WO2018223478A1 - 双激光束熔敷成形冲击锻打复合增材制造方法 - Google Patents

双激光束熔敷成形冲击锻打复合增材制造方法 Download PDF

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WO2018223478A1
WO2018223478A1 PCT/CN2017/092076 CN2017092076W WO2018223478A1 WO 2018223478 A1 WO2018223478 A1 WO 2018223478A1 CN 2017092076 W CN2017092076 W CN 2017092076W WO 2018223478 A1 WO2018223478 A1 WO 2018223478A1
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Prior art keywords
laser
forging
impact
laser beam
layer
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PCT/CN2017/092076
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English (en)
French (fr)
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张永康
张峥
关蕾
杨青天
杨智帆
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广东工业大学
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Priority to US16/153,711 priority Critical patent/US20190047050A1/en
Publication of WO2018223478A1 publication Critical patent/WO2018223478A1/zh

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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • 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
    • B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • B23K26/356—Working by laser beam, e.g. welding, cutting or boring for surface treatment by shock processing
    • 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
    • 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
    • B22F10/20—Direct sintering or melting
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • 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
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • 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
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/364—Process control of energy beam parameters for post-heating, e.g. remelting
    • 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
    • B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
    • 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
    • B22F12/43—Radiation means characterised by the type, e.g. laser or electron beam pulsed; frequency modulated
    • 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
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B22F12/45—Two or more
    • 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
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • 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
    • B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
    • 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
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/0604—Shaping the laser beam, e.g. by masks or multi-focusing by a combination of beams
    • B23K26/0608—Shaping the laser beam, e.g. by masks or multi-focusing by a combination of beams in the same heat affected zone [HAZ]
    • 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
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
    • B23K26/0622—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses
    • B23K26/0624—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses using ultrashort pulses, i.e. pulses of 1ns or less
    • 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
    • B23K26/14—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
    • B23K26/144—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor the fluid stream containing particles, e.g. powder
    • 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
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • C23C24/106—Coating with metal alloys or metal elements only
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • 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
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D10/00—Modifying the physical properties by methods other than heat treatment or deformation
    • C21D10/005—Modifying the physical properties by methods other than heat treatment or deformation by laser shock processing
    • 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

Definitions

  • the invention relates to the technical field of additive manufacturing, in particular to a method for manufacturing a double-laser beam welding forming impact forging composite additive.
  • Additive manufacturing is different from traditional “removal” manufacturing. It does not require original embryos and molds. It is an important development direction of advanced manufacturing technology to directly generate objects of any shape by adding materials according to computer graphics data.
  • the existing pure laser cladding 3D forming process is essentially a "free additive forming" process, and the following common technical problems are common: (1) internal defects: process parameters, external environment, fluctuations and changes in molten pool melt state, scanning Changes in the fill trajectory, etc., may produce various special internal metallurgical defects in the local area of the part, such as pores, unfused, cracked and loose internal defects. These internal defects are the fatal fatigue initiating source of the bearing structure, which affects the internal quality, mechanical properties of the final formed part and the safety of the service. There are some differences between the structural characteristics exhibited by additive metal materials and the common as-cast, forged and as-welded metals. This kind of structural characteristics is unfavorable to metal materials in many cases.
  • the microstructure of the laser-molded laser formed by Inconel 718 in the nickel-based alloy has a texture phenomenon, and there are also Nb and Mo elements in the ⁇ -based solid solution. Segregation.
  • Thermal stress and deformation cracking 3D printing forming is a continuous cycle process of “pitch-by-point scanning melting-by-line scanning lap-layer-by-layer solidification stacking”. The heat transfer efficiency of different parts of the section is different, and the core material is cooled. Slow, the surface material cools faster.
  • Chinese patent CN 103862050 A metal 3D printer and printing method based on interlayer impact strengthening process
  • the special feature of the invention patent is that after a certain number of layers per welding, the 3D printing forming is stopped, and then the welding is performed by a heating device. The upper surface of the layer is heated to 100 ° C - 700 ° C, and then the laser coating is strengthened by laser impact or mechanical shot peening Chemical. This is a combination of three processes of welding, heating and strengthening. Heating and strengthening are post-treatment processes of the deposited layer, not composite processing.
  • the process parameters of these three processes are selected independently, and are not affected and are implemented separately.
  • the following problems affect the practicability: (1) after the molten layer is cooled and then laser shock-strengthened, the plastic deformation is small, and it is difficult to eliminate internal defects such as voids, shrinkage, and microcracks inside the deposited layer; (2) melting
  • the complexity of the coating heating device will increase exponentially with the increase of the size of the welded parts and the increase of structural complexity, and it is even difficult to achieve, and the local heating technology is more difficult. Heating a cooled 3D printed large component to 700 ° C will take a very long time, and after a few layers of heating, a heating cycle will be very inefficient.
  • Chinese patent CN 104525944 A discloses a high energy beam-ultrasonic composite additive manufacturing method for metal materials, and discloses the following technical features: "The metal forming material is melted by a high energy beam, and after a certain number of layers are melted/solidified layer by layer, The solidification is subjected to ultrasonic shock, and then the layer-by-layer melting/solidification stacking and ultrasonic impact process are continued until the molding process of the entire metal member is completed.
