CN115106545B - Coaxially-coupled multi-laser material increasing and decreasing composite forming device and method - Google Patents
Coaxially-coupled multi-laser material increasing and decreasing composite forming device and method Download PDFInfo
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- 239000002131 composite material Substances 0.000 title claims abstract description 42
- 238000000034 method Methods 0.000 title claims abstract description 17
- 230000003247 decreasing effect Effects 0.000 title claims abstract description 15
- 239000000654 additive Substances 0.000 claims abstract description 52
- 230000000996 additive effect Effects 0.000 claims abstract description 52
- 239000000835 fiber Substances 0.000 claims abstract description 16
- 238000009826 distribution Methods 0.000 claims abstract description 15
- 239000000843 powder Substances 0.000 claims description 23
- 238000000465 moulding Methods 0.000 claims description 20
- 238000004519 manufacturing process Methods 0.000 claims description 19
- 230000009467 reduction Effects 0.000 claims description 19
- 238000005498 polishing Methods 0.000 claims description 13
- 230000000694 effects Effects 0.000 claims description 10
- 238000005520 cutting process Methods 0.000 claims description 9
- 238000002844 melting Methods 0.000 claims description 9
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- 238000005859 coupling reaction Methods 0.000 claims description 7
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- 230000008878 coupling Effects 0.000 claims description 6
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- 230000008569 process Effects 0.000 claims description 5
- 238000005728 strengthening Methods 0.000 claims description 4
- 238000004381 surface treatment Methods 0.000 claims description 4
- 238000010438 heat treatment Methods 0.000 claims description 3
- 230000033228 biological regulation Effects 0.000 claims description 2
- 238000003801 milling Methods 0.000 abstract 1
- 230000007547 defect Effects 0.000 description 7
- 238000005516 engineering process Methods 0.000 description 7
- 238000010586 diagram Methods 0.000 description 6
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- 238000003892 spreading Methods 0.000 description 4
- 230000007480 spreading Effects 0.000 description 4
- 230000002411 adverse Effects 0.000 description 2
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- 238000005542 laser surface treatment Methods 0.000 description 2
- 238000003672 processing method Methods 0.000 description 2
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/80—Plants, production lines or modules
- B22F12/82—Combination of additive manufacturing apparatus or devices with other processing apparatus or devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
- B22F10/364—Process control of energy beam parameters for post-heating, e.g. remelting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/40—Radiation means
- B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
- B22F12/43—Radiation means characterised by the type, e.g. laser or electron beam pulsed; frequency modulated
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/40—Radiation means
- B22F12/44—Radiation means characterised by the configuration of the radiation means
- B22F12/45—Two or more
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
- B23K26/064—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
- B23K26/3568—Modifying rugosity
- B23K26/3576—Diminishing rugosity, e.g. grinding; Polishing; Smoothing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/70—Auxiliary operations or equipment
- B23K26/702—Auxiliary equipment
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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
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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
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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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
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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Abstract
The invention discloses a coaxially-coupled multi-laser material increasing and decreasing composite forming device and method; the device comprises a material increasing/decreasing laser light path device which consists of a plurality of sets of composite laser units in which pulse laser and continuous laser are coaxially coupled; the laser emitted by the ultrafast laser of the composite laser unit is shaped into the required beam space distribution after passing through the second collimator and the second beam shaper; the laser emitted by the continuous fiber laser is shaped into the required beam space distribution as continuous laser after passing through the first collimator and the first beam shaper; the shaped emergent beams of the continuous laser path and the pulse laser path are coaxially coupled into a beam of composite laser through a 45-degree beam combining lens and focused on the surface of a workpiece; according to the invention, each laser unit works independently, can cover the whole forming area, and can perform additive forming and subtractive milling in different areas at the same time, so that the efficiency of composite forming is improved.
Description
Technical Field
The invention relates to the technical field of additive manufacturing, in particular to a coaxially-coupled multi-laser additive and subtractive composite forming device and method.
