JP7089662B2 - 積層造形と表面コーティングの複合成形システム及び方法 - Google Patents
積層造形と表面コーティングの複合成形システム及び方法 Download PDFInfo
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Description
A . J . Pinkkerton , L . Li ,Effects of Geometry and Composition in Coaxial Laser Deposition Of 316L Steel for Rapid Protyping,Annals Of the CIRP,Vol.52,1(2003),p181-184)。 Matz J . E . ,Eagar T.W.Carbide formation In Al loy 718 during electron-beam solid freeform fabrication. Metallurgical and Materials Transactions A:Physical Metallurgy and Materials Science,2002,v33(8):p2559-2567 Haiou Zhang,Jipeng Xu,Guilan Wang,Fundamental Study on Plasma Deposition Manufacturing,Surface and Coating Technology,v. 171(1-3)2003,pp .112~118 Zhang Haiou、Wu Hongjun、Wang Guilan、Chen Jing、プラズマ溶融で直接成形した超合金部品の微細構造に関する研究、華中科学技術大学ジャーナル(Natural Science Edition)、v 33、n 11、2005、p54-56 Pawlowski L.The science and engineering of thermal spray coatings, second edition[M].New York:John Wiley & Sons,2008:15 Baranovski V E,Baranovski AV.Gas dynamic cold spray method and apparatus:US, 20160047052[P].2016-02-18 Li Wenya、Zhang Dongdong、Huang Chunjie、Guo Xueping、積層造形及び修理再製造の分野でのコールドスプレー技術の応用研究状況[J]、溶接、2016、(4):2-8、73 Liu Jiyan、Ma Shining、Li Changqing、et al、電気スパーク溶融コーティングの特性と応用[C]、第7回全国(中国)表面工学会議及び第2回表面工学青年学術フォーラム議事録、2008:123-126 Fan Baohu、Peng Bonan、Zhang Hengchao、特許文献から化学溶融ダイヤモンドフィルムテクノロジーの進行状況の分析[J] .真空、2016(05):37~40
成形しようとする部品の3次元モデルに従って、積層成形軌道とコーティング強化軌道をプリセットするステップ1と、
積層成形装置は、プリセット積層成形軌道に従って上記作業台の上で、層ごとに成形しようとする部品を複数層成形し、次に、レーザー支援コールドスプレー装置は、プリセットされたコーティング強化軌道に従って、成形しようとする部品の内面及び外面にコーティング強化処理を実行するステップ2と、
部品の製造が完了するまでステップ2を数回繰り返すステップ3と、を含む上記システムを使用して実現される、積層造形と表面コーティングの複合成形方法を提案する。
1.本発明は、部品についてショートプロセスの積層造形及び表面強化複合加工を行う場合、積層造形プロセス中に、成形しようとする部品の外面、又は内部キャビティに対して層ごと、又は間隔層ごと(つまりある層を加工する後、その直後の層を加工しなくてもっと後の層を加工する方式)にコーティング及び強化をするのに対し、従来の表面塗装工程は、部品の積層造形が完了した後に行われるため、複雑な部品の場合、塗布が困難、塗布効果が悪いなどの問題があるが、本発明は、複雑な内部キャビティ及び外壁構造、且つ高い表面強化要件を有する既存の航空エンジン部品などの直接積層造形及び表面コーティング複合成形における技術的ボトルネックを効果的に克服できる。
すべての図面において、同じ図面の記号は同じ素子又は構造を示すために使用され、その中で、1作業台、2基板、3ミリング・研磨複合装置、4マイクロローリング装置、5成形しようとする部品、6成形しようとする部品の内面及び外面、7積層成形装置、8積層成形表面、9レーザー支援コールドスプレー装置である。
好ましくは、粉体貯蔵供給ユニットには、2つ以上の粉体貯蔵供給タンクが含まれ、粉体貯蔵供給ユニットの粉末供給速度は40~70g/分、粉末粒径は5~60μm、予熱温度は400~800℃である。
具体的に、該複合装置は5軸リンケージ工作機械に設置され、ダブルガントリー又はロボットアームと連携して、ショートプロセスの複合積層造形を実現し、このうち、積層成形装置7、マイクロローリング装置4、及びミリング・研磨複合装置3は、一つのダブルガントリー又はロボットアームに配置され、同時に、各装置には昇降装置が装備されているため、各装置は独立して動作し、必要な機器を自由に切り替えることができ、レーザー支援コールドスプレー装置9がもう一つのガントリー又はロボットアームに配置され、同時に、作業台1は工作機械のC軸とA軸に従って回転できるため、加工中に成形しようとする部品5の加工面は、加工設備と垂直になり、より良い成形品質と効果が達成できる。
