CN115213426A - Laser melting forming method and system - Google Patents
Laser melting forming method and system Download PDFInfo
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- CN115213426A CN115213426A CN202110411622.3A CN202110411622A CN115213426A CN 115213426 A CN115213426 A CN 115213426A CN 202110411622 A CN202110411622 A CN 202110411622A CN 115213426 A CN115213426 A CN 115213426A
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- 238000000034 method Methods 0.000 title claims abstract description 56
- 238000002844 melting Methods 0.000 title abstract description 33
- 230000008018 melting Effects 0.000 title abstract description 33
- 239000000843 powder Substances 0.000 claims description 54
- 229910045601 alloy Inorganic materials 0.000 claims description 38
- 239000000956 alloy Substances 0.000 claims description 38
- 238000000465 moulding Methods 0.000 claims description 30
- 230000008569 process Effects 0.000 claims description 27
- 230000004927 fusion Effects 0.000 claims description 11
- 238000005192 partition Methods 0.000 claims description 11
- 238000003754 machining Methods 0.000 claims description 6
- 229910000838 Al alloy Inorganic materials 0.000 claims description 3
- 238000009825 accumulation Methods 0.000 abstract description 9
- 239000012071 phase Substances 0.000 description 61
- 238000009826 distribution Methods 0.000 description 17
- 229910052751 metal Inorganic materials 0.000 description 15
- 239000002184 metal Substances 0.000 description 15
- 239000011148 porous material Substances 0.000 description 13
- 238000001816 cooling Methods 0.000 description 11
- 239000007789 gas Substances 0.000 description 10
- 238000005516 engineering process Methods 0.000 description 9
- 238000010309 melting process Methods 0.000 description 7
- 239000002245 particle Substances 0.000 description 7
- 239000007787 solid Substances 0.000 description 5
- 238000007711 solidification Methods 0.000 description 5
- 230000008023 solidification Effects 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- 230000009471 action Effects 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 238000004080 punching Methods 0.000 description 4
- 238000000889 atomisation Methods 0.000 description 3
- 238000001513 hot isostatic pressing Methods 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 239000007791 liquid phase Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
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- 230000000717 retained effect Effects 0.000 description 2
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- 238000003892 spreading Methods 0.000 description 2
- 230000007480 spreading Effects 0.000 description 2
- 238000010146 3D printing Methods 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
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- 229910052757 nitrogen Inorganic materials 0.000 description 1
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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
- 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
- B22F2203/00—Controlling
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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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- Laser Beam Processing (AREA)
Abstract
The invention relates to the technical field of laser processing, and discloses a laser melting forming method and a laser melting forming system, wherein the method comprises the following steps: determining a first part frame area and a first entity filling area according to a first layer processing parameter corresponding to the layer number; carrying out laser scanning on the frame area of the first part through a first laser beam; controlling the phase angle of the second laser beam to deflect a first angle, and performing laser scanning on the first entity filling area through the second laser beam; and controlling the phase angle of the third laser beam to deflect a second angle, and confirming that the layer processing corresponding to the layer number is finished after the laser remelting scanning is carried out on the first entity filling area through the third laser beam. The invention avoids the heat accumulation of local areas, effectively reduces the porosity of the laser melting formed part, realizes the high density of the final formed part, and has low cost and simple operation.
Description
Technical Field
The invention relates to the technical field of laser processing, in particular to a laser melting forming method and a laser melting forming system.
Background
The selective laser melting technology is an additive manufacturing technology for completely melting metal powder through laser beams and forming the metal powder through cooling and solidification, belongs to an important subdivision technical field of a metal 3D printing technology, is not influenced by the complexity of parts, has incomparable advantages of a traditional casting method, does not need to open a die, and is particularly suitable for rapid verification of products. At present, when a selective laser melting technology is used for forming processing, a laser beam is used as a heat source, two-dimensional sections are formed by melting layer by layer, and the two-dimensional sections are accumulated layer by layer, so that the processing of three-dimensional parts is finally realized. However, in the forming process, due to the common influence of the quality of the raw materials, the forming process parameters and the forming process characteristics, for example, gas carried in hollow powder in the raw materials is finally accumulated in a formed part to form a hole, the unreasonable forming process parameters cause uneven melting of a melting pool, splashing of liquid drops, incomplete melting of the raw materials and the like to form a hole, the forming process characteristics cause metal powder to form a melting pool under the thermal shock action of laser, meanwhile, part of metal is gasified, when the laser is turned off, a large back-punching force is formed, the metal liquid flows to the center of the melting pool under the action of the back-punching force, a closed lock hole is formed at the bottom of the melting pool, metal vapor is captured by a solidification front edge to form a nearly circular lock hole, and finally, the density of the part is not high, and the mechanical performance of the part is influenced.