Background
The powder bed laser melting technology (Laser powder bed fusion, LPBF) is a metal additive technology which uses high-energy laser beams to melt metal powder layer by layer and solidify, stack and mold, can integrally and quickly manufacture precise complex structural parts which cannot be molded by the traditional processing method, and has the advantages of high molding precision, high density, excellent mechanical property, capability of molding complex fine structures and the like compared with other additive molding modes. However, by adopting a layer-by-layer fusion stacking molding mode, a large amount of powder is adhered to the edge of the molded part, and a step effect is also generated between layers, so that the molding precision and the surface quality of the part are reduced. During the additive forming process, some forming defects such as splashing, spheroidization, cracks and the like can reduce the overall performance of the finally formed part, and meanwhile, the defects can have adverse effects on the next layer of powder spreading, aggravate the negative effects of the defects and even cause printing failure.
In recent years, a hybrid manufacturing method using other processing methods in combination with additive manufacturing has received attention.
One or more processing technologies are combined with additive manufacturing, the advantages of the additive manufacturing are reserved, the defects of the additive manufacturing are eliminated or reduced by other processing technologies, the purpose of complementary advantages is achieved, and the combination with ultrafast laser material reduction is one mode.
There are researchers to adopt a mode of combining continuous fiber laser material increase and ultrafast pulse laser material decrease to carry out laser material increase and decrease composite processing, but the processing mode has some technical problems, such as low efficiency of composite processing, difficult organic combination of two processes and alignment precision of two types of lasers.
Therefore, the composite processing efficiency is increased, different types of lasers are flexibly configured, and the alignment precision of the different types of laser beams is improved, so that the method has great significance for manufacturing the ultrafast pulse laser composite increase and decrease material.
Disclosure of Invention
The invention aims to overcome the defects and shortcomings of the prior art and provide a coaxially-coupled multi-laser material increasing and decreasing composite forming device and method.
Based on a powder bed laser melting technology and an ultrafast laser cutting technology, continuous laser and ultrafast laser are coaxially coupled to form a set of composite laser unit, and the coupling precision of the two types of laser is greatly improved; meanwhile, the coordination work of a plurality of sets of same-breadth compound laser units can improve the efficiency of compound forming in multiple. Through the rotation of multiple working modes of material addition molding, ultrafast laser material reduction cutting and laser surface treatment, the high-efficiency integrated material increase and decrease composite manufacturing of large-size complex-structure metal parts with low defects, high performance, high molding precision and high surface quality is finally realized.
The invention is realized by the following technical scheme:
a coaxially coupled multi-laser material increasing and decreasing composite forming device comprises a material increasing and decreasing laser light path device which is composed of a plurality of sets of composite laser units in which pulse lasers and continuous lasers are coaxially coupled;
the compound laser unit comprises a continuous fiber laser 9, a second collimator 10, a second beam shaper 11, an ultrafast laser 8, a first collimator 13, a first beam shaper 14, a 45-degree beam combining mirror 12, an X-axis scanning galvanometer 15, a Y-axis scanning galvanometer 17 and an f-theta mirror 16;
the laser emitted by the ultrafast laser 8 is shaped into a required beam space distribution as pulse laser after passing through a second collimator 10 and a second beam shaper 11;
the laser beam emitted by the continuous fiber laser 9 is shaped into a required beam space distribution as continuous laser after passing through a first collimator 13 and a first beam shaper 14;
the shaped continuous laser path and the shaped emergent beam of the pulse laser path are coaxially coupled into a beam of composite laser through a 45-degree beam combining lens 12, and then are focused on the surface of a workpiece after passing through an X-axis scanning galvanometer 15, a Y-axis scanning galvanometer 17 and an f-theta lens 16.
The composite laser units are at least two sets of composite laser units which are mutually independent and can cover the whole working area.
The spatial distribution of the light beam refers to, for example, a flat-top beam or a Bessel beam.
The continuous fiber laser 9 is a 1090nm fiber laser; the ultrafast laser 8 is a picosecond laser or a femtosecond laser, the wavelength is 1030nm, and the pulse frequency is: the picosecond laser is 50 kHz-2 MHz, and the femtosecond laser is 1 kHz-1 MHz.
