JP2022514359A - 2次元プリントのためのパルス変調レーザを使用した付加製造システム - Google Patents
2次元プリントのためのパルス変調レーザを使用した付加製造システム Download PDFInfo
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- JP2022514359A JP2022514359A JP2021535586A JP2021535586A JP2022514359A JP 2022514359 A JP2022514359 A JP 2022514359A JP 2021535586 A JP2021535586 A JP 2021535586A JP 2021535586 A JP2021535586 A JP 2021535586A JP 2022514359 A JP2022514359 A JP 2022514359A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
- B23K26/0626—Energy control of the laser beam
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
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- B23K26/064—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
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- B23K26/073—Shaping the laser spot
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/12—Working by laser beam, e.g. welding, cutting or boring in a special atmosphere, e.g. in an enclosure
- B23K26/123—Working by laser beam, e.g. welding, cutting or boring in a special atmosphere, e.g. in an enclosure in an atmosphere of particular gases
- B23K26/125—Working by laser beam, e.g. welding, cutting or boring in a special atmosphere, e.g. in an enclosure in an atmosphere of particular gases of mixed gases
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/12—Working by laser beam, e.g. welding, cutting or boring in a special atmosphere, e.g. in an enclosure
- B23K26/127—Working by laser beam, e.g. welding, cutting or boring in a special atmosphere, e.g. in an enclosure in an enclosure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/34—Laser welding for purposes other than joining
- B23K26/342—Build-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/141—Processes of additive manufacturing using only solid materials
- B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
-
- 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
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- 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
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
-
- 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
- B33Y70/00—Materials specially adapted for additive manufacturing
-
- 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
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/64—Treatment of workpieces or articles after build-up by thermal means
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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
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/40—Radiation means
- B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
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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
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Abstract
Description
本開示は、参照によりその全体が組み込まれる、2018年12月19日に出願の米国特許出願第62/781,996号の優先権を主張する非仮特許出願の一部である。
