CN116422900A - Laser selective melting process optimization method based on molten pool lap joint model - Google Patents
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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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
- B33Y50/00—Data acquisition or data processing for additive manufacturing
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Abstract
The invention provides a laser selective melting process optimization method based on a molten pool lap joint model, which belongs to the field of additive manufacturing, and specifically comprises the following steps: performing laser selective melting forming on the alloy powder within a first parameter range to prepare a sample, and then performing forming effect analysis on the sample; in the second parameter range, performing laser selective melting single-channel forming on the alloy powder to obtain the size of a molten pool and establishing a molten pool lap joint model according to the size of the molten pool; according to the molten pool lap joint model, the molten pool lap joint rate of different parameter combinations in the first parameter range and the second parameter range is obtained, and according to the relation between the forming effect in the first parameter range and the molten pool lap joint rate, the forming effect of laser melting forming in the second parameter range is predicted, so that an optimized process parameter interval is obtained. The invention can scientifically and efficiently carry out the optimization design of the forming process and realize the optimization of the alloy laser selective melting process, thereby solving the problems of high cost, low efficiency and the like of the current process optimization.
Description
Technical Field
The invention belongs to the field of additive manufacturing, and particularly relates to a laser selective melting process optimization method based on a molten pool lap joint model.
Background
The additive manufacturing technology (commonly called as the 3D printing technology) is a technology developed in the last thirty years based on digital model design software to decompose materials into layer-by-layer data so as to realize additive manufacturing of solid parts, has the advantages of high forming speed, short production period, high material utilization rate, good material adaptability, no need of drawing and tooling equipment, high digitization degree and the like, and is widely applied to the fields of mechanical manufacturing, aerospace, biomedical treatment and the like.
Copper and copper alloy have the characteristics of excellent electrical conductivity, thermal conductivity, high hardness, wear resistance, crack resistance and the like, are widely applied to the fields of rail transit, aerospace, electronic information and the like, and play an important role in national economy and technological progress. With the industrial development, the demand of China for high-performance copper alloy parts is continuously increased, particularly the rapid development of the electronic industry, and new requirements and challenges are provided for the performance of copper alloy: in the microelectronics field, there are many requirements for frame materials to ensure reliability and durability of integrated circuits, the most central of which is the requirement for conductivity and strength; the requirements on copper alloy in the fields of resistance spot welding electrodes, electrical engineering switch contact bridges and the like are also concentrated on the mechanical properties and the conductivity of the copper alloy; in the fields of electric power and rail transit, materials are required to keep stable current carrying under the conditions of arc erosion, high temperature, high speed and extreme weather, and high requirements are put on the hardness, conductivity and current carrying friction and wear characteristics of copper alloy.
Although the copper alloy is convenient for extrusion, casting and forming, the welding is difficult, the preparation of copper alloy parts with complex shapes is difficult to realize by casting and forging processes, compared with the traditional process, the laser selective melting technology (selective laser melting, SLM) is used as an additive manufacturing (additive manufacturing, AM) technology, a high-energy laser is used as a heat source, single-layer metal powder is melted and quickly solidified by layer-by-layer powder spreading and layer-by-layer laser irradiation, and the formed areas are covered by the metal powder to automatically realize layer-by-layer stacking, so that compact solid parts are manufactured. Compared with other metal part forming methods, the SLM technology has the characteristics of high forming speed and high material utilization rate, and can manufacture parts with complex structures such as cavities, grids, multiple holes, inner runners and the like.
At present, most of researches on CuCrZr laser selective melting technology are orthogonal test methods, the density of CuCrZr alloy parts manufactured by laser selective melting is 97% -99%, the density of few researches can reach 99.5%, the technical maturity of preparing high-density parts is low, and theoretical analysis of technological parameters and defect formation is lacked. Some process optimization measures proposed in the prior researches, such as using a high-power laser, a short-wavelength laser and the like, have higher cost and low operability, and are not easy to popularize and popularize in a large range.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide a laser selective melting process optimization method based on a molten pool lap joint model, which aims to solve the problems of high cost and low efficiency of the existing process optimization.
