens and a rectangular uniform distribution shaping lens, and metal powder at the edge of a model slice is directly melted by a laser beam in Gaussian distribution through a scanning galvanometer;
3) adjusting the shaping lens fixing support through a rotating shaft, enabling laser emitted by a laser to penetrate through the rectangular uniformly-distributed shaping lens to form rectangular uniformly-distributed laser beams, and remelting the molten metal powder in the steps 1) and 2) through scanning galvanometer fusion;
4) repeating the steps 1) to 3) until the formed part is printed.
Compared with the prior art, the invention adopting the technical scheme has the following technical effects: the invention utilizes the light beam customization module, utilizes three energy distribution forms, is loaded in the selective laser melting process, utilizes the hollow distribution light spots to quickly melt and solidify the interior of the model slice, utilizes the Gaussian distribution light spots to melt the edge of the model slice, and then utilizes the rectangular uniformly distributed light spots to remelt, thereby obviously reducing the pore defects of key holes, incomplete fusion and the like and having the beneficial effect of improving the mechanical property of metal additive manufacturing parts.
Drawings
FIG. 1 is a schematic view of an apparatus for reducing internal void defects in a selectively laser melted formed metal part using a custom beam;
FIG. 2 is a main configuration of a beam customization module;
FIG. 3 shows three working states of the beam customization module, wherein (A) is a hollow distribution, (B) is a rectangular uniform distribution, and (C) is a Gaussian distribution (without shaping);
FIG. 4 is an example of a print model;
FIG. 5 is a diagram of additive manufacturing of a 316L stainless steel part having a greater number of void defects using only a Gaussian distributed laser beam;
FIG. 6 is a metallographic view of hollow distribution melting/rectangular uniform distribution remelting laser beam additive manufacturing 316L stainless steel parts, wherein no large-size void defects are present;
FIG. 7 is a diagram of additive manufacturing of a Ti6Al4V part having a more porous defect using only a Gaussian distribution laser beam;
FIG. 8 is a diagram of a hollow distribution melting/rectangular uniform distribution remelting laser beam additive manufacturing Ti6Al4V part, wherein the number of pores is small and no large-size pore defect exists;
the method comprises the following steps of 1-scanning galvanometer, 2-beam customization module, 3-laser, 4-forming part, 5-scraper, 6-forming cavity, 7-forming cylinder, 8-powder feeding cylinder, 9-hollow distribution shaping lens, 10-shaping lens fixing support, 11-rectangular uniformly distributed shaping lens, 12-rotating shaft, 13-laser, 14-model slice edge and 15-model slice inside.
Detailed Description
As the Gaussian-distributed laser heat source is generally adopted in the selective laser melting forming process, the phenomena of overburning and keyhole often occur due to overhigh central energy of a light beam, so that a pore defect is formed, and meanwhile, the defect of poor fusion is easily formed at the boundary of a molten pool due to insufficient energy. Both of these defects have a great influence on the mechanical properties, especially fatigue properties, of the additively manufactured parts.
Aiming at the current situation, the invention provides a method for customizing by utilizing a light beam, which converts a conventional laser beam with circular Gaussian distribution into a customized light beam with spatial distribution meeting the requirement of melting powder, controllable temperature gradient and discontinuous time domain distribution. The beam customization module in the invention can realize three energy modes: gaussian distribution, hollow distribution and rectangular uniform distribution. Aiming at a filling area melted in a selective laser area, hollow distribution light spots are used for quickly melting and solidifying metal powder, and the temperature gradient is reduced; aiming at the outer contour of selective laser melting, the Gaussian distribution is used for enhancing the melting effect of the edge and improving the surface roughness; and remelting the molten metal by using rectangular uniformly distributed laser, thereby obviously reducing the internal porosity of the part. The invention can reduce unsteady state flow of the molten pool, promote the powder at the edge of the molten pool to be completely melted, finally effectively reduce the pore defect of the part melted and formed by selective laser area, and obviously improve the mechanical property of the part.
As shown in fig. 2, the light beam customization module includes the plastic lens fixed bolster, and the one end of plastic lens fixed bolster is equipped with cavity distribution plastic lens, and the other end is equipped with rectangle equipartition plastic lens, and the middle part of plastic lens fixed bolster is equipped with the axis of rotation. By rotating the shaft, the beam customization module can be adjusted to three states as shown in (a) to (C) of fig. 3, which respectively realize three energy modes: hollow distribution, rectangular uniform distribution and Gaussian distribution.
The invention relates to a method for reducing internal pore defects of a metal part formed by selective laser melting by utilizing a customized light beam, which comprises the following steps of:
step 1, as shown in fig. 1, a laser, a beam customization module and a scanning galvanometer are connected in sequence and are arranged on a forming cavity;
step 2, scraping the metal powder in the powder feeding cylinder into the forming cylinder by using a scraper and paving the metal powder;
