CN115889810A - Selective laser melting forming deformation control technology for thin-wall closely-arranged runner component - Google Patents
Selective laser melting forming deformation control technology for thin-wall closely-arranged runner component Download PDFInfo
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- CN115889810A CN115889810A CN202211339082.3A CN202211339082A CN115889810A CN 115889810 A CN115889810 A CN 115889810A CN 202211339082 A CN202211339082 A CN 202211339082A CN 115889810 A CN115889810 A CN 115889810A
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- 238000002844 melting Methods 0.000 title claims abstract description 29
- 230000008018 melting Effects 0.000 title claims abstract description 29
- 238000005516 engineering process Methods 0.000 title description 7
- 239000007921 spray Substances 0.000 claims abstract description 71
- 238000000034 method Methods 0.000 claims abstract description 57
- 230000007704 transition Effects 0.000 claims abstract description 49
- 230000008569 process Effects 0.000 claims abstract description 39
- 239000000758 substrate Substances 0.000 claims abstract description 18
- 238000004519 manufacturing process Methods 0.000 abstract description 15
- 238000012938 design process Methods 0.000 abstract description 2
- 230000035882 stress Effects 0.000 description 11
- 238000010586 diagram Methods 0.000 description 5
- 239000010410 layer Substances 0.000 description 5
- 238000003466 welding Methods 0.000 description 5
- 238000005336 cracking Methods 0.000 description 4
- 238000005304 joining Methods 0.000 description 3
- 238000001816 cooling Methods 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 230000008646 thermal stress Effects 0.000 description 2
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000001172 regenerating effect Effects 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
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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 application relates to the field of selective laser melting and forming, and particularly discloses a selective laser melting and forming method, which comprises the following steps: processing a transition connection area on the substrate through a selective laser melting forming process; processing the transition connection area to obtain a spray pipe through a selective laser melting forming process, wherein the thickness of the transition connection area corresponds to the axial height of the spray pipe; after the nozzle has been machined, the transition region is removed from the nozzle. The method further comprises the following steps: in the process of processing the spray pipe through the selective laser melting forming process, a support structure is processed in an inner cavity of the spray pipe and is connected with the inner wall of the spray pipe; after the nozzle is machined, the support structure is removed from the nozzle. Aiming at the technical problem of large deformation, the method adopts a design process fillet to reduce the stress of a part-substrate joint surface and adopts a hierarchical array axisymmetric conformal inner support structure to control the structural deformation, so that the high-precision manufacturing of the part is realized.
Description
Technical Field
The application relates to the technical field of selective laser melting forming, in particular to a selective laser melting forming deformation control technology for a thin-wall closely-spaced runner component.
Background
The nozzle is used for ensuring the specific impulse performance of the rocket engine and is one of key parts influencing the success or failure of the engine. The jet pipe is used in engine to expand the high temperature and high pressure gas produced in the combustion chamber and jet out at high speed to produce thrust. The inner wall of the spray pipe bears high temperature (up to 3000 ℃), vibration and high speed (several times of factors) gas heat washing, and the working condition is extremely severe. In order to ensure the stable operation of the nozzle under the high-temperature working condition, most of the existing rocket engine nozzles adopt a regenerative cooling structure, and fuel is introduced into an interlayer to cool the nozzle. The specific structural form mainly comprises two structural forms of a spiral variable cross-section tube bundle type and a wall plate groove close-packed flow passage, and the wall thickness of the inner wall of the spray tube structure is generally smaller than 1mm in order to ensure the cooling efficiency. The shape of the spray pipe is mostly a bell-jar type or a cone type structure, and the diameter and the height of the large end are generally more than 500 mm. The existing manufacturing process generally adopts the mode of welding preformed thin-wall square pipes or welding groove-wall plates. The manufacturing method for manufacturing and welding the large-size thin-wall curved surface structure of the spray pipe in a segmented manner has the technical limitations of variable cross-section bent pipes, long manufacturing period of the inner wall of the groove, large welding deformation, low manufacturing efficiency and the like. A Selective Laser Melting (SLM) technology belongs to the field of additive manufacturing, and is used for Melting a loose powder thin layer by high-energy Laser, and forming a three-dimensional part with certain density in a mode of powder laying layer by layer and fusing and stacking layer by layer. Compared with the traditional machining process, the SLM technology can realize the manufacturing of complex thin-wall precise components such as variable cross sections, complex internal runners and the like, and has the advantages of high forming precision, good internal quality, excellent mechanical property, convenience for integrated manufacturing and the like. The integral manufacturing of the large-size thin-wall closely-arranged runner structure of the spray pipe can be realized by adopting the SLM, the technical limitation of the segmented manufacturing and welding method is overcome, but the technical problem of large stress deformation exists in the SLM forming of the large-size closely-arranged runner thin-wall component.