In the prior art, in order to reduce holes, after selective laser forming is completed, a post-treatment process is generally added to a formed part (for example, a hot isostatic pressing technology: the part is placed in a special sheath which can be made of metal or ceramic, nitrogen and argon are used as pressurizing media, and the part with shrinkage porosity is subjected to thermal densification treatment at high temperature and high pressure, so that the porosity is reduced, and the high density of the formed part is realized, thereby achieving the required performance requirement). The scheme has the disadvantages that firstly, the sheath needs to be customized for each part according to the structural modeling of the part, so that more time is spent and the cost is increased; meanwhile, the hot isostatic pressing technology is complex in process, more parameters are involved, and process parameters matched with the materials need to be formulated according to different materials to ensure performance; thirdly, the hot isostatic pressing technology has extremely low popularization rate, and the scale and industrialization are not realized at present, so that the production cost is further improved.
Disclosure of Invention
The embodiment of the invention provides a laser melting forming method and a laser melting forming system, and solves the problems that the method for reducing the porosity of a laser melting formed part in the prior art is complex in process, high in cost and the like.
In order to achieve the above object, the present invention provides a laser fusion molding method, comprising:
receiving a first layer of processing instruction containing the layer number of the part to be processed, and laying a layer of alloy powder with a preset thickness;
determining a first part frame area and a first entity filling area corresponding to the layer of alloy powder according to the first layer processing parameter corresponding to the layer number;
emitting a first laser beam according to a first forming parameter, and carrying out laser scanning on the frame area of the first part through the first laser beam;
after the phase angle of a second laser beam is controlled to deflect a first angle, the second laser beam is emitted according to a second forming parameter, and the first entity filling area is subjected to laser scanning through the second laser beam;
and after controlling the phase angle of the third laser beam to deflect a second angle, emitting the third laser beam according to a third forming parameter, and after carrying out laser remelting scanning on the first entity filling area through the third laser beam, confirming that the layer processing corresponding to the layer number is finished.
The invention also provides a laser melting forming system which comprises a controller used for executing the laser melting forming method.
The invention provides a laser melting forming method and a system, wherein in the laser melting forming method, a first layer of processing instructions containing the layer number of a part to be processed is received, and a layer of alloy powder with preset thickness is laid; determining a first part frame area and a first entity filling area corresponding to the layer of alloy powder according to a first layer processing parameter corresponding to the layer number; emitting a first laser beam according to a first forming parameter, and carrying out laser scanning on the frame area of the first part through the first laser beam; after the phase angle of a second laser beam is controlled to deflect a first angle, the second laser beam is emitted according to a second forming parameter, and the first entity filling area is subjected to laser scanning through the second laser beam; and after controlling the phase angle of the third laser beam to deflect a second angle, emitting the third laser beam according to a third forming parameter, and after carrying out laser remelting scanning on the first entity filling area through the third laser beam, confirming that the layer processing corresponding to the layer number is finished.
The laser scanning method is used for carrying out laser scanning on different areas (such as a first part frame area and a first entity filling area) through different forming parameters, so that the processing requirements of different processing areas can be met in the part processing process; when the first entity filling area of each layer is subjected to laser scanning, the phase angle of the second laser beam deflects by a first angle according to a certain rule, so that the heat distribution during laser scanning processing is more uniform; meanwhile, when the laser remelting scanning is carried out on the first entity filling area of each layer, the phase angle of the third laser beam is deflected by a second angle according to a certain rule, so that the heat distribution during the laser remelting scanning is more uniform, the heat distribution during the laser scanning is uniform, the heat accumulation of a local area can be avoided, a molten pool has good metallurgical bonding performance, the porosity is greatly reduced, and the pore distribution tends to be uniform; meanwhile, through carrying out laser remelting scanning on each layer of metal powder, the defects formed during primary forming can be reduced, such as holes and the like caused by unmelted particles, air holes in the molten pool can be heated to escape in the melting process (and because preheating is carried out during primary laser scanning, the cooling speed of the molten pool can be obviously reduced, so that bubbles wrapped in the molten pool can escape in more enough time), the porosity of the laser melting forming part can be effectively reduced, the high density of the final forming part is realized, and the part can meet the required performance requirement. The invention has low cost, simple operation (the controller can directly control the laser parameters only by adjusting the laser parameters and does not need manual processing), and can be used in batch, therefore, the invention can promote the wide application of the laser melting molding technology in the automobile industry.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments of the present invention will be briefly introduced below, and it is obvious that the drawings in the description below are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a flow chart of a laser fusion molding method according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the present invention, there is provided a laser fusion molding method, as shown in fig. 1, the laser fusion molding method including the steps S10 to S50 of:
s10, receiving a first layer of processing instruction containing the layer number of the part to be processed, and laying a layer of alloy powder with a preset thickness; understandably, the part to be machined includes a predetermined total number of machining layers. The layer number refers to the number of layers corresponding to one of the total processing layers of the part to be processed. In the present invention, it is first necessary to process the machining data of the part to be machined, for example, the determination of the total number of machining layers and the predetermined and stored first-layer machining parameters associated with each layer number.