step 3, closing the laser switch, adjusting the state of the beam customization module through the rotating shaft as shown in (A) in fig. 3, opening the laser switch, and melting the powder in the model slice shown in fig. 4 by using the laser beam distributed in the hollow way;
step 4, closing the laser switch, adjusting the state of the beam customization module through the rotating shaft as shown in (C) in fig. 3, opening the laser switch, and melting the powder at the edge of the model slice shown in fig. 4 by using the laser beam with Gaussian distribution (i.e. without shaping);
step 5, closing a laser switch, adjusting the state of the beam customization module through a rotating shaft as shown in (B) of the figure 3, opening the laser switch, and remelting the edges and the inside of the model slices as shown in the figure 4 by utilizing the laser beams uniformly distributed in a rectangular shape;
and (5) repeating the steps 2, 3, 4 and 5 for multiple times, and finally printing a formed piece with less internal pore defects.
Example 1: manufacture of 316L stainless steel parts
A method for reducing internal void defects in a laser selective melt formed metal part using a custom beam, comprising the steps of:
step 1, a laser, a beam customization module and a scanning galvanometer are connected in sequence and are arranged on a forming cavity;
step 2, scraping the metal powder in the powder feeding cylinder into the forming cylinder by using a scraper and paving the metal powder; the used material is 316L stainless steel, the grain diameter is 15-53 microns, and the layer thickness is 30 microns;
step 3, closing the laser switch, adjusting the state of the beam customization module through the rotating shaft as shown in (A) in fig. 3, opening the laser switch, and melting powder in the model by utilizing the laser beams distributed in a hollow manner; the laser power is 180W, the scanning speed is 1m/s, and the lap joint rate is 40 percent;
step 4, closing the laser switch, adjusting the state of the beam customization module through the rotating shaft as shown in (C) in fig. 3, opening the laser switch, and melting powder at the edge of the model slice by using a laser beam with Gaussian distribution (i.e. without shaping); the laser power is 150W, and the scanning speed is 1 m/s;
step 5, closing a laser switch, adjusting the state of the beam customization module through a rotating shaft as shown in (B) of the figure 3, opening the laser switch, and remelting the edge of the model slice and the inside of the model slice by utilizing the laser beams uniformly distributed in a rectangular shape; the laser power is 150W, the scanning speed is 1.2m/s, and the lap joint rate is 40 percent;
and (3) repeating the steps 2, 3, 4 and 5 for multiple times, and finally printing a 6-formed part with less internal pore defects, wherein a gold phase diagram of the 6-formed part is shown in FIG. 6. FIG. 5 is a diagram of additive manufacturing of a 316L stainless steel part with only a Gaussian distribution laser beam, wherein there are more void defects. It can be seen from the contrast that rationally using the customization light beam, the inside hole of additive manufacturing part significantly reduces, and the hole size also significantly reduces.
Example 2: production of Ti6Al4V parts
A method for reducing internal void defects in a laser selective melt formed metal part using a custom beam, comprising the steps of:
step 1, a laser, a beam customization module and a scanning galvanometer are connected in sequence and are arranged on a forming cavity;
step 2, scraping the metal powder in the powder feeding cylinder into the forming cylinder by using a scraper and paving the metal powder; the used material is Ti6Al4V titanium alloy, the grain diameter is 15-53 microns, and the layer thickness is 30 microns;
step 3, closing the laser switch, adjusting the state of the beam customization module through the rotating shaft as shown in (A) in fig. 3, opening the laser switch, and melting powder in the model by utilizing the laser beams distributed in a hollow manner; the laser power is 200W, the scanning speed is 1m/s, and the lap joint rate is 30 percent;
step 4, closing the laser switch, adjusting the state of the beam customization module through the rotating shaft as shown in (C) in fig. 3, opening the laser switch, and melting powder at the edge of the model slice by using a laser beam with Gaussian distribution (i.e. without shaping); the laser power is 180W, and the scanning speed is 1 m/s;
step 5, closing a laser switch, adjusting the state of the beam customization module through a rotating shaft as shown in (B) of the figure 3, opening the laser switch, and remelting the edge of the model slice and the inside of the model slice by utilizing the laser beams uniformly distributed in a rectangular shape; the laser power is 180W, the scanning speed is 1.2m/s, and the lap joint rate is 30 percent;
and (3) repeating the steps 2, 3, 4 and 5 for multiple times, and finally printing a formed part with less internal pore defects, wherein a gold phase diagram of the formed part is shown in FIG. 8. FIG. 7 is a diagram of additive manufacturing of Ti6Al4V titanium alloy gold phase with only Gaussian distribution laser beam, with more void defects. It can be seen from the contrast that rationally using the customization light beam, the inside hole of additive manufacturing part significantly reduces, and the hole size also significantly reduces.
It should be noted that the above description of the embodiments is only for the purpose of assisting understanding of the method of the present application and the core idea thereof, and that those skilled in the art can make several improvements and modifications to the present application without departing from the principle of the present application, and these improvements and modifications are also within the protection scope of the claims of the present application.