A molding method of a coaxially coupled multi-laser material increasing and decreasing composite molding device comprises the following steps:
according to the attribute requirements of the parts, carrying out data processing on the models of the parts, and respectively planning path data of material addition and material reduction;
an additive processing step:
after passing through the first collimator 13 and the first beam shaper 14, the continuous laser is focused on the forming processing surface of the workpiece, SLM (selective laser beam) additive forming is carried out under the control of an X-axis scanning galvanometer, the first beam shaper 14 shapes focused light spots into flat top light or light spots of required types, fine adjustment and control are carried out on a heating area and a melting area of the workpiece, a melting pool with smaller and more uniform required temperature gradient is obtained, and the final performance of additive manufactured parts is improved;
or selecting pulse laser, and performing additive forming on the workpiece by using ultra-fast laser;
or, simultaneously introducing continuous laser and pulse laser, wherein the continuous laser heats and softens the powder, and the pulse laser melts and moulds the powder;
secondly, material reduction treatment:
the ultrafast laser 8 is adjusted to a subtractive mode, and the second beam shaper 11 converts the laser beam into a bessel beam to increase the rayleigh depth;
thirdly, surface treatment:
in the additive processing step, after a slice is formed on the workpiece in an additive mode, remelting is carried out on the additive forming surface of the workpiece by using continuous laser; or, using ultrafast laser to polish the surface of the additive molding surface; or, using ultrafast laser to perform impact strengthening on a selected area of the surface, and adjusting the surface stress distribution;
and fourthly, repeating the material adding processing step, the material reducing processing step and the surface processing step according to the slice and path data of the material adding and the material reducing of the part until the forming processing of the whole workpiece is completed.
In the material reduction treatment step, ultra-fast laser is used for scanning and cutting the profile of the workpiece formed by the material addition, so that powder adhesion and step effect at the edge of the part are eliminated, and arc-shaped protrusions at the edge of the melt channel are cut off;
in the above-mentioned additive processing step, the desired profile should be positively compensated for in the path planning of additive manufacturing according to the cutting margin of the subtractive processing, and the margin of the subtractive processing should be reserved.
In the material reduction processing step, pulse laser is performed on each layer after SLM molding or after molding a plurality of layers;
in the step of the additive processing, after the additive manufacturing of the workpiece is completed in one layer, pulse laser is used for carrying out rough surface polishing so as to remove fluctuation formed by splashing, spheroidization and uneven melting channel in the additive manufacturing process;
in the step of the material adding treatment, when the area is judged to be the last layer of the material adding of the workpiece, namely the upper surface of the part, pulse laser is used for carrying out fine polishing for a plurality of times; in the process of workpiece material addition, namely, the area of the non-final layer, only rough polishing or no polishing is carried out.
Compared with the prior art, the invention has the following advantages and effects:
1. the invention integrates various processing technologies of laser material-increasing forming, laser material-reducing forming (including laser edge cutting, direct removal of internal materials of parts) and laser surface processing (laser remelting, laser polishing and laser shock peening) into a whole, and can realize in-situ integrated forming of high-precision, high-surface-quality and high-performance metal parts;
2. the invention adopts the coaxial coupling light path design, can greatly improve the alignment precision of the fiber laser and the pulse laser, and obviously improve the final forming precision of the composite forming;
3. the invention integrates a plurality of sets of independent working identical-breadth composite laser units, mutually and cooperatively works, material adding and material subtracting can be simultaneously carried out, each laser unit is flexibly distributed to carry out material adding and material subtracting according to working conditions, the condition that part of laser units wait for the completion of working procedures of other laser units is avoided, and the composite forming efficiency is improved in multiple times
4. The beam shaping function of the invention can accurately regulate and control the laser energy distribution, and improve the quality uniformity of parts manufactured by additive materials and the dimensional accuracy of the material reduction process.
5. The invention remelting, rough polishing and impact strengthening are carried out on the internal sheet layers of the parts, and the integral mechanical properties of the parts can be improved under the condition that the molding materials are unchanged.
Drawings
FIG. 1 is a schematic diagram of a coaxially coupled multiple laser add-drop composite forming apparatus of the present invention;
FIG. 2 is a schematic diagram of the optical path connection of the composite laser unit of the present invention;
FIG. 3 is a schematic diagram of a composite laser unit of the present invention coaxially coupling two types of lasers;
FIG. 4 is a schematic diagram of a composite manufacturing process of the present invention;
FIG. 5 is a schematic diagram of the operation of profile trimming in a laser subtractive mode;
fig. 6 is a schematic diagram of part sheet surface polishing in a laser surface treatment mode.