Further, the laying of a layer of alloy powder with a preset thickness comprises: and controlling the powder paving device to pave a layer of alloy powder, and controlling the scraper to scrape the layer of alloy powder to enable the thickness of the layer of alloy powder to be equal to the preset thickness. That is, before the layer corresponding to each layer number is processed, a layer processing instruction (for example, the first layer processing instruction) including the layer number is generated, the layer processing instruction indicates that the layer processing is started on the processing layer corresponding to the layer number, and after the controller receives the layer processing instruction, the powder spreading device (for example, the upper powder falling and powder spreading device) is controlled to start to spread a layer of alloy powder particles, and the scraper is controlled to scrape the layer of alloy powder to make the thickness of the layer of alloy powder reach the preset thickness. Preferably, the predetermined thickness is 30 to 200 μm, and in a specific embodiment, the predetermined thickness is 50 μm, and the alloy powder is an aluminum alloy (e.g., a cast aluminum alloy AlSi10 Mg) powder. The alloy powder particles are prepared by using an air atomization method.
S20, determining a first part frame area and a first entity filling area corresponding to the layer of alloy powder according to the first layer of processing parameters corresponding to the layer number; understandably, the frame region position of the first part comprises a peripheral frame and an inner frame which correspond to the part to be processed in the processing layer corresponding to the layer number; the first solid filling area refers to other areas needing laser scanning processing except the first part frame area in the processing layer. It should be understood that the positions of the first part frame region and the first entity filling region corresponding to each processing layer may be the same or different, and therefore, the pre-stored first layer processing parameters need to be called according to the layer number in the first layer processing instruction, where the positions of the first part frame region and the first entity filling region in the processing layer corresponding to the layer number are marked in the first layer processing parameters.
When the part to be processed is processed by laser melting molding, molding processing parameters and laser processing modes of a first part frame region and a first entity filling region of the part to be processed can be different (the same is true for each processing layer, and the description is omitted in the invention), so that different processing effects are realized; for example, in the subsequent step S30, the frame region of the first part is subjected to unidirectional laser scanning by using the first molding parameter, which is mainly used to improve the roughness of the outer surface of the part to be processed; in subsequent steps S40 and S50, the first entity filling region is subjected to laser scanning and laser remelting scanning according to the second forming parameter and the third forming parameter, so that the temperature field of the part to be processed in the processing process is uniformly distributed, heat accumulation in a local region is avoided, generation of pores is reduced, and the density of the finally processed part to be processed is improved.
S30, emitting a first laser beam according to a first forming parameter (wherein the first laser beam can be emitted by a first laser), and carrying out laser scanning on the first part frame region through the first laser beam; furthermore, the scanning mode of the first laser beam for performing laser scanning on the frame area of the first part is unidirectional scanning (or other scanning modes can be selected according to requirements); understandably, the first forming parameters mainly include laser power, laser scanning speed, etc., which can be determined according to the type of alloy powder and the state of the alloy powder. Understandably, the first molding parameters corresponding to each processing layer may be the same or different. Preferably, the first molding parameters include: the value range of the laser scanning speed is as follows: 200 mm/s-1600 mm/s; the value range of the laser power is as follows: 200W-1000W; the value range of the scanning interval is as follows: 20-2000 mu m; the value range of the defocusing amount is as follows: 0.1-3 mm; the value range of the circulating air volume is as follows: 0 to 80m 3 and/H. In one embodiment, the laser scanning speed is 300mm/s; laser power 275W; the scanning distance is 150 mu m; the defocusing amount is 0.1mm; the circulating air volume was 55m3/H. Understandably, the unidirectional laser scanning is performed on the frame area of the first part through the first forming parameters, and the unidirectional laser scanning is mainly used for improving the roughness of the outer surface of the part to be processed.
S40, after controlling a phase angle of a second laser beam (wherein the second laser beam can be emitted by a second laser) to deflect a first angle, emitting the second laser beam according to a second forming parameter, and performing laser scanning on the first entity filling area through the second laser beam; understandably, the alloy powder used in the invention is prepared by using an air atomization method, in the process of preparing the alloy powder by using the air atomization method, because the cooling speed is extremely high, the metal liquid drops are easy to surround gas by complex gas flow, the gas is locked into the particles under the condition of rapid cooling solidification to form hollow powder, and in the processing process, the gas in the powder particles is finally accumulated in the formed part to be processed to form pores; in the process of processing the processing layer corresponding to the layer number, heat accumulation can be caused along with the laser scanning, the temperature of a molten pool, the liquid phase time of the molten pool and the size of the molten pool tend to increase, and the cooling speed tends to decrease. When the temperature of the molten pool is relatively low, the solid solubility of the evaporated metal vapor and argon in the molten pool is low, and the solute is rapidly cooled and solidified to form a relatively small amount of air holes. However, when the temperature of the molten pool is higher, the solubility of the gas is correspondingly increased, and under the conditions of more liquid phase time and relatively lower cooling speed, the dissolved gas is precipitated by the violent molten pool convection, the gas holes can be fused with each other and escape, and along with the cooling and solidification of the molten pool, more gas holes are precipitated and retained in the molten pool, and finally more metallurgical gas holes are formed. In the process of performing layer-by-layer laser scanning on each processing layer, if a fixed laser scanning mode is adopted for each processing layer, for example, when laser phase angles of laser scanning are the same, the problems of uneven heat distribution and concentrated local areas generated by laser scanning, deformation and the like caused by large stress generated inside a part are caused, and bubbles are not beneficial to overflow uniformly (so that holes are unevenly distributed, the size of the holes is increased, and the holes are increased).