  • Chinese patent CN 103305828 A discloses an apparatus for ultrasonically reinforced and strengthened cladding layer and a method thereof, and discloses the following technical features: “A laser impact layer is ultrasonically impacted by an ultrasonic gun after preparation of a laser cladding layer is completed, Ensure that the coverage rate reaches 100%. Finally, after the impact of a laser cladding layer is completed, the next laser cladding process is carried out, and the ultrasonic impact and the laser cladding cycle are alternated to finally realize the preparation of the complete laser cladding layer.
  • the two invention patents are a combination of two processes of welding or melting/solidification-ultrasonic impact. The process parameters of the two processes are independent of each other, and are not affected by each other, and are not separately processed.
  • the invention provides a double laser beam welding forming impact forging composite additive manufacturing method, which adopts a dual laser beam simultaneous composite manufacturing process, that is, the first continuous laser uses a thermal effect to weld the metal powder, and the second short pulse laser Synchronous impact forging of the material in the welding zone is carried out by using the mechanical effect of the shock wave to perform composite manufacturing, and the material of the welding zone is stacked layer by layer to form a workpiece.
  • the choice of the two laser beam parameters interacts with each other, and the best match between the two can ensure the best forming speed and forging quality.
  • the method is significantly different from the above method in the composite manufacturing process, and the metal melting is performed in the metal deposition stage.
  • the two processes of coating and plastic impact forging improve the processing efficiency of the parts while ensuring the forming quality, effectively solving the contradiction between the manufacturing efficiency and quality of the metal cladding forming.
  • the Chinese patent CN 106141439 A discloses a laser shock device for eliminating residual stress of a laser-melted shaped article, and discloses the following technical features: "The top of the forming cavity is provided with a laser sintering system and a short-pulse laser emitting system, and a hydraulic cylinder is disposed in the forming cylinder.
  • the piston rod of the hydraulic cylinder is provided with a bottom plate on which the laser shock wave detecting system for detecting shock waves, the short pulse laser emitting system and the laser shock wave detecting system are all connected with the main control system, and the forming laser sintering system (2)
  • the main control system (8) adjusts the steering direction of the three-dimensional adjustment mechanism (12) on the scanning galvanometer (13) according to the sectional profile information of the shaped product, so that the scanning galvanometer (13) is rotated to make the
  • the short pulse laser trajectory of the scanning galvanometer (13) moves along the cross-sectional profile of the product to impact-strengthen the product (see paragraph [0019] of the specification), which is sintered first and then impact-strengthened, which is SLM sintering-laser
  • the integration of the two processes of impact strengthening is not a composite process, and its essence is consistent with the Chinese patent CN 103862050 A.
  • This patent is essentially different from the present invention.
  • it has the following problems that affect the practicality: (1) After the SLM sintered layer formed product has a section, the product is impact-strengthened, and the plastic deformation is small, and it is difficult to eliminate voids, shrinkage, microcracks, etc. inside the deposited layer. Internal defects; (2) Laser shock enhancement is a special term that was first proposed by the United States (Laser shock-processing, Laser peening, Laser shock-peening), and was listed as the key manufacturing technology of the fourth generation of aero-engines by the United States.
  • One of the currently used lasers for engineering applications is a neodymium glass laser, a YAG laser and a YLF laser.
  • the laser pulse power density must exceed 10 9 W/cm 2 , but it is not currently possible to transmit such a high pulsed laser beam with an optical fiber; (3) shock wave
  • the strength decays negatively in the general metal material, and the attenuation is faster in the sintered layer with defects such as void shrinkage.
  • the propagation law is more complicated. It is difficult to detect the effective signal with the PVDF pressure sensor. Increased, the laser shock wave signal detection is more difficult to identify, and even the authenticity of the signal cannot be discriminated.
  • the object of the present invention is to provide a double laser beam welding forming impact forging composite additive manufacturing method, which can avoid the problems of pores, unfusion and shrinkage, and improve the mechanical properties and fatigue strength of the metal parts.
  • the method includes the following steps:
  • the first continuous laser uses a thermal effect to deposit the metal powder, while the second short pulse laser directly acts on the surface of the deposited metal in the forging temperature range, and the surface of the metal absorbs the energy of the laser beam and is vaporized and ionized.
  • Shock wave using the second beam of short pulse laser shock wave mechanical effect The impact layer is subjected to impact forging in the forging temperature range.
  • the amount of coaxial powder feeding is monitored and controlled by the powder feeder.
  • the amount of coaxial powder feeding determines the thickness and area of the welding zone, and affects the moving speed of the first continuous laser beam and the second beam of short pulse laser forging parameters; If the amount of powder exceeds/does not reach the first continuous laser processing amount, the moving speed of the first continuous laser beam is lowered/increased to form a coupling control.
