CN115365513A - Easy-to-remove support structure for SLM (Selective laser melting) forming and preparation method and application thereof - Google Patents
Easy-to-remove support structure for SLM (Selective laser melting) forming and preparation method and application thereof Download PDFInfo
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- CN115365513A CN115365513A CN202210993434.0A CN202210993434A CN115365513A CN 115365513 A CN115365513 A CN 115365513A CN 202210993434 A CN202210993434 A CN 202210993434A CN 115365513 A CN115365513 A CN 115365513A
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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
- B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
- B22F10/47—Structures for supporting workpieces or articles during manufacture and removed afterwards characterised by structural features
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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
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
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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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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Powder Metallurgy (AREA)
Abstract
The invention belongs to the technical field of selective laser melting and discloses an easily-removed support structure for SLM (Selective laser melting) and a preparation method and application thereof, wherein the support structure comprises a support block and a powder interlayer formed between a forming piece and the support block when the support structure is used, and the powder interlayer is laid by metal powder and is used for isolating the forming piece from the support block; the support structure is formed during the fabrication of the shaped piece. The support structure and the forming part are prepared together, any other redundant design is not needed, the support structure and the forming part are easy to realize and generate in the processing process, and the cost is reduced; the supporting structure is simple, only the printing process needs to be properly adjusted in the actual use process, the design flow of the supporting part with the complex structure can be simplified, and the cost is saved.
Description
Technical Field
The invention belongs to the technical field of selective laser melting, and particularly relates to an easily-removed support structure for SLM (selective laser melting) forming, and a preparation method and application thereof.
Background
An Additive Manufacturing (AM), also called a 3D printing technology, divides a three-dimensional object into two-dimensional planes, performs layer-to-layer forming, fuses multidisciplinary knowledge of materials, computers, machinery and the like, and particularly, a Manufacturing process of stacking discrete materials layer by layer can realize integration of material preparation and structure forming, which is an effective way for Manufacturing complex high-performance parts. The Selective Laser Melting (SLM) technology uses a Laser beam as a moving heat source, and rapidly melts and solidifies metal powder by selectively scanning a specific region, then spreads a thin metal powder layer on a forming surface, and continuously repeats the above steps, and finally forms a final forming member by Melting and stacking layer by layer. Because the laser selective melting forming metal material does not need a tooling die and a clamp, the laser selective melting forming metal material is hardly restricted by the complexity of parts, and the laser selective melting forming metal material has high forming precision, short processing period and excellent mechanical property of formed parts, and has wide application prospect in the fields of aerospace, automobile manufacturing, biomedical treatment, industrial production and the like.
With the development of science and technology, the current parts tend to be more complex and multifunctional, and the internal structure usually comprises a complex and changeable structure such as a suspension plane, an inner flow passage, a hole and a thin-wall part. Although the SLM technology can theoretically form any complex shape, when laser is melted and formed in a powder bed, if the current layer is larger than the cross section area of the previous layer, that is, an overhanging surface appears, the epitaxial part is easy to drop slag and collapse in the forming process due to no support constraint of a casting mold and a mold, and serious deformation and even forming failure occur. Good support design is required to restrain the deformation of the part and ensure the stability of the forming process.
On one hand, the SLM supporting structure needs to ensure that deformation and collapse do not occur in the forming process, and on the other hand, the strength cannot be too high, so that the SLM supporting structure cannot be removed or is difficult to remove. At present, most supports for SLM printing are porous and mesh-shaped support structures, and after forming, the supports are removed through machining and a surface grinding method is used for ensuring a forming surface. And the support at some tiny internal flow passages and hole structures is difficult to remove, and the formed piece is easy to damage. Therefore, it is necessary to design an easily removable support structure for SLM forming, which improves the efficiency and accuracy of support removal on the basis of ensuring the printing quality.
Disclosure of Invention
Aiming at the defects or improvement requirements of the prior art, the invention provides an easily-removed support structure for SLM forming and a preparation method and application thereof, wherein metal powder is used as a support interlayer to separate a formed part from a support block, the metal block partially surrounded by a powder layer is used as a support body, the support structure can be directly removed after printing is finished, machining and surface treatment are not needed, the support structure is ensured not to influence the quality of the formed part, the quick removal of the SLM forming support structure can be realized, and the problems of difficult support removal and poor support surface precision in the existing SLM forming process are solved.
To achieve the above object, according to one aspect of the present invention, there is provided an easy-to-remove support structure for SLM forming, the support structure comprising a support block and a powder barrier layer formed between a shaped piece and the support block when the support structure is in use, the powder barrier layer being laid out of metal powder and used for isolating the shaped piece from the support block; the support structure is formed during the fabrication of the shaped piece.