Preferably, said first angle of laser phase angle deflection of the second laser beam is not an integer divisor of 360. That is, the first angle of the specific deflection can be adjusted according to actual conditions (further, the first angle is greater than 0 ° and less than 180 °), but the main principle is to reduce the repetition rate of the laser phase angle at the same angle that may be repeated, for example, the angle of the clockwise deflection is 90 ° each time, and at this time, when the laser phase angle of the first layer is 0 °, the fifth layer will be 0 ° again, and therefore, it is not suitable that the first angle is 90 °, and therefore, preferably, the angle value of the first angle is not an integer divisor of 360 °, for example, the first angle is preferably a prime number (not an integer divisor of 360 °) in the range of 50 ° to 90 °, for example, the first angle may be 57 ° and 67 °. Specifically, the deflection of the laser phase angle of the second laser beam may be achieved by XY-axis galvanometers of the second laser, that is, after the second laser beam is incident on the XY-axis galvanometers, the reflection angles of the galvanometers are controlled by the controller, so that the two galvanometers can scan along X and Y axes respectively, thereby achieving the first angle of laser beam deflection.
Understandably, in the present invention, the first laser and the second laser may be the same laser or two different lasers (or may be two laser heads disposed on the same laser, etc.). The laser scanning mode of the second laser beam on the first entity filling area may be set according to requirements, for example, the laser scanning mode of the second laser beam on the first entity filling area is preferably raster scanning or partition scanning; the grating length of the grating type scanning, the partition length of the partition type scanning, the partition form and the like can be set according to actual needs. Understandably, the second forming parameters mainly include laser power, laser scanning speed, zone frame overlapping amount (overlapping portion of adjacent molten pool), etc., which can be determined according to the type of alloy powder and the state of the alloy powder. Understandably, the second molding parameters corresponding to each processing layer may be the same or different. Further, the second molding parameters include: the value range of the laser scanning speed is as follows: 200 mm/s-1600 mm/s; the value range of the laser power is as follows: 200W-1000W; the value range of the scanning interval is as follows: 20-2000 mu m; the value range of the defocusing amount is as follows: 0.1-3 mm; value of zone frame overlapThe range is as follows: 40-80 μm; the value range of the circulating air volume is as follows: 0 to 80m 3 and/H. In a specific embodiment, the second molding parameters include: the laser scanning speed is 1400mm/s; laser power 400W; the scanning distance is 150 mu m; the overlapping amount of the subarea frame (the overlapping part of the adjacent molten pools) is 60 mu m; the defocusing amount is 2.5mm; the circulating air volume was 55m3/H.
And S50, after controlling the phase angle of a third laser beam (wherein the third laser beam can be emitted by a third laser) to deflect a second angle, emitting the third laser beam according to a third forming parameter, and after performing laser remelting scanning on the first entity filling area through the third laser beam, confirming that the layer processing corresponding to the layer number is completed. Understandably, in the laser melting forming process, as the processing height is increased continuously, a larger heat affected zone is generated by a higher depth of a molten pool, a significant preheating effect is generated on a processing layer which is solidified before, and the retained air holes are promoted to expand and become larger. Along with the continuous accumulation of heat, the highest temperature of a molten pool is higher and higher, alloy powder forms a deeper molten pool under the thermal shock effect of laser, a large amount of metal is gasified, when the laser is turned off, a larger back-punching force is formed, most of metal liquid flows to the center of the molten pool under the action of the back-punching force, a closed lock hole is formed at the bottom of the molten pool, and in the process, metal vapor can be captured by a solidification front edge to form a nearly circular lock hole; under the subsequent heat, the air holes can expand and grow, and even float upwards and escape under the action of buoyancy effect. Therefore, in the present invention, after the processing layer is formed in the step S40 by performing laser scanning with the second laser beam, a secondary laser remelting scanning is performed in the step S50, so as to reduce defects formed during the first forming, such as holes caused by unmelted particles, and also to allow the air holes inside the molten pool to escape during the melting process (and, due to the preheating during the first laser scanning, the cooling speed of the molten pool can be significantly reduced, so that the air bubbles wrapped in the molten pool escape more sufficiently), so that the air holes inside the molten pool escape during the melting process, thereby reducing the porosity, and simultaneously, uniformly distributing the heat, and avoiding the deformation and other problems caused by the large stress generated inside the part.