Reference numerals in the drawings: a powder recovery cylinder 1; a forming cylinder 2; a subtractive mode laser beam 3; an additive mode laser beam 4; a powder cylinder 5; a powder spreading vehicle 6; a working chamber 7; an ultrafast laser 8; a continuous fiber laser 9; a second collimator 10; a second beam shaper 11; a 45 DEG beam combiner 12; a first collimator 13; a first beam shaper 14; an X-axis scanning galvanometer 15; f-theta mirror 16; the Y-axis scans the galvanometer 17.
Detailed Description
The present invention will be described in further detail with reference to specific examples.
The invention discloses a coaxially coupled multi-laser material increasing and decreasing composite forming device, which comprises a material increasing and decreasing laser light path device consisting of a plurality of sets of composite laser units in which pulse lasers and continuous lasers are coaxially coupled;
the compound laser unit comprises a continuous fiber laser 9, a second collimator 10, a second beam shaper 11, an ultrafast laser 8, a first collimator 13, a first beam shaper 14, a 45-degree beam combining mirror 12, an X-axis scanning galvanometer 15, a Y-axis scanning galvanometer 17 and an f-theta mirror 16;
the laser emitted by the ultrafast laser 8 is shaped into a required beam space distribution as pulse laser after passing through a second collimator 10 and a second beam shaper 11;
the laser beam emitted by the continuous fiber laser 9 is shaped into a required beam space distribution as continuous laser after passing through a first collimator 13 and a first beam shaper 14;
the shaped continuous laser path and the shaped emergent beam of the pulse laser path are coaxially coupled into a beam of composite laser through a 45-degree beam combining lens 12, and then are focused on the surface of a workpiece after passing through an X-axis scanning galvanometer 15, a Y-axis scanning galvanometer 17 and an f-theta lens 16.
The composite laser units are at least two sets of mutually independent composite laser units which can cover the whole working area;
according to the embodiment of the invention, four sets of composite laser units are adopted, the working parameters of two types of lasers are adjusted to realize the simultaneous operation of material adding, material subtracting and surface treatment respectively through the coordination work of partition planning, and when a part of laser units are used for material adding, other laser units can be used for material subtracting treatment in a formed area. According to actual working conditions, the working modes of each set of laser units are flexibly switched, and when the material adding processing areas are more, more laser units can be distributed for material adding processing; when the material reduction processing areas are more, more laser units are distributed to perform material reduction processing, so that the situations that the material adding and material reduction processes wait for each other and the processing efficiency is dragged slowly are avoided.
The spatial distribution of the light beam refers to, for example, a flat-top beam or a Bessel beam.
The continuous fiber laser 9 is a 1090nm fiber laser; the ultrafast laser 8 is a picosecond laser or a femtosecond laser, the wavelength is 1030nm, and the pulse frequency is: the picosecond laser is 50 kHz-2 MHz, and the femtosecond laser is 1 kHz-1 MHz.
The forming efficiency of the invention is more than 200cm < 3 >/h, the repeated positioning precision of the two types of lasers is less than or equal to 3 mu m, the inner cavity structure and the shape forming precision are better than +/-5 mu m/100mm, and the optimal surface roughness Ra of the composite manufacturing is less than or equal to 2 mu m.
A molding method of a coaxially coupled multi-laser material increasing and decreasing composite molding device comprises the following steps:
according to the attribute requirements of the parts, carrying out data processing on the models of the parts, respectively planning path data of material addition and material reduction, and completing preparation works such as powder addition, substrate installation, oxygen discharge, protection gas filling and the like;
an additive processing step:
after passing through the first collimator 13 and the first beam shaper 14, the continuous laser is focused on the forming processing surface of the workpiece, SLM (selective laser beam) additive forming is carried out under the control of an X-axis scanning galvanometer, the first beam shaper 14 shapes focused light spots into flat top light or other types of light spots, fine regulation and control are carried out on a heating area and a melting area of the workpiece, a melting pool with smaller and more uniform required temperature gradient is obtained, and the final performance of additive manufactured parts is improved;
or, pulse laser is selected to be introduced, and the ultrafast laser is used for carrying out additive forming on the workpiece, so that compared with continuous laser additive, the ultrafast laser additive has higher instantaneous temperature and smaller heat affected zone, and is suitable for additive manufacturing of high-melting-point materials.