Furthermore, the thickness of the powder interlayer is 0.08-0.4 mm.
Further, the particle size of the metal powder is 15 to 53 μm.
Further, the sphericity of the metal powder is greater than 0.8.
Further, the fluidity of the metal powder is more than 10s/50g.
Further, the loose packed density of the metal powder is more than 55% of the compact material, and the tap density is more than 62% of the compact material.
Further, the metal powder contains a hollow powder containing an involved gas in a proportion of 1% or less.
Further, the support block is formed by the same forming process as the forming piece.
The invention also provides a preparation method of the easy-to-remove support structure for SLM forming, which is used for preparing the easy-to-remove support structure for SLM forming.
The invention also provides the use of an easy-to-remove support structure for SLM shaping as described above in the preparation of a shaped piece using an SLM, comprising the steps of:
(1) Slicing the integral three-dimensional model, and dividing the integral three-dimensional model into a forming area and a non-forming area; the integral three-dimensional model comprises a three-dimensional model of a to-be-formed piece and a three-dimensional model of the supporting structure arranged in the three-dimensional model of the to-be-formed piece, the areas corresponding to the powder interlayer are non-forming areas, and the areas corresponding to the to-be-formed piece and the supporting block are forming areas;
(2) Performing selective laser melting forming, wherein laser beams only scan the powder in a forming area to melt and solidify the corresponding powder, and the metal powder paved in a non-forming area is not scanned by the laser beams;
(3) And directly separating the support structure from the formed part after selective laser melting forming so as to obtain the formed part.
Generally, compared with the prior art, the easy-to-remove support structure for SLM forming and the preparation method and application thereof provided by the invention mainly have the following beneficial effects:
1. the support structure of the invention is prepared together with the shaped piece without any other redundant design, is easy to realize and generate in the processing process, and reduces the cost.
2. Be provided with the powder interlayer between support block and the forming piece, the powder interlayer is laid by metal powder and is formed, has realized keeping apart between support block and the forming piece from this, directly takes out the supporting shoe body from the forming piece after using the completion to the powder that will form the powder interlayer is clear away, need not to have directly taken out the support through processing such as follow-up machining, and has guaranteed that the supporting surface has higher precision.
3. The support structure is simple, only the printing process needs to be properly adjusted in the actual use process, the design flow of the support part with the complex structure can be simplified, and the cost is saved.
Drawings
Fig. 1 is a schematic diagram of a usage state of an easy-to-remove support structure for SLM shaping provided by the present invention.
The same reference numbers will be used throughout the drawings to refer to the same or like elements or structures, wherein: 1-forming piece, 2-supporting block and 3-powder interlayer.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and do not limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
Referring to fig. 1, the present invention provides an easy-to-remove support structure for SLM forming, the support structure includes a support block 2 and a powder isolation layer 3 formed between a forming member 1 and the support block 2 when the support structure is used, the powder isolation layer 3 is formed by laying metal powder; the support structure is formed during the production of the shaped piece 1, i.e. the support structure is produced together with the shaped piece 1. When the support structure is used, the support block 2 is located inside the forming member 1.
In the embodiment, the thickness of the powder interlayer 3 is 0.08-0.4 mm, so that the powder interlayer and the formed piece are not bonded or slide.
The powder particle size range adopted by the powder interlayer 3 is 15-53 mu m, so that the spheroidization and agglomeration phenomena in the printing process are reduced, the surface smoothness is higher, and the consistency and uniformity of printing can be fully guaranteed.
The sphericity of the powder adopted by the powder interlayer 3 is greater than 0.8, so that the powder is uniformly spread, and the density of the printing component is improved. The powder fluidity adopted by the powder interlayer 3 is more than 10s/50g, and the SLM forming powder laying requirement is met.
The loose packing density of the powder adopted by the powder interlayer 3 is more than 55% of the compact material of the powder interlayer, and the tap density is more than 62% of the compact material of the powder interlayer, so that the high compactness of the formed member is ensured.
The powder used by the powder interlayer 3 requires that the proportion of the hollow powder containing the involved gas is not more than 1 percent so as to reduce the defects of air gaps, involved and precipitated air holes, cracks and the like formed in the printing process.
The supporting block 2 adopts the same forming process as the forming piece 1, and the state of the supporting block 2 is the same as that of the forming piece 1.
The present invention will be described in further detail below with reference to several embodiments.