In this embodiment, the remelting laser scanning path is the same as the first laser scanning path (the path of laser scanning by the second laser beam in step S40), but before laser remelting scanning is performed on each processing layer, the laser phase angle of the third laser beam is deflected by a second angle according to a preset rule (for example, each time the laser remelting scanning is performed on each processing layer), so that the temperature field distribution of the part to be processed in the laser scanning process is uniform (heat distribution is uniform), heat accumulation in a local area is avoided, generation of pores is reduced, the size of the pores is also reduced, the pore distribution tends to be uniform, in the laser remelting process, pores inside the molten pool can be heated and escape in the melting process, the molten pool has good metallurgical bonding, the porosity is greatly reduced, meanwhile, due to the preheating of the molten pool by the first scanning (laser scanning by the second laser beam in step S40), the cooling speed is significantly reduced, and the bubbles wrapped in the molten pool have enough time to escape, so as to obtain the part to be processed with high density.
Preferably, the second angle of laser phase angle deflection of the third laser beam is not an integer divisor of 360. That is, the specific second angle of deflection can be adjusted according to actual conditions (further, the second angle is greater than 0 ° and less than 180 °), but the main principle is to minimize the repetition rate of the same angle at which the laser phase angle may be repeated, and therefore, preferably, the value of the second angle is not an integer divisor of 360 degrees, for example, the second angle is preferably a prime number (not an integer divisor of 360 degrees) in the range of 50 ° to 90 °, for example, the second angle may be 57 ° or 67 °. Understandably, the second angle may be the same as or different from the first angle described above. Specifically, the deflection of the phase angle of the laser beam can be realized by the XY-axis galvanometer of the third laser, that is, after the third laser beam enters the XY-axis galvanometer, the controller controls the reflection angle of the galvanometer, so that the two galvanometers can scan along the X axis and the Y axis respectively, thereby achieving the second angle of laser beam deflection.
In the present invention, the third laser and the second laser may be the same laser or two different lasers (or may be two laser heads disposed on the same laser, etc.). Thus, three lasers can be classified into the following cases:
when the third laser, the first laser and the second laser are different lasers, the deflection of the phase angle of the third laser beam each time is not associated with the laser phase angle of the second laser beam or the second laser beam, that is, the phase angles of the three laser beams are independently adjusted, and the first angle is adjusted only on the basis of the phase angle of the second laser beam finally corresponding to the upper processing layer in the step S40; in step S50, the second angle is adjusted only based on the phase angle of the third laser beam finally corresponding to the previous processing layer.
When the second laser and the third laser are the same laser (the two lasers are not the same as the first laser), each time of deflection of the phase angle of the third laser beam is associated with the laser phase angle of the second laser beam, and each time of deflection of the phase angle of the second laser beam is also associated with the laser phase angle of the third laser beam; that is, in step S40, the current layer (the processing layer corresponding to the layer number) is adjusted by the first angle based on the phase angle of the third laser beam (i.e., the second laser beam) finally corresponding to the previous processing layer; in step S50, the second angle is adjusted based on the laser phase angle of the second laser beam (i.e. the third laser beam) after the laser scanning in step S40 is completed (i.e. based on the phase angle after the first angle has been deflected). Understandably, when the third laser and the second laser are the same laser, the adjustment of the laser phase angle is continuously performed, that is, the phase angle of the laser beam is firstly deflected by a first angle (for example, the laser phase angle is deflected by a first angle 57 ° from 0 °) in step S40, and then the laser phase angle is continuously deflected by a second angle (for example, the laser phase angle is 124 ° after the laser phase angle is deflected by a second angle 67 ° from 57 °) on the basis of the first angle in step S50. Further, when the third laser and the second laser are the same laser, at this time, the sum of the angle values of the first angle and the second angle is not an integer divisor of 360, so that it can be ensured that the repetition rate of the laser phase angle at the same angle is low. It is understood that the above-described deflection of the phase angle in the continuous correlation between the phase angles of the previous processed layer and the present layer can achieve uniform heat distribution, and can avoid the problems such as deformation due to large stress generated in the part while uniformly distributing the heat.
When the first laser, the second laser and the third laser are the same laser, the deflection of the phase angles of the laser beams of the three lasers are related to each other; that is, in step S40, the first angle is adjusted based on the laser phase angle of the first laser beam (i.e., the second laser beam) after the laser scanning of step S30 is completed in the present layer (the processing layer corresponding to the layer number). In step S50, the second angle is adjusted based on the laser phase angle of the second laser beam (i.e., the third laser beam) after the laser scanning in step S40 in this layer is completed (i.e., based on the phase angle after the first angle has been deflected).
When the third laser and the first laser are the same laser (and the second laser is not the same laser), each time the phase angle of the third laser beam is deflected, the deflection is associated with the laser phase angle of the first laser beam, but not associated with the laser phase angle of the second laser beam; that is, in step S40, the first angle is adjusted only based on the phase angle of the second laser beam finally corresponding to the previous processing layer. In step S50, the second angle is adjusted based on the laser phase angle of the first laser beam (i.e., the third laser beam) after the laser scanning is completed in step S30 in the present layer (the processing layer corresponding to the layer number).