  • the second short-pulse laser forging parameter is monitored and controlled by the beam quality detecting instrument or device, and the pulse width of the pulsed laser is determined by the thickness of the material of the welding zone, so that the entire material of the cladding layer is fully forged and punched;
  • the material area determines the pulse laser forging frequency and the spot size, ensuring that the laser impact forging movement speed matches the laser deposition speed, and ensures that the forging zone temperature is always within the temperature range most susceptible to plastic deformation; such as the material area of the deposition zone/ If the thickness exceeds the second short pulse laser processing limit, the first continuous laser beam moving speed is reduced to form a closed loop control, and vice versa.
  • the double laser beam simultaneously and mutually synergistically stacks the material of the deposition zone layer by layer to form a workpiece, so that the processing efficiency is improved by 1 to 2 times.
  • the laser impact forging frequency and pulse power density By adjusting the laser impact forging frequency and pulse power density, the difference between the cooling rate of different materials and the forging temperature interval is solved, so that the deposited layer can complete the impact strengthening under high plasticity and low deformation resistance and the forging frequency by laser impact
  • the laser welding speed and powder feeding parameters are regulated with pressure parameters.
  • the laser impact forging makes the deposited layer crystal grains remarkably finer, and the strength and fatigue life of different materials after welding can be increased by several times to several tens of times.
  • the stability of the above various process parameters ensures that the layer-by-layer grain size is controllable, thereby achieving uniformity of the grain size of the entire deposited layer.
  • the internal defects and thermal stress such as pores of the deposited layer are eliminated, the internal quality and comprehensive mechanical properties of the metal parts are improved, and the macroscopic deformation and cracking problems are effectively controlled.
  • the dual laser beam welding forming impact forging composite additive manufacturing method is characterized in that the first continuous laser beam forging temperature field model and on-line detection are established according to the forging temperature characteristics of different deposited metal materials. Control method; by testing the grain size, residual stress distribution and microstructure of the forged cladding layer, the forging temperature field model is improved, so that the material is deposited and cooled to be in the most suitable metal plastic forming temperature range (forging temperature).
  • the impact is forged by the second short pulse laser to form a closed loop control.
  • the dual laser beam welding forming impact forging composite additive manufacturing method is characterized in that the double laser beam composite manufacturing process parameters are subjected to on-line detection and control, and the second short pulse laser can perform front or side of the deposited layer. Impact forging at any angle or position within 15° ⁇ 165°, with precise parameters of laser pulse energy, laser pulse width, repetition frequency, spot size and shape. Adjustable, it can process welded parts with different structural features.
  • the double laser beam welding forming impact forging composite additive manufacturing method breaks through the quality defects of the conventional metal cladding forming, and avoids the secondary heating and heat caused by the secondary strengthening process.
  • the disadvantages of stress and efficiency reduction are proposed.
  • the composite manufacturing process based on laser thermal effect and shock wave mechanical effect is proposed. Simultaneous laser impact treatment is applied to the welding zone while the heat source melts the metal powder to form the welding zone, and the forming process is completed in one step. Strengthen the process, with remarkable features of high efficiency and high quality.
  • 1 is a implementation step of a method for manufacturing a double laser beam welding forming impact forging composite additive according to the present invention
  • FIG. 2 is a schematic view of the microstructure of the deposited layer, wherein the deposited layer-1, the molten pool-2, the metal powder-3, the continuous laser-4, the short pulse laser-5, the plasma-6, the shock wave-7, the pores, the shrinkage Loose and unfused defects - 8, fused metal crystals - 9, short pulse laser variable angle - 10.
  • Figure 3 is a first continuous laser deposition temperature field model with a spot diameter of 3 mm.
  • FIG. 1 is a step of a specific embodiment of the present invention.
  • the dual laser beams work simultaneously and in cooperation with each other, and the parameters include the first continuous laser powder feeding amount, the moving speed, the second short pulse laser repetition frequency, the pulse width, the spot diameter and the angle, and the two lasers. distance.
  • the first continuous laser parameter is determined by the material properties of the formed part.
  • °C, laser cladding metal, the temperature of the molten pool can be obtained by the following energy conservation equation:
  • the formula is derived from the formula (6) of the paper “Three-dimensional numerical simulation of temperature field evolution during laser metal cladding forming process” (see Zhang Dongyun, Wu Rui, Zhang Huifeng, et al. Three-dimensional numerical values of temperature field evolution during laser metal cladding forming process) Simulation [J]. China Laser, 2015, 42(5): 104-115.); where ⁇ is the density function, h is the heat dissipation coefficient, H is the thermal enthalpy function, T is the temperature, and k is the thermal conductivity.
  • V is the velocity function
  • f s is the state parameter
  • the value range is [0,1]
  • f s 0 means solid state
  • f s 1 means liquid state
  • subscript s represents solid state
  • l represents liquid status
  • the first laser power density was set to 2500 W
  • the outer diameter of the spot was 3 mm
  • the initial coaxial powder feeding amount was 10.2 g/min
  • the initial deposited layer thickness was 0.43 mm
  • the initial laser beam moving speed was 3 mm/s.
  • the continuous laser thermal effect produces a molten pool (2), which is monitored online by the beam quality inspection instrument and fed back to the controller in real time.
  • the first continuous laser beam forging temperature field model was established by ABAQUS software, as shown in Fig. 3.