Disclosure of Invention
The application provides a deformation control technology for selective laser melting forming of thin-wall closely-arranged flow channel members. Aiming at the technical problem of large deformation, the patent provides two means of reducing part-substrate joint surface stress by adopting a design process fillet and controlling structural deformation by adopting a hierarchical array axisymmetric conformal internal support structure, so that high-precision manufacturing of parts is realized.
In a first aspect, a selective laser melting method is provided, including:
processing a transition connection area on the substrate by a selective laser melting forming process;
processing the transition connection area to obtain a spray pipe through a selective laser melting forming process, wherein the thickness of the transition connection area corresponds to the axial height of the spray pipe;
after the nozzle is machined, the transition zone is removed from the nozzle.
Compared with the prior art, the scheme provided by the application at least comprises the following beneficial technical effects:
the spray pipe structure belongs to a large-size thin-wall structure for a selective laser melting forming process, has the characteristics of large projection area and small actual contact area on a forming substrate, and the shape of the contact surface between a part and the substrate is suddenly increased, so that the part is warped and cracked due to increased stress generated in the forming process. Therefore, the transition connection area is added at the lower end of the part, and the thickness of the transition connection area is designed, so that smooth transition between the substrate and the jet pipe is realized, the stress of a contact surface is reduced, and the jet pipe is prevented from warping and cracking.
With reference to the first aspect, in certain implementations of the first aspect, a thickness of the transition joint region and an axial height of the nozzle tube satisfy any one of:
the height of the axis of the spray pipe is less than 400mm, and the thickness of the transition connection area is 5-15 mm;
the height of the axis of the spray pipe is 400-800 mm, and the thickness of the transition connection area is 15-30 mm;
the height of the axis of the spray pipe is larger than 800mm, and the thickness of the transition connecting area is 30-50 mm.
The thickness of the transition connection area is adjusted according to the height of the spray pipe, so that the stress of a contact surface is reduced, and the spray pipe is prevented from warping and cracking.
With reference to the first aspect, in certain implementations of the first aspect, the method further includes:
and processing a process fillet on the transition connecting area by a selective laser melting forming process, wherein the process fillet is a fillet between the transition connecting area and the spray pipe, and the radius of the process fillet corresponds to the shaft height of the spray pipe.
By designing the process fillet connected with the spray pipe in the transition connection area, smooth transition between the substrate and the spray pipe is realized, the stress of a contact surface is reduced, and the spray pipe is prevented from warping and cracking.
With reference to the first aspect, in certain implementations of the first aspect, a radius of the process fillet and an axial height of the nozzle satisfy any one of:
the height of the axis of the spray pipe is less than 400mm, and the thickness of the transition connection area is 3-7 mm;
the height of the shaft of the spray pipe is 400-800 mm, and the thickness of the transition connection area is 7-15 mm;
the height of the axis of the spray pipe is larger than 800mm, and the thickness of the transition connecting area is 15-25 mm.
The process fillet is adjusted according to the height of the spray pipe, so that the stress of a contact surface is reduced, and the spray pipe is prevented from warping and cracking.
With reference to the first aspect, in certain implementations of the first aspect, the method further includes:
in the process of processing the spray pipe through a selective laser melting forming process, a support structure is processed in an inner cavity of the spray pipe, and the support structure is connected with the inner wall of the spray pipe;
after the nozzle is machined, removing the support structure from the nozzle.