Or simultaneously introducing continuous laser and pulse laser, wherein the continuous laser heats and softens the powder, and the pulse laser melts and molds the powder, so as to obtain the additive manufactured part with higher molding quality.
Secondly, material reduction treatment:
the ultrafast laser 8 is adjusted to a material reduction mode with high single pulse energy, and the second beam shaper 11 converts the laser beam into a Bessel beam to increase the Rayleigh depth and reduce adverse factors of cutting quality degradation caused by beam diffraction, so that a smoother tangential plane is obtained.
Specifically, the profile of the metal part formed by the additive is scanned and cut by using ultra-fast laser, so that powder adhesion and step effect at the edge of the part are eliminated, arc-shaped protrusions at the edge of a melt channel are cut off, the surface quality of the side surface and the inner cavity of the part is improved, and the forming precision of the part is improved. And simultaneously, micro holes, micro grooves and surface microstructures can be processed in the additive forming sheet layer, and fine structures can be processed in the part.
Thirdly, surface treatment:
in the additive processing step, after a slice is formed on the workpiece in an additive mode, remelting is carried out on the additive forming surface of the workpiece by using continuous laser;
or, using ultra-fast laser to polish the surface of the additive forming surface, improving the powder spreading effect of the next layer and improving the quality of the upper surface of the sample;
or, using ultrafast laser to perform impact strengthening on a selected or specific area of the surface, and adjusting the surface stress distribution so as to improve the surface structure and performance;
the remelting aims to reduce the occurrence of forming defects such as pores, cracks, unmelted and the like, reduce the surface roughness and improve the quality of the next layer of powder paving.
And fourthly, repeating the material adding processing step, the material reducing processing step and the surface processing step according to the slice and path data of the material adding and the material reducing of the part until the forming processing of the whole workpiece is completed.
In the material reduction processing step, ultra-fast laser is used for scanning and cutting the profile of the workpiece formed by the material increase, so that powder adhesion and step effect at the edge of the part are eliminated, arc-shaped protrusions at the edge of the melt channel are cut off, the surface quality of the side surface and the inner cavity of the part is improved, and the forming precision of the part is improved. And simultaneously, micro holes, micro grooves and surface microstructures can be processed in the additive forming sheet layer, and fine structures can be processed in the part.
In the above-mentioned additive processing step, the desired profile should be positively compensated for in the path planning of additive manufacturing according to the cutting margin of the subtractive processing, and the margin of the subtractive processing should be reserved.
In the above-mentioned material reduction processing step, the pulse laser is performed on each layer after SLM molding, or after molding several layers, specifically, may be set according to the side surface quality requirement and the thickness of the molded layer.
In the step of the material increase processing, after the material increase manufacturing of the workpiece is completed in one layer, pulse laser is used for carrying out surface rough polishing so as to remove fluctuation formed by splashing, spheroidization and uneven melting channel in the material increase manufacturing process, improve the powder spreading effect of the next layer, and finally play the roles of improving the material increase forming quality and reducing the porosity.
In the step of the material adding treatment, when the area is judged to be the last layer of the material adding of the workpiece, namely the upper surface of the part, pulse laser is used for carrying out fine polishing for a plurality of times so as to obtain a sample with high surface quality; in the process of workpiece material addition, namely, the area of the non-final layer, only rough polishing or no polishing is carried out.
The embodiments of the present invention are not limited to the above examples, and any other changes, modifications, substitutions, combinations, and simplifications that do not depart from the spirit and principles of the invention should be made and equivalents should be construed as falling within the scope of the invention.