  • the material is deposited and cooled to be in the most suitable metal plastic forming temperature range (forging temperature), and the second short pulse laser is used for impact forging to form a closed loop control.
  • the most suitable forging temperature range of the Fe 313 alloy powder is (0.5T to 0.8T), that is, 746 ° C to 1194 ° C, and the temperature distribution of the molten pool region can be obtained by the beam quality detecting instrument.
  • the temperature distribution of the outer edge of the beam spot of the laser beam shows that the time taken for the material at the edge of the first laser spot to be cooled from 1500 ° C (higher than the melting point) to the most suitable forging temperature range of 746 ° C to 1194 ° C is 0.11 s to 0.43. s. Therefore, according to the initial moving speed of the first continuous laser beam of 3 mm/s, the distance of the second short-pulse laser from the edge of the first laser spot is determined to be 0.33 mm to 1.29 mm.
  • the center of the second laser beam is 0.33 mm to 1.29 mm from the edge of the first laser spot.
  • the second short pulse laser parameter is determined by the initial value of the first continuous laser.
  • the material In order to eliminate the internal defects and thermal stress of the pores of the deposited layer, improve the internal quality and comprehensive mechanical properties of the part, and effectively control the macroscopic deformation and cracking problems, the material must be deposited and cooled to be in the most suitable metal plastic forming temperature range.
  • the purpose of the present invention can be achieved by performing impact forging in this temperature range.
  • the spot shape of the short pulse laser is a square spot with a size of 3 ⁇ 3 mm 2 , and the forging frequency is determined to be 20 Hz, so that the material in the most suitable forging temperature interval is fully forged, and the first laser beam moving rate is determined to determine the second beam moving.
  • the rate is 3mm/s.
  • the impact is generated by the second short pulse laser (5), and the plasma is generated by the impact (6), and passes through a certain depth of the deposited layer in the form of a shock wave (1), which makes the pores, shrinkage and not under the action of the shock wave mechanical effect.
  • the fusion defect (8) is closed to achieve the purpose of equivalent forging;
  • the powder feeder controls the thickness and area of the welding zone and affects the moving speed of the first continuous laser beam.
  • the initial powder feed amount 10.2 g/min will increase/decrease, resulting in an over/under reaching the throughput of the first continuous laser initial parameter.
  • the initial parameter processing amount is continuous laser moving speed 3 mm/s, and the thickness of the deposited layer is 0.42 mm), at which time the initial moving speed of the first continuous laser beam is lowered/increased by 3 mm/s.
  • the second short pulse laser forging parameter is determined by the initial value of the first continuous laser.
  • the second short pulse laser parameter changes accordingly.
  • the initial value of the second beam short pulse laser cannot satisfy the sufficient treatment of the material of the cladding layer, and the beam quality
  • the detecting instrument reduces the moving speed of the first continuous laser beam at this time, reduces the material area of the welding zone, forms a closed loop control, and ensures full forging of the material, and vice versa.
  • the second short-pulse laser can be used for impact-forging of the deposited layer at any angle or position within 15° ⁇ 165° on the front or side. It has precise parameters such as laser pulse energy, laser pulse width, repetition frequency, spot size and shape. Controlled and adjustable, it can process welded parts with different structural features.
  • the invention solves the difference of the cooling rate of different materials and the range of the forging temperature by adjusting the laser impact forging frequency and the pulse power density, so that the deposited layer is subjected to impact strengthening under high plasticity and low deformation resistance and is forged by laser impact.
  • Frequency and pressure parameters are used to control the laser deposition speed and powder feeding parameters.
  • the laser impact forging makes the deposited layer crystal grains remarkably finer, and the strength and fatigue life of different materials after welding can be increased by several times to several tens of times.
  • the stability of the above various process parameters ensures that the layer-by-layer grain size is controllable, thereby achieving uniformity of the grain size of the entire deposited layer.
  • the internal defects and thermal stress such as pores of the deposited layer are eliminated, the internal quality and comprehensive mechanical properties of the metal parts are improved, and the macroscopic deformation and cracking problems are effectively controlled.