In order to achieve the above purpose, the invention provides a laser selective melting process optimization method based on a molten pool lap joint model, which comprises the following steps:
s1, in a first parameter range, performing laser selective melting forming on alloy powder by utilizing different parameter combinations to prepare a sample, then analyzing the forming effect of the sample, and simultaneously obtaining the size of a molten pool with different parameter combinations through laser selective melting single-channel forming;
s2, in a second parameter range, carrying out laser selective melting single-channel forming on the alloy powder by utilizing different parameter combinations so as to obtain the sizes of molten pools with different parameter combinations and establishing a molten pool lap joint model according to the sizes;
s3, according to the molten pool lap joint model, the molten pool lap joint rate of different parameter combinations in a first parameter range is obtained, and the relation between the forming effect and the molten pool lap joint rate is analyzed;
s4, calculating the lap rate of the molten pool of different parameter combinations in a second parameter range according to the lap model of the molten pool, and predicting the forming effect of laser melting forming in the second parameter range according to the relation between the forming effect and the lap rate of the molten pool in the first parameter range so as to obtain an optimized process parameter interval, thereby realizing the optimization of the laser selective melting process based on the lap model of the molten pool.
As a further preferred, in step S1, the shaping effect includes compactness and printability, the printability including: forming quality, defects and microstructure.
As a further preferred aspect, in steps S1 and S2, the alloy powder is a CuCrZr alloy powder, wherein the mass ratio of each component is Cu: cr: zr=98.3 to 99:0.7 to 1.1:0.3 to 0.6.
As a new preferred step, the first parameter range includes three variables of laser power, scan line spacing and exposure time; the second parameter range includes two variables, laser power and exposure time.
As a further preferable mode, the values of the variables in the first parameter range are 3-5; and the values of all variables in the second parameter range are 10-20.
As a further preferred option, in step S3, a bath overlap model is created using ProE and bath overlap rate calculation is performed using CAXA.
As a further preferable mode, the optimization method of the laser selective melting process based on the molten pool lap joint model further comprises a step S5, specifically: and (5) performing laser selective melting in an optimized process parameter interval, and then performing forming effect verification.
In general, the above technical solutions conceived by the present invention have the following compared with the prior art
The beneficial effects are that:
1. according to the invention, the influence of different process parameters on the shape and the size of a molten pool is determined through laser selective melting single-channel forming, so that a molten pool lap model of process parameters-molten pool size is built, the molten pool lap rate is calculated, and the best molten pool lap state can be found by combining compactness and printability analysis results, so that the formation of defects is predicted and avoided, the forming process optimization design is scientifically and efficiently carried out, the alloy laser selective melting process optimization is realized, and the problems of higher process optimization cost, lower efficiency and the like in the prior art are solved;
2. meanwhile, the invention optimizes the value quantity of the variables in the first parameter range and the second parameter range, prepares the sample in the small parameter range, and performs single-channel forming in the large parameter range, thereby effectively improving the process optimization efficiency and reducing the optimization cost.
Drawings
FIG. 1 is a flow chart of a method for optimizing a laser selective melting process based on a molten pool lap model provided by an embodiment of the invention;
FIG. 2 is an SEM image of alloy powder for selective laser melting in an embodiment of the invention;
FIG. 3 is a graph showing the analysis of the molding effect of the sample prepared in the examples of the present invention;
FIG. 4 is a graph showing the relationship between sample density and energy density and defect analysis within a first parameter range in accordance with an embodiment of the present invention;
FIG. 5 shows cross-sectional lap conditions and different parameter combinations obtained based on a lap joint model of a molten pool in an embodiment of the invention, wherein (a) is the lap joint condition of the lap joint model under different parameters, and (b) is the corresponding different lap ratio of the lap joint model under different parameters;
FIG. 6 shows the sample forming condition and microstructure morphology after process optimization in the example of the present invention, wherein (a) is the sample macroscopic forming condition after process optimization based on a molten pool lap model, (b) is the non-corroded microstructure, and (c) is the corroded microstructure.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
As shown in fig. 1, the invention provides a laser selective melting process optimization method based on a molten pool lap joint model, which comprises the following steps:
s1, in a first parameter range, performing laser selective melting forming on alloy powder by utilizing different parameter combinations to prepare a sample, and then performing forming effect analysis on the sample, including compactness and printability analysis, and simultaneously obtaining the size of a molten pool with different parameter combinations through laser selective melting single-channel forming;
s2, in a second parameter range, carrying out laser selective melting single-channel forming on the alloy powder by utilizing different parameter combinations so as to obtain the sizes of molten pools with different parameter combinations and establishing a molten pool lap joint model according to the sizes;
s3, according to the molten pool lap joint model, cutting a section of the model along the printing direction, obtaining the molten pool lap joint rate of different parameter combinations in a first parameter range, and analyzing the relation between the forming effect and the molten pool lap joint rate;
s4, calculating the lap rate of the molten pool of different parameter combinations in a second parameter range according to the lap model of the molten pool, analyzing the condition of the lap rate of the molten pool corresponding to the lap rate of the molten pool according to the analysis result of the density and the printability in the first parameter range, and predicting the density and the printability of laser melting forming in the second parameter range so as to calculate the optimal lap rate and further obtain an optimized technological parameter interval;
s5, selecting part of process parameters in the optimized process parameter interval to perform laser selective melting, and then performing compactness test and printability verification.