When the second laser and the first laser are the same laser (and the second laser is not the same as the third laser), each time the phase angle of the second laser beam is deflected, the deflection is associated with the laser phase angle of the first laser beam, but not associated with the laser phase angle of the third laser beam; that is, in step S40, the first angle is adjusted only on the basis of the laser phase angle of the first laser beam (that is, the second laser beam) after the laser scanning in step S30 is completed in the present layer (the processing layer corresponding to the layer number). In step S50, the second angle is adjusted only based on the phase angle of the third laser beam finally corresponding to the previous processing layer.
The mode of performing laser remelting scanning on the first entity filling area by the third laser beam may be set according to requirements, for example, the mode of performing laser remelting scanning on the first entity filling area by the third laser beam is preferably raster scanning or partition scanning; the grating length of the grating type scanning, the partition length of the partition type scanning, the partition form and the like can be set according to actual needs. Specifically, the laser remelting scanning mode of the third laser beam on the first solid filling area is generally regular polygonal partition scanning, and the width of a single partition is generally 8mm, that is, first, a cross section to be remelted is uniformly partitioned according to the actual size of the part to be processed, for example, when the laser phase angle is 124 °, the first solid filling area is partitioned along the X direction by 124 ° according to the size of 80mm × 80mm. Understandably, the third forming parameters mainly include laser power, laser scanning speed, zone frame overlapping amount (overlapping portion of adjacent molten pools), etc., which can be determined according to the type of alloy powder and the state of the alloy powder. Understandably, the third molding parameters corresponding to each processing layer may be the same or different. Further, the third forming parameters include: the value range of the laser scanning speed is as follows: 200 mm/s-1600 mm/s; the value range of the laser power is as follows: 200W-1000W; the value range of the scanning interval is as follows: 20-2000 mu m; the value range of the defocusing amount is as follows: 0.1-3 mm; the value range of the overlap joint quantity of the partitioned frame is as follows: 40-80 μm; the value range of the circulating air volume is as follows: 0 to 80m 3 And H is (c). In a specific embodiment, the third forming parameters include: the laser scanning speed is 1400mm/s; laser power 400W; the scanning distance is 150 mu m; the lapping amount of the partitioned frame is 60 mu m; the defocusing amount is 2.5mm; circulating air volume of 55m 3 and/H. In the laser remelting scanning process, the remelting lines are ensured to be uniformly distributed, and the remelting lines among all the subarea areas are connected without disconnection.
In an embodiment, in the step S50, after the confirming that the layer processing corresponding to the layer number is completed, the method further includes:
and when the layer number is equal to the total processing layer number of the part to be processed, determining that the part to be processed is processed. That is, when the layer number is equal to the total number of layers to be processed of the part to be processed, it indicates that the part to be processed has been processed, and at this time, the laser scanning of all the laser beams may be stopped to prompt that the part to be processed has been processed. And when the layer number is smaller than the total processing layer number of the part to be processed, indicating that the part to be processed is not processed, and at the moment, continuing to process the layer of the next processing layer.
According to the invention, laser scanning is carried out on different areas (such as a first part frame area and a first entity filling area) through different forming parameters, so that the processing requirements of different processing areas can be met in the processing process of the part to be processed; when the first entity filling area of each layer is subjected to laser scanning, the phase angle of the second laser beam deflects by a first angle according to a certain rule, so that the heat distribution during laser scanning processing is more uniform; meanwhile, when the laser remelting scanning is carried out on the first entity filling area of each layer, the phase angle of the third laser beam is deflected by a second angle according to a certain rule, so that the heat distribution during the laser remelting scanning is more uniform, the heat distribution during the laser scanning is uniform, the heat accumulation of a local area can be avoided, a molten pool has good metallurgical bonding performance, the porosity is greatly reduced, and the pore distribution tends to be uniform; meanwhile, through carrying out laser remelting scanning on each layer of metal powder, air holes in the molten pool can be heated and escaped in the melting process (and due to preheating during laser scanning for the first time, the cooling speed of the molten pool can be obviously reduced, so that bubbles wrapped in the molten pool have more sufficient time to escape), thereby effectively reducing the porosity of the part to be processed formed through laser melting, realizing the high density of the part to be processed which is finally formed, and further enabling the part to be processed to meet the required performance requirement. The invention has low cost and simple operation (the laser parameters can be directly controlled by the controller only by adjusting and manual processing is not needed), and can be used in batch, therefore, the invention can promote the wide application of the laser melting molding technology in the automobile industry.