For a bell jar or a conical nozzle structure, due to the high height of the bell jar or the conical nozzle structure, concave deformation can be generated in the middle section of a part under the influence of forming thermal stress and solidification shrinkage stress when the selective laser melting forming is carried out. By increasing the manufacturing process, the supporting structure is processed in the inner cavity of the spray pipe in the process of processing the spray pipe. The support structure may be an axisymmetric stepped array conformal inner support. The support structure can be used for controlling the deformation of the component by increasing the axisymmetric hierarchical array conformal support in the part process design stage aiming at the concave deformation.
With reference to the first aspect, in certain implementations of the first aspect, a 3-stage support structure is disposed within the nozzle, the 3-stage support structure satisfying:
the 1 st stage supporting structure is arranged at the position where the radius of the spray pipe is less than 0.1-0.2 Dmm;
the 2 nd stage supporting structure is arranged at the position of the spray pipe with the radius of 0.15D-0.5 Dmm;
the 3 rd-stage supporting structure is arranged at the position where the radius of the spray pipe is 0.5D-Dmm, wherein D is the difference value between the radius of the large end and the radius of the small end of the spray pipe.
The multi-stage supporting structure is designed and arranged according to the radius of the spray pipe, so that the reasonable control on the deformation of the component is favorably realized.
With reference to the first aspect, in certain implementations of the first aspect, a length ratio of the level 1 support structure, the level 2 support structure, and the level 3 support structure is 4:2:1.
the multi-stage supporting structure is designed and arranged according to the height of the spray pipe, so that the reasonable control on the deformation of the component is favorably realized.
With reference to the first aspect, in certain implementations of the first aspect, a diameter ratio of the level 1 support structure, the level 2 support structure, and the level 3 support structure is 1:2:4.
the size of the multi-stage supporting structure is reasonably designed, and the deformation of the component is reasonably controlled.
With reference to the first aspect, in certain implementations of the first aspect, the number ratio of the level 1 support structures, the level 2 support structures, and the level 3 support structures is 1:2:4.
the number of the multi-stage supporting structures is reasonably designed, so that the deformation of the component can be reasonably controlled.
With reference to the first aspect, in certain implementation manners of the first aspect, an included angle between two adjacent 1 st-stage support structures is 45 °, an included angle between two adjacent 2 nd-stage support structures is 30 °, and an included angle between two adjacent 3 rd-stage support structures is 15 °.
The arrangement mode of the multi-stage supporting structures is reasonably designed, and the deformation of the members can be reasonably controlled.
Drawings
Fig. 1 is a schematic configuration view of a nozzle.
Fig. 2 is a schematic structural view of a nozzle flow passage.
Fig. 3 is a schematic diagram of a component obtained by a selective laser melting method according to an embodiment of the present disclosure.
Fig. 4 is a schematic structural diagram of a support structure according to an embodiment of the present application.
Fig. 5 is a schematic structural diagram of a support structure according to an embodiment of the present application.
Fig. 6 is a schematic structural diagram of a support structure according to an embodiment of the present application.
Detailed Description
The present application is described in further detail below with reference to the figures and the specific embodiments.
Fig. 1 is a schematic structural diagram of a nozzle provided in an embodiment of the present application. The nozzle may have two open ends, which may be a small end and a large end, respectively. The distance between the small end and the large end is the axial height of the spray pipe. The material of the spray pipe can be titanium alloy, high-temperature alloy, stainless steel and the like. As shown in fig. 2, a flow passage structure may be provided on the nozzle. The characteristic form of the flow passage structure can be a spiral flow passage, a straight flow passage and the like, and the wall thickness of the flow passage is more than or equal to 0.6mm.
In the embodiment of the application, aiming at the spray pipe shown in fig. 1 or fig. 2, deformation control is performed on selective laser melting forming through the design of the substrate and the process fillet.
The spray pipe structure belongs to a large-size thin-wall structure for a selective laser melting forming process, the spray pipe structure has the characteristics that the projection area is large but the actual contact area is small on a forming substrate, the shape of the contact surface between a part and the substrate is suddenly increased, and increased stress can be generated in the forming process to cause the part to warp and crack. Therefore, through the adoption of the manufacturing process, a transition connecting area is processed on the base plate, the transition connecting area is a transition area between the base plate and the spray pipe, and the transition connecting area is connected between the base plate and the spray pipe. Through adding the transition joining region at the part lower extreme to the thickness of design transition joining region, and the technology fillet of transition joining region and being connected with the spray tube realize the rounding off of base plate and spray tube, reduce the stress of contact surface, avoid spray tube warpage fracture. As shown in particular in fig. 2. The thickness and process fillet specific parameters of the transition joint region may be related to the axial height of the nozzle. Specifically, the following table 1 may be referred to.