Abstract

一种双激光束熔敷成形冲击锻打复合增材制造方法：1)两束不同功能的激光束同时且相互协同逐层堆叠熔敷区材料形成工件；2)第一束连续激光（4）利用热效应对金属粉末（3）进行熔敷，与此同时第二束短脉冲激光（5）直接作用在锻造温度范围内的熔敷金属表面，利用第二束短脉冲激光（5）冲击波力学效应对处于锻造温度范围内的熔敷层进行冲击锻打。从而提高了整个块体材料的强度和塑性以及晶粒尺寸的均匀性，消除了熔敷层的气孔等内部缺陷和热应力，显著提高了金属零件的内部质量和机械力学综合性能，并有效控制宏观变形与开裂问题。

Description

双激光束熔敷成形冲击锻打复合增材制造方法 技术领域
本发明涉及增材制造技术领域，特别涉及一种双激光束熔敷成形冲击锻打复合增材制造方法。
背景技术
增材制造区别于传统的“去除”制造，不需要原胚和模具，直接根据计算机图形数据，通过增加材料的方法生成任何形状的物体，是先进制造技术的重要发展方向。
现有单纯激光熔敷3D成形工艺其实质是“自由增材成形”工艺，普遍存在如下共性技术问题：(1)内部缺陷：工艺参数、外部环境、熔池熔体状态的波动及变化、扫描填充轨迹的变换等，都可能在零件内部局部区域产生各种特殊的内部冶金缺陷，例如，气孔、未熔合、裂纹和缩松内部缺陷等。这些内部缺陷是承力结构件致命的疲劳萌生源，其影响最终成形零件的内部质量、力学性能及构件的服役使用安全。增材制造金属材料所呈现出的组织特征与常见的铸态、锻态、焊态金属存在着一定的差异。这种组织特征在很多情况下对金属材料而言是不利的，例如，镍基合金Inconel 718选区激光熔化成型的显微组织出现了织构现象，ν基固溶体中还存在有Nb、Mo元素的偏析。(2)热应力与变形开裂：3D打印成形是一个“逐点扫描熔化-逐线扫描搭接-逐层凝固堆积”的不断循环过程，零件截面不同部位传热效率不同，芯部材料冷却较慢，表层材料冷却较快。在这种强约束下移动熔池的快速凝固收缩、循环加热及非均匀冷却下的非平衡固态相变过程中，零件内产生复杂热应力、组织应力及应力集中和变形，严重影响零件几何尺寸和力学性能，导致零件严重翘曲变形和开裂。
因此，如何在通过金属增材制造金属零件时，尽量避免气孔、未融合和缩松问题，是本领域技术人员亟待解决的技术问题。中国专利CN 103862050 A基于层间冲击强化工艺的金属3D打印机及打印方法，该发明专利的特殊之处在于，采取每熔敷一定的层数后，停止3D打印成形，然后通过加热装置将熔敷层上表面加热到100℃-700℃，再对熔敷层进行激光冲击强化或机械喷丸强 化。这是熔敷-加热-强化三道工序的组合，加热和强化是熔敷层的后处理工艺，不是复合加工。这三道工序的工艺参数选择各自独立，不影响，单独实施。其存在如下影响实用性的问题：(1)熔敷层冷却后再激光冲击强化，其塑性变形小，很难消除熔敷层内部的空洞、缩松、微裂纹等内部缺陷；(2)熔敷层加热装置复杂程度随着熔敷零件的尺寸增大和结构复杂性增加将成倍增加，甚至难以实现，局部加温技术难度更大。将一个冷却后的3D打印大型构件加热到700℃将需要非常长的时间，熔敷数层后就一次加温循环，则效率十分低下。(3)机械喷丸很难实现局面区域喷丸强化，而且喷丸的丸粒清理十分困难。中国专利CN 105935771 A一种金属模具3D打印激光微区处理方法，采用分层激光熔敷沉积后，再对熔敷层进行第二次激光表面淬火处理，由此类推，形成金属模具。该方法是通过两次工艺形成金属模具，加工效率低。而且，激光表面淬火仅能够改变零件表面硬度，很难消除熔敷沉积层的内部缺陷，多次反复的激光淬火使得内应力更大，更容易发生变形与开裂。
中国专利CN 104525944 A公开了一种金属材料高能束-超声复合增材制造方法，并且公开了如下技术特征：“由高能束熔化金属成形材料，在逐层熔化/凝固堆积一定层数后，对凝固进行超声冲击，然后继续逐层熔化/凝固堆积和超声冲击过程，直至完成整个金属构件的成型过程”。中国专利CN 103305828 A公开了一种超声冲击强化熔敷层的装置及其方法，并且公开了如下技术特征：“一道激光熔敷层制备完成后，利用超声枪对激光熔敷层进行超声冲击，确保敷盖率达到100％，最后，一道激光熔敷层冲击结束后，进行下一道激光熔敷工艺，超声冲击与激光熔敷循环交替进行，最终实现完整激光熔敷层的制备”。这两个发明专利都是熔敷或熔化/凝固-超声冲击两道工序的组合，这两道工序的工艺参数选择各自独立，互不影响，单独实施，不是复合加工。
本发明提出了双激光束熔敷成形冲击锻打复合增材制造方法，采用双激光束同时复合制造工艺，即第一束连续激光利用热效应对金属粉末进行熔敷，同时第二束短脉冲激光利用冲击波力学效应对熔敷区材料进行同步冲击锻打，进行复合制造，逐层堆叠熔敷区材料形成工件。两束激光束参数选择相互影响，两者之间有最佳的匹配，才能够保证成形速度与锻打质量的最佳。本方法与上述方法显著不同的是复合制造工艺，在金属熔敷阶段进行金属熔 敷与塑性冲击锻打两项工艺，提升了零件加工效率的同时保证成形质量，有效的解决了金属熔敷成形的制造效率和质量之间的矛盾。