Further, in step S1, the forming effect includes compactness and printability, wherein the printability includes: shaping quality, defects and microstructure printability analysis was performed using a ZEISS AX10 optical microscope and a ST-100E fully automated electron densitometer.
Further, in the steps S1 and S2, alloy powder is prepared by rotating electrode atomization, wherein the alloy powder is CuCrZr alloy powder, and the mass ratio of each component is Cu: cr: zr=98.3 to 99:0.7 to 1.1:0.3 to 0.6. And selecting three variable parameters of laser power, scanning line spacing and exposure time as orthogonal test factors, and performing experiments to prepare a sample.
Further, the values of the variable parameters in the first parameter range are 3-5; the values of all variable parameters in the second parameter range are 10-20, the sample is prepared by carrying out block forming pre-experiment in the small parameter range, and the single-channel forming by laser selective melting is carried out in the large parameter range, so that the workload and experiment cost of parameter optimization can be effectively reduced.
Further, in step S3, a bath overlap model is established using ProE, and a bath overlap rate calculation is performed using CAXA.
The technical scheme provided by the invention is further described below according to a specific embodiment.
1. Selective laser melting
And collecting the mixed alloy powder in a powder cylinder, cleaning, sand blasting, removing a surface oxide layer, and then installing the base plate, and finally completing replacement and installation of the scraper. The air extractor is opened, argon is filled for protection, so that the oxygen content in the equipment is ensured to be below 100ppm, and the stainless steel substrate is preheated to 170 ℃. 5X 5mm was done using QuantaM software 3 And (3) establishing a cube model and setting technological parameters, and automatically starting sample manufacturing by an equipment system after model data are imported into the equipment. In the experiment, three variables of laser power, scanning line spacing and exposure time are selected as orthogonal experimental factors, and experimental preparation samples are carried out, wherein the first parameter range comprises 4 laser powers (P/W: 310, 330, 350 and 370), 3 scanning line spacing (h/mu m:50, 70 and 90) and 3 exposure time (theta/mu s:120, 150 and 200).
2. Density analysis
And (3) placing the wire-cut sample into absolute ethyl alcohol, ultrasonically cleaning the sample to remove impurities adhered to the surface, drying the sample, placing the sample on a measuring table of an ST-100E full-automatic electronic densimeter, weighing the sample after the reading is stable, recording data by a key, weighing the sample in a hanging basket in a water tank, directly obtaining a result by the key after the reading is stable, and recording the data to realize density analysis. At least 3 measurements are guaranteed per sample, and an average is taken to reduce errors.
3. Printability analysis
Printability analysis is three: forming quality analysis, defect analysis and microstructure analysis.
The forming quality analysis is directly carried out in the printing process, and the forming quality problems such as warping, overheating and the like in the layer-by-layer manufacturing process of the samples with different process parameters are analyzed;
the defect analysis uses a ZEISS AX10 optical microscope to analyze the surface porosity and the pore morphology of the polished sample, and classifies and judges the printing defects;
and analyzing the microstructure by using a ZEISS AX10 optical microscope to analyze the polished and corroded sample, and observing the appearance of a molten pool and the lap joint condition of the molten pool.