The transitional coupling zone may be a cubic structure and may project toward the substrate along a centerline of the nozzle, and the projected area of the nozzle may be located within the projected area of the transitional coupling zone. After the nozzle has been machined, the transition zone can be removed from the nozzle.
TABLE 1 thickness of transition connection region and specific parameters of process fillet
| Model of component | X | Y | Z |
| Height of component | <400mm | 400-800mm | 800-1000 |
| Thickness of transition joint region | 10mm | 20mm | 40mm |
| Art round corner | 5mm | 10mm | 20mm |
For a bell jar or a conical nozzle structure, due to the high height of the bell jar or the conical nozzle structure, concave deformation can be generated in the middle section of a part under the influence of forming thermal stress and solidification shrinkage stress when the selective laser melting forming is carried out. By increasing the manufacturing process, the supporting structure is processed in the inner cavity of the spray pipe in the process of processing the spray pipe. The support structure may be an axisymmetric stepped array conformal inner support. In the embodiment of the application, aiming at the spray pipe shown in fig. 1 or fig. 2, deformation control is performed on selective laser melting forming of a large-size thin-wall closely-arranged flow channel structure of the spray pipe by the aid of a hierarchical array axisymmetric conformal internal support structure design. See in particular fig. 4 and 5. The support structure can be used for controlling the deformation of the component by increasing the axisymmetric hierarchical array conformal support in the part process design stage aiming at the concave deformation.
The support structure may be connected to the inner wall of the spout. The central symmetry axis of the support structure coincides with the member axis. The support structure may be symmetrically disposed relative to the central axis of the lance and perpendicularly disposed relative to the central axis of the lance.
Referring to fig. 1, the number of stages of the hierarchical array support is determined according to the sizes of the small end and the large end of the member. And D, determining the value of the radius range from the large end radius to the small end radius. Specifically, the D value is less than 100mm, the support grades are 1, the diameter of the support structure is 1mm close to the small end of the member; d is 100-300mm, the number of the supporting grades is 2, the supporting structure is positioned at the transition section of the member, and the diameter of the supporting structure is 2mm: d is 300-600mm, the support grades are 3, the diameter of the support structure is 4mm near the large end of the member.
The dimensional characteristics of the axisymmetric hierarchical array conformal inner support are as follows: defining 1 stage near the middle axis, the ratio of the widths between stages is 1:2:4; the ratio of the support structure length (the ratio of the support structure distance to the large end opening along the centerline of the lance) is 4:2:1. the 1-stage supports are symmetrically distributed on the central axis, the number of the supports is a, and the supports are close to the small end of the component; the 2-stage supports are symmetrically distributed on the central axis, the number of the supports is 2a, and the supports are positioned at the transition section of the component; the 3-stage supports are symmetrically distributed on the central axis, the number of the supports is 4a, and the supports are close to the large end of the component.
Table 2 internal support structure design table
The support of the 1-level, the 2-level and the 3-level is divided into three directions, and theta is distributed at included angles of 15 degrees, 30 degrees and 45 degrees. That is, level 1 supports may be provided every 45 ° and level 1 supports according to a 45 ° variation. The level 2 supports may be arranged at 30 intervals, with the level 2 supports being supported in 30 variations. The 3-stage supports may be arranged at 15 ° intervals, and the stages 3 are supported with 15 ° variation. As shown in table 3 above. The height of the inner support is in following fit with the interior of the nozzle, see fig. 6.
Table 3 inner support structure angle changing design table
The present application is described in further detail in conjunction with the following.
Example 1
A spray pipe A: the height of the component is 600mm; the thickness of the connection with the substrate is designed to be 20mm, and the process fillet is 10mm; as shown in table 4.
TABLE 4 substrate and Process fillets
D = large end radius-small end radius =600mm, and the hierarchical array support design is as in table 5.