Example 1
The raw material for printing is GH3536 nickel-based superalloy powder, and the schematic structure of the embodiment is shown in FIG. 1, and the structure has two cantilever beams, wherein the bottom beam field is 50mm, the beam height is 10mm, the two upper beams are 15mm in length, the beam height is 8mm, and the beam width is 10mm. The distance between the overhanging surfaces is too large, and a supporting structure needs to be arranged between the two surfaces, so that the situations of deformation, collapse and the like in the printing process are prevented.
The use and preparation of the support structure comprises the following steps:
step S1: selecting GH3536 powder with the powder density of 8.32g/cm 3 The particle size range is 21.5-59.7 μm, the fluidity is 16.7s/50g, and the loose density and the compact density are 4.689 and 5.4832g/cm respectively 3 The sphericity was 0.91, and no hollow powder defect was observed.
Step S1: the technological parameters of the selected forming entity are laser power 240W, scanning speed 600mm/s, scanning interval 100 μm and powder layer thickness 40 μm.
Step S2: a powder layer with the thickness of 0.20mm (five layers thick) is laid on the surface of the forming piece to be supported, and the powder layer is used as a separation layer between the forming piece and the support block body, so that the support is convenient to remove.
Step S2: printing a support block on the powder layer, and selecting forming parameters of a phase diagram of a formed solid: the laser power is 240W, the scanning speed is 600mm/s, the scanning distance is 0.1mm, and the powder layer thickness is 0.04mm. And a powder interlayer is ensured between the support block and the forming piece.
And step S3: a powder interlayer with the thickness of 0.20mm (five layers thick) is paved above the support block body.
And step S4: and (3) continuously printing the forming piece entity of the upper layer on the powder interlayer, wherein the forming parameters are kept unchanged: the laser power is 240W, the scanning speed is 600mm/s, the scanning interval is 0.1mm, and the powder layer spreading thickness is 0.04mm.
Above-mentioned bearing structure is after printing, has the one deck powder interlayer between support block and the forming part, can directly get rid of, and gets rid of bearing structure back supporting surface precision height, need not to carry out surface treatment, has guaranteed the forming part quality and has improved work efficiency.
Comparative example 1
This comparative example used the same support structure design method as example 1, except that the thickness of the powder barrier was 0.06mm.
Since the powder barrier is too thin, the laser melts it during scanning, causing the support mass to bond with the form. After the forming is finished, the block support and the forming piece are not separated, and the block support and the forming piece are still required to be subjected to post-processing machining for being taken out.
Comparative example 2
This comparative example used the same support structure design method as example 1, except that the thickness of the powder barrier was 0.5mm.
Because the powder interlayer is too thick, the gap is too large, and the middle block body is easy to slide during the printing process, so that the printing quality and the supporting effect are influenced.
The invention also provides a preparation method of the easy-to-remove support structure for SLM forming, and simultaneously provides application of the easy-to-remove support structure for SLM forming in preparation of a formed part by SLM, wherein the support structure and the formed part are prepared together. The application specifically comprises the following steps:
step one, establishing a three-dimensional model of a to-be-formed piece, and adding the three-dimensional model of the supporting structure in the three-dimensional model of the to-be-formed piece to obtain an integral three-dimensional model.
And secondly, slicing the integral three-dimensional model, and setting a forming area and a non-forming area, wherein the areas corresponding to the powder interlayer are the non-forming areas, and the areas corresponding to the to-be-formed piece and the support block are the forming areas.
Setting forming process parameters, and carrying out selective laser melting forming under the protection of inert gas, wherein the powder laid by the forming area is the material of the to-be-formed piece, the material laid by the non-forming area is metal powder, the laser beam only scans the powder positioned in the forming area to melt and solidify the corresponding powder, and the non-forming area only lays the metal powder and does not adopt the laser beam to scan.
And fourthly, after selective laser melting and forming, drawing the support structure away from the forming piece, and removing metal powder to obtain the forming piece.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (10)
1. An easy-to-remove support structure for SLM forming, characterized by:
the supporting structure comprises a supporting block body and a powder interlayer formed between a forming piece and the supporting block body when the supporting structure is used, wherein the powder interlayer is formed by laying metal powder and is used for isolating the forming piece from the supporting block body; the support structure is formed during the fabrication of the shaped piece.
2. The easy-to-remove support structure for SLM shaping as claimed in claim 1 wherein: the thickness of the powder interlayer is 0.08 mm-0.4 mm.
3. The easy-to-remove support structure for SLM shaping as claimed in claim 1 wherein: the particle size of the metal powder is 15-53 mu m.