In an embodiment, after confirming that the layer processing corresponding to the layer number is completed, the step S50 further includes:
when the layer number is confirmed to be smaller than the total processing layer number of the part to be processed, receiving a second layer of processing instruction containing the next layer number, and laying a layer of alloy powder with the preset thickness; the total processing layer number refers to the total layer number of the parts to be processed which are required to be processed by laser scanning, and when the layer number is smaller than the total processing layer number of the parts to be processed, the parts to be processed are not processed, and at the moment, layer processing of the next processing layer is required to be continued. Wherein, the next layer number is the layer number adjacent to and behind the layer number in the step S10 in the total processing layer number. After the controller receives the second layer of processing instruction, the controller instructs to start layer processing on the processing layer corresponding to the next layer number, namely, the powder paving device is controlled to start paving a layer of alloy powder particles, and the scraper is controlled to scrape the layer of alloy powder to enable the thickness of the layer of alloy powder to reach the preset thickness.
Determining a second part frame area and a second entity filling area corresponding to the layer of alloy powder according to the second layer of processing parameters corresponding to the next layer number; the frame region position of the second part comprises a peripheral frame and an inner frame which correspond to the part to be processed in the processing layer corresponding to the next layer number; and the second solid filling area refers to other areas needing laser scanning processing except for the second part frame area in the processing layer. Understandably, the first part bounding region and the first entity filling region may be the same as or different from the second part bounding region and the second entity filling region, and therefore, the pre-stored second layer processing parameters need to be called according to the next layer number in the second layer processing instruction.
Emitting a first laser beam according to a first forming parameter, and carrying out laser scanning on the frame area of the second part through the first laser beam; further, the scanning mode of the first laser beam for scanning the second part frame region (and the part frame regions of all other processing layers are the same) is unidirectional scanning; as can be seen from the above, the first molding parameters preferably include: the laser scanning speed is 300mm/s; laser power 275W; the scanning distance is 150 mu m; the defocusing amount is 0.1mm; circulating air volume is 55m3/H. However, in the present invention, the first forming parameter of each layer may also be changed as required, that is, the first forming parameter may also be adjusted to meet different processing requirements while increasing the roughness of the outer surface of the part to be processed.
After the phase angle of a second laser beam is controlled to deflect a first angle, the second laser beam is emitted according to a second forming parameter, and laser scanning is carried out on the second entity filling area through the second laser beam; that is, before laser scanning is performed on the processing layer corresponding to the next layer number, the laser phase angle of the second laser beam is deflected by a first angle according to a preset rule (for example, the laser phase angle is deflected towards the same direction every time), so that the temperature field of the part to be processed in the laser scanning process is uniformly distributed (heat distribution is uniform), heat accumulation in a local area is avoided, the generation of pores is reduced, the size of the pores is also reduced, and the density of the part to be processed is improved. In the invention, in order to meet different processing requirements, the second forming parameter of each layer can be adjusted according to the requirements.
After the phase angle of a third laser beam is controlled to deflect a second angle, the third laser beam is emitted according to a third forming parameter, and after laser remelting scanning is carried out on the first entity filling area through the third laser beam, layer processing corresponding to the next layer number is confirmed to be completed; that is, after the cross section of the processing layer corresponding to the next layer number is formed by performing laser scanning through the second laser beam in the above step, secondary laser remelting scanning needs to be performed continuously in the step, so that the air holes in the molten pool are heated and escaped in the melting process, and the porosity is reduced. In this embodiment, the remelting laser scanning path is the same as the laser scanning path performed by the second laser beam, but the laser phase angle of the third laser beam is deflected by a second angle according to a preset rule (for example, each time the laser phase angle is deflected towards the same direction), so that the temperature field distribution of the part to be processed in the laser scanning process is uniform (the heat distribution is uniform), the heat accumulation in a local area is avoided, the generation of pores is reduced, the size of the gaps is also reduced, the pore distribution tends to be uniform, in the laser remelting process, pores in the molten pool can be heated and escaped in the melting process, the molten pool has good metallurgical bonding, the porosity is greatly reduced, meanwhile, due to the preheating performed by the second laser beam, the cooling speed of the molten pool is significantly reduced, and bubbles wrapped in the molten pool have enough time to escape, so that the part to be processed with high density is obtained. In the invention, in order to meet different processing requirements, the third forming parameter of each layer can be adjusted according to the requirements.
And when the next layer number is confirmed to be equal to the total processing layer number of the part to be processed, confirming that the part to be processed is processed. That is, when the next layer number is equal to the total number of layers to be processed of the part to be processed, it indicates that the part to be processed has been processed, and at this time, the laser scanning of all the laser beams may be stopped to prompt that the part to be processed has been processed.
In one embodiment, a laser melt molding system is provided that includes a controller for performing the above-described laser melt molding method. Understandably, the controller is installed in a laser melt molding system. The specific definition of the controller can be referred to the definition of the laser melting forming method, and is not described herein again. The various modules in the controller described above may be implemented in whole or in part by software, hardware, and combinations thereof. The modules can be embedded in a hardware form or independent from the laser melting molding system, and can also be stored in a storage device in the laser melting molding system in a software form, so as to be called to execute the corresponding operations of the modules.