Claims (2)
1. The coaxial coupling multi-laser material increasing and decreasing composite forming method is characterized in that the coaxial coupling multi-laser material increasing and decreasing composite forming device is adopted;
the coaxial-coupling multi-laser material increasing and decreasing composite forming device comprises a material increasing and decreasing laser light path device which consists of a composite laser unit formed by coaxially coupling pulse laser and continuous laser;
the compound laser unit comprises a continuous fiber laser (9), a second collimator (10), a second beam shaper (11), an ultrafast laser (8), a first collimator (13), a first beam shaper (14), a 45-degree beam combining mirror (12), an X-axis scanning galvanometer (15), a Y-axis scanning galvanometer (17) and an f-theta mirror (16);
the laser emitted by the ultrafast laser (8) is shaped into required light beam space distribution as pulse laser after passing through a second collimator (10) and a second beam shaper (11);
the laser emitted by the continuous fiber laser (9) is shaped into the required beam space distribution as continuous laser after passing through a first collimator (13) and a first beam shaper (14);
the shaped emergent beams of the continuous laser path and the pulse laser path are coaxially coupled into a beam of composite laser through a 45-degree beam combining lens (12), and then are focused on the surface of a workpiece after passing through an X-axis scanning galvanometer (15), a Y-axis scanning galvanometer (17) and an f-theta lens (16);
the beam spatial distribution refers to a flat-top beam or a Bessel beam;
the forming method comprises the following steps:
performing data processing on the model of the part, and respectively planning path data of material adding and material subtracting;
an additive processing step:
after passing through a first collimator (13) and a first beam shaper (14), continuous laser is focused on the forming processing surface of a workpiece, SLM (selective laser beam) additive forming is carried out under the control of an X-axis scanning galvanometer, the first beam shaper (14) shapes focused light spots into flat top light, and fine regulation and control are carried out on a heating area and a melting area of the workpiece, so that a molten pool with uniform required temperature gradient is obtained, and the final performance of additive manufactured parts is improved;
or selecting pulse laser, and performing additive forming on the workpiece by using ultra-fast laser;
or, simultaneously introducing continuous laser and pulse laser, wherein the continuous laser heats and softens the powder, and the pulse laser melts and moulds the powder;
secondly, material reduction treatment:
the ultrafast laser (8) is adjusted to a material reduction mode, and the second beam shaper (11) converts the laser beam into a Bessel beam so as to increase the Rayleigh depth;
thirdly, surface treatment:
in the additive processing step, after a slice is formed on the workpiece in an additive mode, remelting is carried out on the additive forming surface of the workpiece by using continuous laser; or, using ultrafast laser to polish the surface of the additive molding surface; or, using ultrafast laser to perform impact strengthening on a selected area of the surface, and adjusting the surface stress distribution;
fourthly, repeating the material adding processing step, the material reducing processing step and the surface processing step according to the slice and path data of the material adding and the material reducing of the part until the forming processing of the whole workpiece is completed;
in the material reduction treatment step, ultra-fast laser is used for scanning and cutting the profile of the workpiece formed by the material addition, so that powder adhesion and step effect at the edge of the part are eliminated, and arc-shaped protrusions at the edge of the melt channel are cut off;
in the additive processing step, according to the cutting allowance of the material reduction processing, when the path planning of the additive manufacturing is carried out, the expected contour is positively compensated, and the allowance of the material reduction is reserved;
in the material reduction processing step, pulse laser is performed on each layer after SLM molding, or is performed after molding a plurality of layers;
in the step of material adding treatment, when the area is judged to be the last layer of the material adding of the workpiece, namely the upper surface of the part, pulse laser is used for carrying out fine polishing for a plurality of times; and in the process of workpiece material addition, namely, the area of the non-final layer, only rough polishing is carried out.
2. The coaxially-coupled multi-laser add-drop composite forming method according to claim 1, wherein the continuous fiber laser (9) is a 1090nm fiber laser; the ultrafast laser (8) is a picosecond laser or a femtosecond laser, the wavelength is 1030nm, and the pulse frequency is: the picosecond laser is 50 kHz-2 MHz, and the femtosecond laser is 1 kHz-1 MHz.
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| CN116890122B (en) * | 2023-09-11 | 2023-11-14 | 中国地质大学（武汉） | Full-period in-situ monitoring method for splash formation, emission and fall back in laser additive manufacturing |
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