4. The easy-to-remove support structure for SLM shaping as claimed in claim 1 wherein: the sphericity of the metal powder is greater than 0.8.
5. An easy-to-remove support structure for SLM shaping as claimed in any one of claims 1-4, characterized in that: the flowability of the metal powder is greater than 10s/50g.
6. Easy-to-remove support structure for SLM forming as claimed in any one of the claims 1-4, characterized in that: the loose packing density of the metal powder is more than 55% of the compact material, and the tap density is more than 62% of the compact material.
7. An easy-to-remove support structure for SLM shaping as claimed in any one of claims 1-4, characterized in that: the metal powder contains a hollow powder of an entraining gas in a proportion of 1% or less.
8. Easy-to-remove support structure for SLM forming as claimed in any one of the claims 1-4, characterized in that: the support block is formed by the same forming process as the forming piece.
9. A method of making an easy-to-remove support structure for SLM forming, characterized by: the manufacturing method is used for manufacturing the easy-to-remove support structure for SLM shaping as claimed in any one of claims 1 to 8.
10. Use of an easy-to-remove support structure for SLM shaping according to any one of claims 1-8 in the preparation of shaped parts using SLMs, characterized in that: the application comprises the following steps:
(1) Slicing the integral three-dimensional model, and dividing the integral three-dimensional model into a forming area and a non-forming area; the integral three-dimensional model comprises a three-dimensional model of a to-be-formed piece and a three-dimensional model of the supporting structure arranged in the three-dimensional model of the to-be-formed piece, areas corresponding to the powder interlayer are non-forming areas, and areas corresponding to the to-be-formed piece and the supporting block are forming areas;
(2) Performing selective laser melting forming, wherein laser beams only scan the powder in a forming area to melt and solidify the corresponding powder, and the metal powder paved in a non-forming area is not scanned by the laser beams;
(3) And directly separating the support structure from the formed part after selective laser melting forming so as to obtain the formed part.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210993434.0A CN115365513A (en) | 2022-08-18 | 2022-08-18 | Easy-to-remove support structure for SLM (Selective laser melting) forming and preparation method and application thereof |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202210993434.0A CN115365513A (en) | 2022-08-18 | 2022-08-18 | Easy-to-remove support structure for SLM (Selective laser melting) forming and preparation method and application thereof |
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| CN115365513A true CN115365513A (en) | 2022-11-22 |
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Citations (6)
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|---|---|---|---|---|
| CN102971099A (en) * | 2010-07-01 | 2013-03-13 | 斯奈克玛 | Process for manufacturing a metal part by selectively melting a powder |
| WO2019226815A1 (en) * | 2018-05-22 | 2019-11-28 | Markforged, Inc. | Sinterable separation material in additive manufacturing |
| US20200108441A1 (en) * | 2018-10-03 | 2020-04-09 | Rolls-Royce Power Engineering Plc | Manufacturing method |
| CN111360253A (en) * | 2020-03-17 | 2020-07-03 | 苏州复浩三维科技有限公司 | 3D printing support removing method |
| CN113976914A (en) * | 2021-11-14 | 2022-01-28 | 中国航发沈阳黎明航空发动机有限责任公司 | Selective laser melting forming process based on control surface bionic structure |
| CN114749682A (en) * | 2022-04-07 | 2022-07-15 | 中国第一汽车股份有限公司 | Isolation material, metal 3D printing part and preparation method thereof |
-
2022
- 2022-08-18 CN CN202210993434.0A patent/CN115365513A/en active Pending
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| CN102971099A (en) * | 2010-07-01 | 2013-03-13 | 斯奈克玛 | Process for manufacturing a metal part by selectively melting a powder |
| WO2019226815A1 (en) * | 2018-05-22 | 2019-11-28 | Markforged, Inc. | Sinterable separation material in additive manufacturing |
| US20200108441A1 (en) * | 2018-10-03 | 2020-04-09 | Rolls-Royce Power Engineering Plc | Manufacturing method |
| CN111360253A (en) * | 2020-03-17 | 2020-07-03 | 苏州复浩三维科技有限公司 | 3D printing support removing method |
| CN113976914A (en) * | 2021-11-14 | 2022-01-28 | 中国航发沈阳黎明航空发动机有限责任公司 | Selective laser melting forming process based on control surface bionic structure |
| CN114749682A (en) * | 2022-04-07 | 2022-07-15 | 中国第一汽车股份有限公司 | Isolation material, metal 3D printing part and preparation method thereof |
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