中国专利CN 106141439 A公开了消除激光熔化成形制品残余应力的激光冲击装置，并且公开了如下技术特征：“成形腔的顶部设置有激光烧结系统和短脉冲激光发射系统，成形缸内设置有液压缸，液压缸的活塞杆上设置有底板，底板上设置有用于检测冲击波的激光冲击波检测系统、短脉冲激光发射系统和激光冲击波检测系统均与主控系统相连接”，“成形激光器烧结系统(2)成形制品一个截面后，主控系统(8)根据成形制品截面轮廓信息调整扫描振镜(13)上三维调整机构(12)的转向方向，从而使扫描振镜(13)进行转动，使经过扫描振镜(13)的短脉冲激光运动轨迹沿制品截面轮廓运动，对制品进行冲击强化(参见说明书第[0019]段)”，其是先烧结成形然后再冲击强化，是SLM烧结成形-激光冲击强化两道工序的集成，不是复合工艺，其实质和中国专利CN 103862050 A是一致的，这与本发明专利有着本质的区别。此外，其存在如下影响实用性的问题：(1)SLM烧结层成形制品一个截面后再对制品进行冲击强化，其塑性变形小，很难消除熔敷层内部的空洞、缩松、微裂纹等内部缺陷；(2)激光冲击强化是一个特指的专用术语，最早由美国率先提出(Laser shock-processing,Laser peening,Laser shock-peening),被美国列为第四代航空发动机的关键制造技术之一，目前工程化应用的激光器是钕玻璃激光器、YAG激光器和YLF激光器，激光脉冲功率密度必须超过109W/cm2，但目前尚不能用光纤传输如此高脉冲激光束；(3)冲击波强度在一般金属材料内部呈负指数的规律衰减，在有空洞缩松等缺陷的烧结层中衰减更快，传播规律更为复杂，采用PVDF压力传感器很难检测到有效信号，随着烧结零件的增高，激光冲击波信号检测越夹越困难，乃至无法判别信号的真伪。
发明内容
本发明的目的是提供一种双激光束熔敷成形冲击锻打复合增材制造方法，能够避免气孔、未融合和缩松问题，提高金属零件的机械性能和疲劳强度。该方法包括以下步骤：
(1)第一束连续激光利用热效应对金属粉末进行熔敷，与此同时第二束短脉冲激光直接作用在锻造温度范围内的熔敷金属表面，金属表层吸收激光束能量后气化电离形成冲击波，利用第二束短脉冲激光冲击波力学效应对处 于锻造温度范围内的熔敷层进行冲击锻打。
同轴送粉量由送粉器监测与控制，同轴送粉量决定了熔敷区厚度与面积，同时影响第一束连续激光束移动速度和第二束短脉冲激光锻打参数；如送粉量超出/未达到第一束连续激光处理量，则降低/升高第一束连续激光束移动速度，形成耦合控制。
第二束短脉冲激光锻打参数由光束质量检测仪器或装置监测与控制，由熔敷区材料厚度确定脉冲激光的脉冲宽度，使整个熔敷层深度材料获得充分锻打透彻；由熔敷区材料面积确定脉冲激光锻打频率和光斑大小，确保激光冲击锻打移动速度与激光熔敷速度匹配，并保证锻打区温度始终处于最容易塑性变形的温度范围内；如熔敷区材料面积/厚度超出第二束短脉冲激光处理极限，则降低第一束连续激光束移动速度，形成闭环控制，反之亦然。
(2)双激光束同时且相互协同地逐层堆叠熔敷区材料形成工件，使得加工效率提高1～2倍。通过调整激光冲击锻打频率及脉冲功率密度，解决了不同材料冷却速率及锻造温度区间大小的差异，使熔敷层在较高的塑性及低变形抗力下完成冲击强化并通过激光冲击锻打频率与压力参数调控激光熔敷速度与送粉参数。激光冲击锻打使熔敷层晶粒显著细化，不同材料熔敷成形后的强度和疲劳寿命可提高几倍到几十倍不等。上述各工艺参数的稳定性保证了逐层晶粒尺寸可控，从而实现整个熔敷层晶粒尺寸的均匀性。消除了熔敷层的气孔等内部缺陷和热应力，提高了金属零件的内部质量和综合力学性能，并有效控制宏观变形与开裂问题。
优选的，双激光束熔敷成形冲击锻打复合增材制造方法，其特征在于，根据不同熔敷金属材料的锻造温度特性，建立所述第一束连续激光束锻造温度场模型与在线检测及控制方法；通过检测锻打熔敷层的晶粒尺寸、残余应力分布和微观组织等试验，完善锻打温度场模型，使材料熔敷-冷却后处于最适合金属塑性成形温度区间(锻造温度)，由第二束短脉冲激光进行冲击锻打，形成闭环控制。
优选的，双激光束熔敷成形冲击锻打复合增材制造方法，其特征在于，双激光束复合制造工艺参数实行在线检测和控制，第二束短脉冲激光可对熔敷层进行正面或者侧面15°～165°内任意角度或者位置的冲击锻打，具有激光脉冲能量、激光脉冲宽度、重复频率、光斑尺寸和形状等参数精确可控可 调，可处理不同结构特点的熔敷成形零件。