本開示は、概して、付加製造に関し、より具体的には、2次元プリントのための制御可能なパルス形状及びタイミングを有する高流束レーザを使用した粉末床溶融付加製造に関する。
Claims (29)
- 付加製造の方法であって、
粉末床を提供することと、
1つ以上のパルスを含み、20kW/cm2を超える流束を有する整形されたレーザビームパルス列を、前記粉末床の画定された2次元領域に向けることと、
画定された前記2次元領域内の粉末を融解及び溶融することと
を含む、方法。 - 前記粉末の粒子の重量で10%未満は、画定された前記2次元領域の外側の領域中に放出される、請求項1に記載の方法。
- 整形された前記レーザビームパルス列は、任意のパルスレーザ源と、少なくとも1つのプリアンプと、少なくとも1つのパワーアンプとを含むシステムによって提供される、請求項1に記載の方法。
- 前記流束は、前記粉末床において20kW/cm2と10GW/cm2との間にある、請求項1に記載の方法。
- 前記粉末床の画定された前記2次元領域は、0.000025cm2と1,000cm2との間にある、請求項1に記載の方法。
- 前記粉末床の厚さは、1~2000μmの範囲、25~250μmの範囲、及び50~100μmの範囲の内の少なくとも1つの間にある、請求項1に記載の方法。
- 予備的なハローテストにより形成されたハローの検出面積に応じて、前記レーザビームエネルギー、パルス幅、又は画定された前記2次元領域の面積の内の少なくとも1つを調整することを含む較正ステップを更に含む、請求項1に記載の方法。
- 予備的なハローテストによって形成されたハローの検出領域に応じて、パルス形状、パルス数、又は時間の関数としてのパルスピーク出力の内の少なくとも1つを調整することを含む較正ステップを更に含む、請求項1に記載の方法。
- 予備的なハローテストによって形成されたハロー領域を検出するステップを更に含み、検出された前記ハローの半径は、画定された前記2次元領域を超えて50ミクロンよりも大きく設定される、請求項1に記載の方法。
- 使用される前記粉末は、前記粉末床においてパルスレーザ強度<10GW/cm2を使用して直径が<100,000μmである、請求項1に記載の方法。
- 使用される前記粉末は、前記粉末床においてパルス強度>20kW/cm2を使用して直径が<500μmである、請求項1に記載の方法。
- 前記レーザの時間的パルス幅は、20ナノ秒と100マイクロ秒との間にある、請求項1に記載の方法。
- レーザパルス列は、1よりも大きいレーザパルス列の数を用いて利用される、請求項1に記載の方法。
- 前記レーザパルスのピーク出力は、時間の関数として調整される、請求項1に記載の方法。
- レーザパルス信号源と、
レーザビームを受け取り、光分離デバイスに向けるための1つ以上のプリアンプモジュールと、
前記光分離デバイスからレーザビームを受け取り、それを粉末床の画定された2次元領域に向けるための1つ以上のアンプモジュールと
を含む、2次元プリントのためのレーザシステム。 - 前記レーザパルス信号源は、方形波、ランプ、任意の事前定義されたパルス形状、又はパルス列の内の少なくとも1つを提供し得る、請求項15に記載の方法。
- 前記光分離デバイスは、ポッケルスセル、ファラデー回転子、ファラデーアイソレータ、音響光学反射器、又は体積型ブラッググレーティングの内の少なくとも1つを含み得る、請求項15に記載の方法。
- 第1のレーザビームを提供するために、レーザパルス信号源をプリアンプモジュール及び光変調器又は分離デバイスに向けることと、
1つ以上のパルスを含み、使用点において20kW/cm2を超える流束を有する整形されたレーザビームパルス列を提供するために、前記第1のレーザビームをアンプモジュールに向けることと
のステップを含むレーザ制御方法。 - 前記流束は、使用点において20kW/cm2と10GW/cm2との間にある、請求項18に記載の方法。
- レーザの時間的パルス幅は、20ナノ秒と100マイクロ秒との間にある、請求項18に記載の方法。
- レーザパルス列は、1よりも多いパルス数を用いて利用される、請求項18に記載の方法。
- 前記レーザパルスのピーク出力は、時間の関数として調整される、請求項18に記載の方法。
- 整形された前記レーザビームパルス列は、0.000025cm2と1,000cm2との間のサイズの2次元領域に向けられる、請求項18に記載の方法。
- 整形された前記レーザビームパルス列は、付加製造ステーション内の使用点に向けられる、請求項18に記載の方法。
- 整形された前記レーザビームパルス列は、画定された2次元領域内の粉末を融解及び溶融するために、付加製造粉末床の画定された2次元領域に向けられる、請求項18に記載の方法。
- 付加製造の方法であって、
粉末床を囲み、He、Ar、Ne、Kr、Xe、CO2、N2、O2、SF6、CH4、CO、N2O、C2H2、C2H4、C2H6、C3H6、C3H8、i-C4H10、C4H10、1-C4H8、cic-2,C4H7、1,3-C4H6、1,2-C4H6、C5H12、n-C5H12、i-C5H12、n-C6H14、C2H3Cl、C7H16、C8H18、C10H22、C11H24、C12H26、C13H28、C14H30、C15H32、C16H34、C6H6、C6H5-CH3、C8H10、C2H5OH、CH3OH、及びiC4H8の内の少なくとも1つを含む雰囲気を有するエンクロージャーを提供することと、
1つ以上のパルスを含み、20kW/cm2を超える流束を有する整形されたレーザビームパルス列を、前記粉末床の画定された2次元領域に向けることと、
画定された前記2次元領域内の粉末を融解及び溶融することと
を含む、方法。 - 前記雰囲気は、体積が少なくとも1%のヘリウムである、請求項26に記載の方法。
- 前記エンクロージャー内の前記雰囲気は、0バールと100バールとの間の絶対圧力に維持される、請求項26に記載の方法。
- 前記エンクロージャー内の前記雰囲気は、20ケルビン度と5000ケルビン度との間の温度に維持される、請求項26に記載の方法。
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US62/781,996 | 2018-12-19 | ||
PCT/US2019/067424 WO2020132215A1 (en) | 2018-12-19 | 2019-12-19 | Additive manufacturing system using a pulse modulated laser for two-dimensional printing |
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