It will be apparent to those skilled in the art that the internal structure of the controller may be divided into different functional units or modules as required to complete all or part of the functions described above. The above-mentioned embodiments are only used for illustrating the technical solutions of the present invention, and not for limiting the same; although the present invention has been described in detail with reference to the foregoing embodiments, it should be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; such modifications and substitutions do not substantially depart from the spirit and scope of the embodiments of the present invention, and are intended to be included within the scope of the present invention.
Claims (10)
1. A laser fusion molding method, comprising:
receiving a first layer of processing instruction containing the layer number of the part to be processed, and laying a layer of alloy powder with a preset thickness;
determining a first part frame area and a first entity filling area corresponding to the layer of alloy powder according to the first layer processing parameter corresponding to the layer number;
emitting a first laser beam according to a first forming parameter, and carrying out laser scanning on the frame area of the first part through the first laser beam;
after the phase angle of a second laser beam is controlled to deflect a first angle, the second laser beam is emitted according to a second forming parameter, and the first entity filling area is subjected to laser scanning through the second laser beam;
and after controlling the phase angle of the third laser beam to deflect a second angle, emitting the third laser beam according to a third forming parameter, and after carrying out laser remelting scanning on the first entity filling area through the third laser beam, confirming that the layer processing corresponding to the layer number is finished.
2. The laser fusion forming method of claim 1, further comprising, after confirming that the layer process corresponding to the layer number is completed:
when the layer number is confirmed to be smaller than the total processing layer number of the part to be processed, receiving a second layer of processing instruction containing the next layer number, and laying a layer of alloy powder with the preset thickness;
determining a second part frame area and a second entity filling area corresponding to the layer of alloy powder according to the second layer of processing parameters corresponding to the next layer number;
emitting a first laser beam according to a first forming parameter, and carrying out laser scanning on the frame area of the second part through the first laser beam;
after the phase angle of a second laser beam is controlled to deflect a first angle, the second laser beam is emitted according to a second forming parameter, and the second entity filling area is subjected to laser scanning through the second laser beam;
after controlling the phase angle of a third laser beam to deflect a second angle, emitting the third laser beam according to a third forming parameter, and confirming that the layer corresponding to the next layer number is processed after performing laser remelting scanning on the first entity filling area through the third laser beam;
and confirming that the machining of the part to be machined is finished when the next layer number is equal to the total machining layer number of the part to be machined.
3. The laser fusion forming method of claim 2, wherein confirming that the layer corresponding to the layer number is processed is completed, further comprises:
and when the layer number is confirmed to be equal to the total processing layer number of the part to be processed, confirming that the part to be processed is processed.
4. The laser melt molding method according to claim 1, wherein the first molding parameters include:
the value range of the laser scanning speed is as follows: 200 mm/s-1600 mm/s;
the value range of the laser power is as follows: 200W-1000W;
the value range of the scanning interval is as follows: 20-2000 mu m;
the value range of the defocusing amount is as follows: 0.1-3 mm;
the value range of the circulating air volume is as follows: 0 to 80m 3 /H。
5. The laser melt molding method according to claim 1, wherein the second molding parameters include:
the value range of the laser scanning speed is as follows: 200 mm/s-1600 mm/s;
the value range of the laser power is as follows: 200W-1000W;
the value range of the scanning interval is as follows: 20-2000 μm;
the value range of the defocusing amount is as follows: 0.1-3 mm;
the value range of the overlap joint quantity of the frame of the subarea is as follows: 40-80 μm;
the value range of the circulating air volume is as follows: 0 to 80m 3 /H。
6. The laser fusion molding method of claim 1 wherein the third molding parameters include:
the value range of the laser scanning speed is as follows: 200 mm/s-1600 mm/s;
the value range of the laser power is as follows: 200W-1000W;
the value range of the scanning interval is as follows: 20-2000 mu m;
the value range of the defocusing amount is as follows: 0.1-3 mm;
the value range of the overlap joint quantity of the frame of the subarea is as follows: 40-80 μm;
the value range of the circulating air volume is as follows: 0 to 80m 3 /H。
7. The laser fusion forming method of claim 1 wherein the predetermined thickness is 30 to 200 μm; the alloy powder is aluminum alloy powder.
8. The laser fusion forming method of claim 1, wherein the scanning mode of the first laser beam to perform laser scanning on the first part frame area is unidirectional scanning; the laser scanning mode of the second laser beam on the first entity filling area is raster scanning or subarea scanning;
the laser remelting scanning mode of the third laser beam on the first entity filling area is raster scanning or partition scanning.
9. The laser fusion forming method of claim 1 wherein the laying of a layer of alloy powder of a predetermined thickness comprises:
and controlling the powder paving device to pave a layer of alloy powder, and controlling the scraper to scrape the layer of alloy powder to enable the thickness of the layer of alloy powder to be equal to the preset thickness.
10. A laser melt molding system comprising a controller for performing the laser melt molding method of any one of claims 1 to 9.
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