JP2021109204A - 付加製造装置 - Google Patents
付加製造装置 Download PDFInfo
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- JP2021109204A JP2021109204A JP2020002751A JP2020002751A JP2021109204A JP 2021109204 A JP2021109204 A JP 2021109204A JP 2020002751 A JP2020002751 A JP 2020002751A JP 2020002751 A JP2020002751 A JP 2020002751A JP 2021109204 A JP2021109204 A JP 2021109204A
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- light beam
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Abstract
Description
本例の付加製造装置は、例えば、指向性エネルギー堆積方式であってLMD方式を採用する。本例において、付加製造装置は、硬質材である硬質粉末材料に結合粉末材料を混合した粉末材料を基台に向けて噴射しながら光ビームを照射することにより、基台に硬質の造形物を付加製造する。粉末材料、特に、硬質粉末材料と基台は、異なる材料でも良く、同一種類の材料でも良い。
図1に示すように、付加製造装置100は、付加材料供給装置110、光ビーム照射装置120及び制御装置130を主に備える。ここで、本例においては、付加製造装置100は、図2及び図3に示すように、大径の円盤部材B1の両側面に小径の円筒部材B2,B2が同軸に一体化された形状を有する基台Bに造形物FFを付加製造する場合を例示する。具体的に、付加製造装置100は、基台Bにおける円筒部材B2,B2の開放端部側の格子で示す周面(図示を省略する軸受の支持部)B2S,B2Sに造形物FFを付加製造する。
次に、造形物FFの付加製造方法について説明する。造形物FFの付加製造方法では、第一段階として、外側光ビームLSにより、造形物FFの付加製造処理における前処理として初期の予熱処理を行う。基台Bの周面B2Sの温度が低い状態では、レーザ照射による熱エネルギーが基台Bに逃げ易い。これにより、第二段階において造形物FFを基台Bに付加製造する場合、スパッタの発生等の溶融の不良要因となり易いため、第一段階で基台Bの周面B2Sを予熱する。このとき、初期の予熱処理における内側光ビームLC及び外側光ビームLSのレーザ出力は、基台Bの周面B2Sが溶融せずに所定の温度となるように制御される。尚、付加製造においては、必要に応じて、第一段階を省略することも可能である。
ここで、第二光ビームBe2による造形物FFの保温処理について具体的に説明する。結合粉末材料P2であるコバルト(Co)は、硬質粉末材料P1である炭化タングステン(WC)を結合するバインダとして作用する。即ち、コバルト(Co)は、付加製造において溶融池MPが溶融状態から凝固状態に遷移する場合、バインダとして炭化タングステン(WC)の粒子同士を結合する。コバルト(Co)をバインダとして作用させて造形物FFの割れを抑制するためには、コバルト(Co)が凝固点(換言すれば、融点であり約1500℃)から冷却するときの単位時間当たりの温度低下即ち冷却速度を適切に管理して保温処理を行う必要がある。
発明者等は、種々の予備的な実験を繰り返し行った結果、結合粉末材料P2のコバルト(Co)が適切にバインダとして作用し、保温処理後において造形物FFの割れを抑制する冷却速度(℃/s)を見出した。以下、このことを具体的に説明する。
上述したように、制御装置130は、外側光ビームLSのパワー密度のビームプロファイルを設定する、換言すれば、外側光照射範囲SSにおいてコバルト(Co)の凝固点での冷却速度を540℃/s以下となるように設定する。ところで、このように冷却速度を設定した場合であっても、冷却により凝固していく溶融池MPが外側光照射範囲SSに含まれている時間が短くなると、結果として、溶融池MP即ち造形物FFが急冷される可能性がある。
上述した本例によれば、制御装置130は、内側光ビームLCが照射されて硬質粉末材料P1及び結合粉末材料P2が溶融することにより形成された溶融池MPを外側光ビームLSが照射する際、外側光ビームLSのパワー密度のビームプロファイルを、溶融池MPにおける冷却速度(℃/s)が溶融池MPに含まれるコバルト(Co)の凝固点において540℃/s以下となるように制御することができる。
例えば、造形物FFを層状に繰り返し付加製造を行う場合、内側光ビームLC及び外側光ビームLSが繰り返し照射されることにより、基台Bや造形物FFの温度が上昇する場合がある。上述したように、溶融池MP(造形物FF)が適切に保温されることにより、造形物FFの割れを抑制することができる。そこで、この第一別例においては、例えば、放射温度計等によって検出された基台Bや造形物FFの温度に基づいて、制御装置130が検出された温度に応じて少なくとも外側光ビームLSのパワー密度のビームプロファイルにおけるピークLSP1を低下させる。