综上所述，本发明所提供的双激光束熔敷成形冲击锻打复合增材制造方法，突破了传统金属熔敷成形的质量缺陷，同时避免了二次强化工艺导致的二次加热、热应力和效率降低的缺点，提出了基于激光热效应和冲击波力学效应复合制造工艺，在热源熔化金属粉末形成熔敷区的同时，对熔敷区同步进行激光冲击处理，在一步制造工序中完成成形与强化工艺，具有高效、高质量的显著特点。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图示出的结构获得其他的附图。
图1为本发明所提出的双激光束熔敷成形冲击锻打复合增材制造方法实施步骤；
图2为熔敷层的微观结构示意图，其中熔敷层—1，熔池—2，金属粉末—3，连续激光—4，短脉冲激光—5，等离子—6，冲击波—7，气孔、缩松和未融合缺陷—8，已融合金属晶体—9，短脉冲激光可变角度—10。
图3第一束连续激光熔敷温度场模型，光斑直径为3mm。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明的一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
请参考图1，图1为本发明所提供的一种具体实施方式的步骤。
1)双激光束同时且相互协同工作，参数包括第一束连续激光送粉量、移动速度，第二束短脉冲激光重复频率、脉冲宽度、光斑直径和角度，还包括两束激光之间的距离。
2)逐层堆叠熔敷区材料形成工件。
下面以“Fe 313合金粉末的双激光束熔敷成形冲击锻打复合增材制造”为实施例，详细说明两束激光参数之间的协调与耦合以及双激光束复合制造工艺。
如图2所示：
●第一束激光参数的初始值设定
第一束连续激光参数由成形零件的材料特性决定，本实施例中，根据Fe313合金粉末的熔点T＝1493℃，所述第一束连续激光束(4)产生的熔池温度设定为1500℃，激光熔敷金属，熔池的温度可以通过下列能量守恒方程得到：
Figure PCTCN2017092076-appb-000001
该公式引自文献“激光金属熔敷成形过程中温度场演化的三维数值模拟”的公式(6)(见张冬云,吴瑞,张晖峰,等.激光金属熔敷成形过程中温度场演化的三维数值模拟[J].中国激光,2015,42(5):104-115.)；其中，式中ρ为密度函数，h为散热系数，H为热焓函数，T为温度，k为热导率，
Figure PCTCN2017092076-appb-000002
是Nabla算子，V是速度函数，fs是状态参数，取值范围为[0,1]，fs＝0表示固态，fs＝1表示液态，下标s代表固体状态，l代表液体状态，
Figure PCTCN2017092076-appb-000003
为保护气体以及粉末等带来的能量变化量。
由此设定第一束激光功率密度为2500W，光斑外环直径3mm，初始同轴送粉量为10.2g/min，初始熔敷层厚度0.43mm，激光束初始移动速度为3mm/s。
●温度监控与反馈
连续激光热效应产生了熔池(2)，熔池区域光束质量检测仪器在线监测，并实时反馈至控制器。
根据Fe 313合金粉末材料的锻造温度特性，采用ABAQUS软件建立所述第一束连续激光束锻造温度场模型，如图3所示。通过分析温度场模型，使材料熔敷-冷却后处于最适合金属塑性成形温度区间(锻造温度)，由第二束短脉冲激光进行冲击锻打，形成闭环控制。
●两束激光之间距离设定
在本实施例中，Fe 313合金粉末的最合适锻打温度区间为(0.5T～0.8T)，即746℃～1194℃，由光束质量检测仪器可获得熔池区域的温度分布。由第一 束激光光斑外环边缘温度分布可知，处于第一束激光光斑边缘的材料由1500℃(高于熔点温度)冷却至最合适锻打温度区间746℃～1194℃所花费的时间为0.11s～0.43s。因此根据第一束连续激光的初始移动速度3mm/s，确定了第二束短脉冲激光距离第一束激光光斑边缘的距离为0.33mm～1.29mm。
即第二束激光中心距离第一束激光光斑边缘0.33mm～1.29mm，
●第二束激光参数的设定
第二束短脉冲激光参数由第一束连续激光初始值决定。为了消除了熔敷层的气孔等内部缺陷和热应力，提高零件的内部质量和综合力学性能，并有效控制宏观变形与开裂问题，必须使材料熔敷-冷却后处于最适合金属塑性成形温度区间，在此温度区间内进行冲击锻打才能实现本发明目的。
由熔敷层厚度0.43mm设定第二束短脉冲激光的脉冲宽度为10ns，由熔敷区面积S＝第一束激光光斑直径×移动速率＝3mm×3mm/s＝9mm2确定第二束短脉冲激光的光斑形状为方形光斑，尺寸为3×3mm2，确定锻打频率20Hz，保证处于最合适锻打温度区间的材料充分锻打，匹配第一束激光移动速率确定第二束激光移动速率3mm/s。