4. Molten pool lap joint model
The bath overlap model uses the ProE software to model the bath dimensions obtained from a single pass forming experiment of different parameter combinations. The second parameter range includes 10 laser powers (P/W: 300, 310, 320, 330, 340, 350, 360, 370, 380, 390) and 9 exposure times (θ/μs:120, 130, 140, 150, 160, 170, 180, 190, 200), and 3 scan line spacings (h/μs: 50, 70, 90) were used for modeling. The interlayer thickness and 67-degree scanning strategy are fixed, different melting widths, melting depths and scanning line distances are input, and the influence of the residual height of a welding bead is not considered in the simulation process of the lap joint model of the molten pool.
5. Overlap ratio calculation and defect prediction
Based on the molten pool lap joint model, the section of the model is cut along the printing direction to obtain the lap joint condition of the molten pool, and the lap joint rate R of the molten pool is calculated and counted L And (3) carrying out defect prediction of CuCrZr laser selective melting, wherein the defect boundary conditions are as follows:
unfused:
d/t < 1 or h/W < 1 or R L ≤3
A key hole:
R L ≥8
wherein D is the depth of the molten pool, W is the width of the molten pool, t is the layer thickness, and h is the scanning line spacing.
6. Verification of process design optimization
Comprising two aspects: compactness testing and microstructure verification.
The compactness test uses a ST-100E full-automatic electronic densimeter, test samples manufactured by using representative technological parameter combinations after model simulation calculation are taken, the compactness of the test samples is measured, each sample is measured at least three times, and an average value is taken to reduce errors.
And (3) microstructure verification, analyzing the polished and corroded sample by using a ZEISS AX10 optical microscope, clearly observing the weld line, namely the weld pool boundary after corrosion, observing the shape of the weld pool and the lap joint condition of the weld pool, and observing the defect position and shape.
7. Analysis of experimental results
FIG. 2 shows the selective laser melting and printing forming effect of 98.7Cu-0.82Cr-0.48Zr alloy powder; the sphericity of the powder produced by the rotary electrode atomization is good, the Hall flow rate is 21.2s/50g, and the powder meets the powder standard of selective laser melting.
FIG. 3 is a forming effect diagram showing the printability of the CuCrZr alloy powder, but the warpage of the sample during printing, affecting sample formation; the whole sample is overheated during the printing process, so that the molten pool collapses, and the forming precision is poor; meanwhile, the surface of the high-energy-density sample has obvious macroscopic keyhole defects.
FIG. 4 is a profile of a CuCrZr alloy analyzed in combination with a ZEISS AX10 optical microscope. It can be seen that the sample has unfused defects under the conditions of high scanning speed, wide scanning line spacing and low laser power (low energy density); under the conditions of low scanning speed and high laser power (high energy density), a keyhole exists. Further analysis of the density energy density cloud chart is combined, and the fact that the forming is good only in a certain energy density range and the forming conditions are different under the same energy density combined by different process parameters is found, the printability of the sample is difficult to completely describe only through the energy density, and the optimal process parameters are the result of the combination of the specific process parameters, so that the forming has higher quality in the combination.
FIG. 5 shows the molten pool overlap condition of different process parameter combinations obtained after the molten pool dimensions obtained in the single experiment of different process parameters and the molten pool overlap model are established, the overlap ratio R can be found by calculating the molten pool overlap ratio based on the overlap model and comparing the overlap ratio R with the microstructure of the corresponding process parameter forming sample L When the temperature is less than or equal to 3, the unfused defect easily occurs, R L And when the temperature is more than or equal to 8, key hole defects are easy to occur, namely, in the lap joint process of the molten pool under different parameter processes, the lap joint times are insufficient to cause unfused, and the molten pool is difficult to exhaust gas under the complex thermal cycle effect due to the excessive lap joint times, so that the positions with poor forming effect are concentrated at the positions below lap joint for 3 times and above 8 times, and the analysis of the positions and defect types generated by the defects is facilitated.