Claims (4)

1. The light beam customization module is characterized by comprising a shaping lens fixing support, wherein a hollow distribution shaping lens is arranged at one end of the shaping lens fixing support, rectangular uniformly distributed shaping lenses are arranged at the other end of the shaping lens fixing support, and a rotating shaft is arranged in the middle of the shaping lens fixing support.
2. The device for reducing the defect of the melting hole in the selective laser area is characterized by comprising the beam customization module as claimed in claim 1, and a scanning galvanometer, a laser, a scraper, a forming cavity, a forming cylinder and a powder feeding cylinder, wherein the forming cylinder and the powder feeding cylinder are respectively arranged at the bottom of the forming cavity, metal powder in the powder feeding cylinder is scraped into the forming cylinder by the scraper and is paved, the laser, the beam customization module and the scanning galvanometer are sequentially connected, the scanning galvanometer is arranged on the forming cavity, and the scanning galvanometer is aligned to a formed part in the forming cylinder.
3. The apparatus for reducing selective laser melting porosity defects of claim 2 wherein the metal powder has a particle size of 15 to 53 microns and the layer thickness of the metal powder in the forming cylinder is 30 microns.
4. The method for reducing selective laser melting void defects based on the device of claim 2, comprising the following steps:
1) adjusting the shaping lens fixing support through the rotating shaft, enabling laser emitted by the laser to penetrate through the hollow distribution shaping lens to form a hollow distributed laser beam, and then melting metal powder in the model slice through the scanning galvanometer;
2) adjusting the shaping lens fixing support through a rotating shaft, so that laser emitted by a laser does not pass through a hollow distribution shaping lens and a rectangular uniform distribution shaping lens, and metal powder at the edge of a model slice is directly melted by a laser beam in Gaussian distribution through a scanning galvanometer;
3) adjusting the shaping lens fixing support through a rotating shaft, enabling laser emitted by a laser to penetrate through the rectangular uniformly-distributed shaping lens to form rectangular uniformly-distributed laser beams, and remelting the molten metal powder in the steps 1) and 2) through scanning galvanometer fusion;
4) repeating the steps 1) to 3) until the formed part is printed.
CN202011559628.7A 2020-12-25 2020-12-25 Light beam customization module and method and device for reducing selective laser melting pore defects Pending CN112775441A (en)

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Cited By (5)

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CN114131049A (en) * 2021-12-21 2022-03-04 宜宾上交大新材料研究中心 Additive manufacturing method of copper and copper alloy
CN114472927A (en) * 2022-01-17 2022-05-13 哈尔滨工程大学 Multi-energy-beam selective laser melting device and material increase method
CN114713844A (en) * 2022-04-14 2022-07-08 季华实验室 Selective metal laser melting forming method and system
CN114871451A (en) * 2022-04-22 2022-08-09 南京航空航天大学 High-formability aluminum alloy material based on laser beam shaping and preparation method thereof
CN115958196A (en) * 2022-11-29 2023-04-14 北京碳垣新材料科技有限公司 Additive manufacturing method based on copper or copper alloy powder and copper or copper alloy profile

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CN115958196A (en) * 2022-11-29 2023-04-14 北京碳垣新材料科技有限公司 Additive manufacturing method based on copper or copper alloy powder and copper or copper alloy profile

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