Table 5 internal support structure concrete design table
Example 2
And (3) spraying pipe B: the height of the component is 900mm; the connection thickness of the design and the substrate is 40mm, and the process fillet is 20mm; as shown in table 6.
TABLE 6 substrate and Process fillet
| Model of component | B |
| Height of component | 900mm |
| Thickness of substrate connection | 40mm |
| Art round corner | 20mm |
D = large end radius-small end radius =900mm, and the hierarchical array support design is as in table 7.
Table 7 internal support structure concrete design table
Although the present invention has been described with reference to the preferred embodiments, it is not intended to limit the present invention, and those skilled in the art can make variations and modifications without departing from the spirit and scope of the present invention.
Claims (10)
1. A selective laser melting method, comprising:
processing a transition connection area on the substrate through a selective laser melting forming process;
processing the transition connection area to obtain a spray pipe through a selective laser melting forming process, wherein the thickness of the transition connection area corresponds to the axial height of the spray pipe;
after the nozzle is machined, the transition zone is removed from the nozzle.
2. The method of claim 1, wherein a thickness of the transition joint region and an axial height of the lance satisfy any of:
the height of the axis of the spray pipe is less than 400mm, and the thickness of the transition connection area is 5-15 mm;
the height of the shaft of the spray pipe is 400-800 mm, and the thickness of the transition connection area is 15-30 mm;
the height of the axis of the spray pipe is larger than 800mm, and the thickness of the transition connecting area is 30-50 mm.
3. The method of claim 1, further comprising:
and processing a process fillet on the transition connection area through a selective laser melting forming process, wherein the process fillet is a fillet between the transition connection area and the spray pipe, and the radius of the process fillet corresponds to the axial height of the spray pipe.
4. The method of claim 3, wherein the radius of the process fillet and the axial height of the nozzle satisfy any one of:
the height of the axis of the spray pipe is less than 400mm, and the thickness of the transition connection area is 3-7 mm;
the height of the shaft of the spray pipe is 400-800 mm, and the thickness of the transition connection area is 7-15 mm;
the height of the axis of the spray pipe is larger than 800mm, and the thickness of the transition connection area is 15-25 mm.
5. The method according to any one of claims 1 to 4, further comprising: in the process of processing the spray pipe through a selective laser melting forming process, a support structure is processed in an inner cavity of the spray pipe, and the support structure is connected with the inner wall of the spray pipe;
after the nozzle is machined, removing the support structure from the nozzle.
6. The method of claim 5, wherein a 3-stage support structure is disposed within the lance, the 3-stage support structure satisfying:
the 1 st stage supporting structure is arranged at the position where the radius of the spray pipe is less than 0.1-0.2 Dmm;
the 2 nd stage supporting structure is arranged at the position of the spray pipe with the radius of 0.15D-0.5 Dmm;
the 3 rd stage supporting structure is arranged at the position where the radius of the spray pipe is 0.5D-Dmm, wherein D is the difference value of the radius of the large end and the radius of the small end of the spray pipe.
7. The method of claim 6, wherein the stage 1 support structure, the stage 2 support structure, and the stage 3 support structure have a length ratio of 4:2:1.
8. the method of claim 6, wherein the stage 1 support structure, the stage 2 support structure, and the stage 3 support structure have a diameter ratio of 1:2:4.
9. the method of claim 6, wherein the number ratio of the level 1 support structure, the level 2 support structure, and the level 3 support structure is 1:2:4.
10. the method of claim 8, wherein the included angle between two adjacent stage 1 support structures is 45 °, the included angle between two adjacent stage 2 support structures is 30 °, and the included angle between two adjacent stage 3 support structures is 15 °.
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| CN202211339082.3A CN115889810A (en) | 2022-10-28 | 2022-10-28 | Selective laser melting forming deformation control technology for thin-wall closely-arranged runner component |
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| CN202211339082.3A CN115889810A (en) | 2022-10-28 | 2022-10-28 | Selective laser melting forming deformation control technology for thin-wall closely-arranged runner component |
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| US20140190942A1 (en) * | 2011-08-10 | 2014-07-10 | Bae Systems Plc | Forming a layered structure |
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