成形しようとする部品5の幾何学的形態とコーティング強化領域の要件に応じて、成形しようとする部品5の3DのCADモデルについて層状スライス処理をして、複数の層状スライスのデータを取得し、層状スライスデータに従って積層成形軌道及びコーティング強化軌道をプリセットするステップS1と、
積層形成装置7は、レーザー及び電気アークなどの速い成形方法を使用して、プリセットされた積層成形軌道に従って基板2上に形成しようとする部品5を層ごとに複数層成形するステップS2と、
レーザー支援コールドスプレー装置9は、プリセットされたコーティング強化軌道に従って、成形しようとする部品の内面及び外面6についてコーティング強化処理を実行し、具体的には、コーティング中に、レーザー支援コールドスプレーガンが成形しようとする部品5と干渉しないように、レーザー支援コールドスプレーガンはコーティングされる表面の法線ベクトルと特定の角度を形成するテップS3と、
部品の製造が完了するまでステップS2からステップS3までのステップを数回繰り返すステップS4と、を含む。
(1)上記システムを使用して、高強度鋼の基板部品の表面に銅又は銅合金をコーティングすることで、部品の表面潤滑を強化し、部品の耐摩耗性を向上させ、得られた部品は、エンジン及び航空宇宙分野の部品に対する完全性、軽量性、強度、及び安定性の要件を満たし、
(2)上記のシステムは、勾配機能と高融点材料のクラッドに特に適しており、例えば、セラミック材料は高融点、耐摩耗性、耐食性などの利点があるが、その脆さと加工の難しさなので高性能材料の製造に適用されにくくなり、同時に、セラミックと金属の特性の違いにより、強固な接合を生成することが困難になり、また、セラミック金属材料と金属の物理的適合性が低く、密着結合を形成することが困難であるが、上記のシステムを使用することで、金属部品の表面にセラミック、又はセラミック金属材料をコーティングして、傾斜機能を有するセラミックコーティングの金属部品を製造できる。
Claims (5)
- 積層成形装置(7)とレーザー支援コールドスプレー装置(9)と作業台(1)が含まれ、ここで、前記積層成形装置(7)とレーザー支援コールドスプレー装置(9)は、作業台(1)の上方に配置され、加工中、前記積層成形装置(7)は、前記作業台(1)の上で成形しようとする部品(5)を層ごとに成形し、前記レーザー支援コールドスプレー装置(9)は、前記成形プロセス中に、成形しようとする部品の複合加工と製造を共同で完了するように、成形しようとする部品の内面及び外面(6)に対してコーティングと強化処理を実行する積層造形と表面コーティングの複合形成システムであって、
前記複合成形システムには、マイクロローリング装置(4)とミリング・研磨複合装置(3)がさらに含まれ、前記複合成形システムは、5軸リンケージ工作機械に設置されて、ダブルガントリー又はロボットアームと連携し、
前記積層成形装置(7)、前記マイクロローリング装置(4)、及び前記ミリング・研磨複合装置(3)は、一つのダブルガントリー又はロボットアームに配置され、前記レーザー支援コールドスプレー装置(9)がもう一つのガントリー又はロボットアームに配置され、
さらに、前記マイクロローリング装置(4)とミリング・研磨複合装置(3)は、前記作業台(1)の上方に配置され、前記マイクロローリング装置(4)とミリング・研磨複合装置(3)は、積層成形装置(7)が成形しようとする部品(5)を層ごとに成形するプロセスで、成形しようとする部品(5)に対して仕上げ加工を行うことを特徴とする積層造形と表面コーティングの複合成形システム。 - 前記レーザー支援コールドスプレー装置(9)には、順次接続されているガス圧縮乾燥ユニット、粉体貯蔵供給ユニットとリングレーザーユニットが含まれ、加工中、粉体貯蔵供給ユニット内の塗料粉体は、ガス圧縮乾燥ユニットに圧縮乾燥されたガスによってリングレーザーユニットに送られて、リングレーザーユニットで加熱された後に、成形しようとする部品の内面及び外面(6)にコーティングされることを特徴とする請求項1に記載の積層造形と表面コーティングの複合成形システム。
- 前記粉体貯蔵供給ユニットには、2つ以上の粉体貯蔵供給タンクが含まれることを特徴とする請求項2に記載の積層造形と表面コーティングの複合成形システム。
- 前記粉体貯蔵供給ユニットの粉末供給速度は40~70g/分、粉末粒径は5~60μm、予熱温度は400~800℃であることを特徴とする請求項2に記載の積層造形と表面コーティングの複合成形システム。
- 成形しようとする部品(5)の3次元モデルに従って、積層成形軌道とコーティング強化軌道をプリセットするステップS1と、
積層成形装置(7)は、プリセットされた積層成形軌道に従って前記作業台(1)の上で、層ごとに複数層の成形しようとする部品(5)を成形し、次に、レーザー支援コールドスプレー装置(9)は、プリセットされたコーティング強化軌道に従って、成形しようとする部品の内面及び外面(6)にコーティング及び強化処理を実行するステップS2と、
部品の製造が完了するまでステップS2を数回繰り返すステップS3と、を含み、請求項1~4のいずれか1項に記載のシステムによって実施されることを特徴とする積層造形と表面コーティングの複合成形方法。
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