FIG. 6 is a graph of R selected after optimization of a process based on a molten pool lap model L The method is mainly focused on the sample forming condition and microstructure morphology under the process parameters of 4-7, and has the advantages of good forming and no defects of unfused and keyhole.
The traditional process optimization method based on the laser energy density and the density is low in efficiency, and the phenomenon that the combination of different process parameters of the same energy density leads to low density is not convinced. According to the invention, through establishing a quantitative relation between parameters and dimensions, a 'technological parameter-molten pool dimension' molten pool overlap mathematical model is built, the formation of defects is predicted and avoided, the forming process optimization design is scientifically and efficiently carried out, the high-density CuCrZr alloy laser selective melting forming process optimization is realized, and the method has important significance in solving the development limit problems of higher cost and lower efficiency of the current process optimization.
It will be readily appreciated by those skilled in the art that the foregoing description is merely a preferred embodiment of the invention and is not intended to limit the invention, but any modifications, equivalents, improvements or alternatives falling within the spirit and principles of the invention are intended to be included within the scope of the invention.
Claims (7)
1. The laser selective melting process optimization method based on the molten pool lap joint model is characterized by comprising the following steps of:
s1, in a first parameter range, performing laser selective melting forming on alloy powder by utilizing different parameter combinations to prepare a sample, then analyzing the forming effect of the sample, and simultaneously obtaining the size of a molten pool with different parameter combinations through laser selective melting single-channel forming;
s2, in a second parameter range, carrying out laser selective melting single-channel forming on the alloy powder by utilizing different parameter combinations so as to obtain the sizes of molten pools with different parameter combinations and establishing a molten pool lap joint model according to the sizes;
s3, according to the molten pool lap joint model, the molten pool lap joint rate of different parameter combinations in a first parameter range is obtained, and the relation between the forming effect and the molten pool lap joint rate is analyzed;
s4, calculating the lap rate of the molten pool of different parameter combinations in a second parameter range according to the lap model of the molten pool, and predicting the forming effect of laser melting forming in the second parameter range according to the relation between the forming effect and the lap rate of the molten pool in the first parameter range so as to obtain an optimized process parameter interval, thereby realizing the optimization of the laser selective melting process based on the lap model of the molten pool.
2. The method of optimizing a molten pool lap model based laser selective melting process of claim 1, wherein in step S1, said forming effect includes compactness and printability, said printability including: forming quality, defects and microstructure.
3. The optimization method of the laser selective melting process based on the molten pool lap joint model as claimed in claim 1, wherein in the steps S1 and S2, the alloy powder is CuCrZr alloy powder, and the mass ratio of each component is Cu: cr: zr=98.3 to 99:0.7 to 1.1:0.3 to 0.6.
4. The method for optimizing a molten pool lap model-based laser selective melting process according to claim 1, wherein said first parameter range includes three variables of laser power, scan line spacing and exposure time; the second parameter range includes two variables, laser power and exposure time.
5. The optimization method of the laser selective melting process based on the molten pool lap joint model according to claim 1, wherein the values of all variables in the first parameter range are 3-5; and the values of all variables in the second parameter range are 10-20.
6. The method for optimizing a laser selective melting process based on a molten pool lap model according to claim 1, wherein in step S3, a molten pool lap model is built using ProE, and a molten pool lap rate calculation is performed using CAXA.
7. The method for optimizing the laser selective melting process based on the molten pool lap joint model according to claim 1, wherein the method for optimizing the laser selective melting process based on the molten pool lap joint model further comprises the following step S5: and (5) performing laser selective melting in an optimized process parameter interval, and then performing forming effect verification.
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| CN117399647A (en) * | 2023-12-14 | 2024-01-16 | 哈尔滨市允巢金属材料有限公司 | Metal material processing control optimization method based on 3D printing |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117399647A (en) * | 2023-12-14 | 2024-01-16 | 哈尔滨市允巢金属材料有限公司 | Metal material processing control optimization method based on 3D printing |
| CN117399647B (en) * | 2023-12-14 | 2024-03-29 | 释空(上海)品牌策划有限公司 | Metal material processing control optimization method based on 3D printing |
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