由第二束短脉冲激光(5)进行冲击，冲击产生等离子体(6)，并以冲击波形式穿过一定的熔敷层深度(1)，在冲击波力学效应作用下使得气孔、缩松和未融合缺陷(8)闭合，达到等效锻造的目的；
●两束激光参数之间的协同配合
送粉器控制熔敷区厚度与面积，同时影响第一束连续激光束移动速度。当熔敷成形遇到面积增大/减小的切片截面时，此时初始送粉量10.2g/min将增大/减小，导致超出/未达到第一束连续激光初始参数下的处理量(初始参数处理量为连续激光移动速度3mm/s，熔敷层厚度0.42mm)，此时则降低/升高第一束连续激光束初始移动速度3mm/s。
第二束短脉冲激光锻打参数由第一束连续激光初始值决定，当第一束连续激光移动速度改变时，第二束短脉冲激光参数随之变化。在本实施例中，如果熔敷区材料面积大于初始值S＝9mm2，厚度超出初始值0.42mm，则第二束短脉冲激光的初始值不能满足对熔敷层材料的充分处理，光束质量检测仪器此时降低第一束连续激光束移动速度，降低熔敷区材料面积，形成闭环控制，保证对材料的充分锻打，反之亦然。
第二束短脉冲激光可对熔敷层进行正面或者侧面15°～165°内任意角度或者位置的冲击锻打，具有激光脉冲能量、激光脉冲宽度、重复频率、光斑尺寸和形状等参数精确可控可调，可处理不同结构特点的熔敷成形零件。
本发明通过调整激光冲击锻打频率及脉冲功率密度，解决了不同材料冷却速率及锻造温度区间大小的差异，使熔敷层在较高的塑性及低变形抗力下完成冲击强化并通过激光冲击锻打频率与压力参数调控激光熔敷速度与送粉参数。激光冲击锻打使熔敷层晶粒显著细化，不同材料熔敷成形后的强度和疲劳寿命可提高几倍到几十倍不等。上述各工艺参数的稳定性保证了逐层晶粒尺寸可控，从而实现整个熔敷层晶粒尺寸的均匀性。消除了熔敷层的气孔等内部缺陷和热应力，提高了金属零件的内部质量和综合力学性能，并有效控制宏观变形与开裂问题。

Claims (3)

  1. 双激光束熔敷成形冲击锻打复合增材制造方法，其特征在于，包括如下步骤：
    所述双激光束熔敷成形冲击锻打复合增材制造是指两束不同功能的激光束同时且相互协同制造金属零件的过程；第一束连续激光利用热效应对金属粉末进行熔敷，与此同时第二束短脉冲激光直接作用在锻造温度范围内的熔敷金属表面，金属表层吸收激光束能量后气化电离形成冲击波，利用第二束短脉冲激光冲击波力学效应对处于锻造温度范围内的熔敷层进行冲击锻打；
    同轴送粉量由送粉器监测与控制，同轴送粉量决定了熔敷区厚度与面积，同时影响第一束连续激光束移动速度和第二束短脉冲激光锻打参数；如送粉量超出/未达到第一束连续激光处理量，则降低/升高第一束连续激光束移动速度，形成耦合控制；
    第二束短脉冲激光锻打参数由光束质量检测仪器或装置监测与控制，由熔敷区材料厚度确定脉冲激光的脉冲宽度，使整个熔敷层深度材料获得充分锻打透彻；由熔敷区材料面积确定脉冲激光锻打频率和光斑大小，确保激光冲击锻打移动速度与激光熔敷速度匹配，并保证锻打区温度始终处于最容易塑性变形的温度范围内；如熔敷区材料面积/厚度超出第二束短脉冲激光处理极限，则降低第一束连续激光束移动速度，形成闭环控制，反之亦然；
    双激光束同时且相互协同地逐层堆叠熔敷区材料形成工件，使得加工效率提高1～2倍；通过调整激光冲击锻打频率及脉冲功率密度，解决了不同材料冷却速率及锻造温度区间大小的差异，使熔敷层在较高的塑性及低变形抗力下完成冲击强化并通过激光冲击锻打频率与压力参数调控激光熔敷速度与送粉参数；激光冲击锻打使熔敷层晶粒显著细化，不同材料熔敷成形后的强度和疲劳寿命可提高几倍到几十倍不等；上述各工艺参数的稳定性保证了逐层晶粒尺寸可控，从而实现整个熔敷层晶粒尺寸的均匀性；消除了熔敷层的气孔等内部缺陷和热应力，提高了金属零件的内部质量和综合力学性能，并有效控制宏观变形与开裂问题。
  2. 如权利要求1所述的双激光束熔敷成形冲击锻打复合增材制造方法，其特征在于，根据不同熔敷金属材料的锻造温度特性，建立所述第一束连续激光束锻造温度场模型与在线检测及控制方法；通过检测锻打熔敷层的晶粒 尺寸、残余应力分布和微观组织等试验，完善锻打温度场模型，使材料熔敷-冷却后处于最适合金属塑性成形温度区间(锻造温度)，由第二束短脉冲激光进行冲击锻打，形成闭环控制。
  3. 如权利要求1所述的双激光束熔敷成形冲击锻打复合增材制造方法，其特征在于，双激光束复合制造工艺参数实行在线检测和控制，第二束短脉冲激光可对熔敷层进行正面或者侧面15°～165°内任意角度或者位置的冲击锻打，具有激光脉冲能量、激光脉冲宽度、重复频率、光斑尺寸和形状等参数精确可控可调，可处理不同结构特点的熔敷成形零件。
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