上述した本例においては、外側光照射範囲SSを円形とし、外側光照射範囲SSが内側光照射範囲CSと同心円状となるようにした。これに代えて、第二別例においては、例えば、外側光ビーム照射装置122を構成する図示省略の光学系を適宜設定することにより、図12に示すように、外側光照射範囲SSの形状を走査方向SDに沿った方向の長軸を有する楕円形状とする。更に、第二別例において、内側光照射範囲CSが外側光照射範囲SSに含まれており、走査方向SDにおいて内側光照射範囲CSよりも後側、即ち、溶融池MP(造形物FF)を保温する側が、基台Bを予熱する側より大きくなるように、外側光照射範囲SSを内側光照射範囲CSに対して配置する。
上記本例においては、第一光ビームBe1及び第二光ビームBe2のパワー密度のビームプロファイルに関し、ピークLSP1を同じとした。例えば、造形物FFを精密に付加製造する場合、上述した比αを「1.5」に設定する可能性が高く、この場合には、図10に示したように、上記本例では第一光ビームBe1のパワー密度も大きくなってしまう。又、例えば、上述した第二別例のように、走査方向SDにおいて内側光照射範囲CSよりも後側となる外側光照射範囲SSを大きくした場合、保温時間が長くなるため第二光ビームBe2のパワー密度をより小さくすることが好ましい。尚、この場合には、光ビーム照射装置120における光学系や第一光ビームBe1及び第二光ビームBe2のパワー密度のビームプロファイルを独立して変更可能な構成とすることがより好ましい。
上述した本例においては、光ビーム照射装置120は、内側光ビーム照射装置121及び外側光ビーム照射装置122を同軸的に配置するようにした。そして、上述した本例においては、外側光ビーム照射装置122は、外側光ビームLSとして円環状の光ビームを照射することにより、内側光ビームLCによる内側光照射範囲CSの外周に外側光照射範囲SSを形成するようにした。
Claims (16)
- 硬質材及び超硬バインダを含む材料を前記材料の融点以上に加熱する内側光ビームを照射する内側光ビーム照射装置と、
前記内側光ビームの外側にて前記材料を前記融点未満に加熱する外側光ビームを照射する外側光ビーム照射装置と、
前記内側光ビーム照射装置及び前記外側光ビーム照射装置の各々について、前記内側光ビーム及び前記外側光ビームの照射、並びに、基台に対する前記内側光ビーム及び前記外側光ビームの相対的な走査を制御する制御装置と、
を備え、
前記制御装置は、
前記内側光ビームが照射されて前記材料が溶融することにより形成された溶融池を前記外側光ビームが照射する際、前記外側光ビームの単位面積当たりの出力を表すパワー密度を、前記溶融池における単位時間当たりの温度低下を表す冷却速度が前記溶融池に含まれる前記超硬バインダの凝固点において540℃/s以下となるように制御する、付加製造装置。 - 前記外側光ビームによる外側光照射範囲の前記外側光ビームの前記走査の方向における長さは、前記内側光ビームによる内側光照射範囲の前記内側光ビームの前記走査の方向における長さに対して1.5倍以上である、請求項1に記載の付加製造装置。
- 前記外側光ビームは、円形状の前記内側光ビームと同軸となる円環状に照射される、請求項1又は2に記載の付加製造装置。
- 前記外側光ビームは、四角形状に照射される、請求項1又は2に記載の付加製造装置。
- 前記外側光ビームは、前記走査の方向に沿った長軸を有する楕円形状に照射される、請求項1又は2に記載の付加製造装置。
- 前記内側光ビームによる内側光照射範囲が前記外側光ビームによる外側光照射範囲に含まれる場合、前記外側光ビームは前記内側光ビームの前記走査の方向において前側よりも後側が長くなる前記楕円形状に照射される、請求項5に記載の付加製造装置。
- 前記外側光ビームは、前記走査の方向に沿った長辺を有する四角形状に照射される、請求項1又は2に記載の付加製造装置。
- 前記内側光ビームによる内側光照射範囲が前記外側光ビームによる外側光照射範囲に含まれる場合、前記外側光ビームは前記内側光ビームの前記走査の方向において前側よりも後側が長くなる前記四角形状に照射される、請求項7に記載の付加製造装置。
- 前記制御装置は、
前記基台上における前記材料の温度に基づいて、少なくとも前記外側光ビームの前記パワー密度を変更する、請求項1−8のうちの何れか一項に記載の付加製造装置。 - 前記外側光ビームは、前記材料の融点未満且つ前記材料を600℃以上に加熱する、請求項1−9のうちの何れか一項に記載の付加製造装置。
- 前記制御装置に制御されることにより、前記基台に対し前記材料の粉末材料を噴射して供給する付加材料供給装置を備え、
前記内側光ビーム照射装置は、前記付加材料供給装置が前記基台に対して供給した前記粉末材料に前記内側光ビームを照射して前記粉末材料を溶融し、
前記外側光ビーム照射装置は、前記内側光ビームの照射によって前記粉末材料が溶融して形成された前記溶融池に前記外側光ビームを照射する、請求項1−10のうちの何れか一項に記載の付加製造装置。 - 前記制御装置は、前記内側光ビーム照射装置によって照射された前記内側光ビームの前記走査の軌跡を追従するように、前記外側光ビーム照射装置によって照射された前記外側光ビームの前記走査を制御する、請求項1−11のうちの何れか一項に記載の付加製造装置。
- 前記制御装置は、少なくとも前記内側光ビームの前記走査の方向に対して後側における前記外側光ビームの前記パワー密度を制御する、請求項1−12のうちの何れか一項に記載の付加製造装置。
- 前記硬質材の融点は、前記超硬バインダの融点よりも高い、請求項1−13のうちの何れか一項に記載の付加製造装置。
- 前記硬質材は、炭化タングステン(WC)である、請求項14に記載の付加製造装置。
- 前記超硬バインダは、コバルト(Co)である、請求項1−15のうちの何れか一項に記載の付加製造装置。
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