WO2019024469A1 - 一种适用于复杂零件和模具的增材加工成形方法 - Google Patents

一种适用于复杂零件和模具的增材加工成形方法 Download PDF

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Publication number
WO2019024469A1
WO2019024469A1 PCT/CN2018/073995 CN2018073995W WO2019024469A1 WO 2019024469 A1 WO2019024469 A1 WO 2019024469A1 CN 2018073995 W CN2018073995 W CN 2018073995W WO 2019024469 A1 WO2019024469 A1 WO 2019024469A1
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layer
layers
molds
processing
stacked
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English (en)
French (fr)
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张海鸥
谢龙龙
王桂兰
张华昱
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Huazhong University of Science and Technology
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Huazhong University of Science and Technology
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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
    • 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
    • B22F10/80—Data acquisition or data 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/007—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of moulds
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • 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
    • B23K28/00—Welding or cutting not covered by groups B23K5/00 - B23K26/00
    • B23K28/02—Combined welding or cutting procedures or apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—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
    • B33Y10/00—Processes of 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
    • B22F10/30—Process control
    • B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
    • 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
    • B22F10/66—Treatment of workpieces or articles after build-up by mechanical means
    • 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 belongs to the field of additive forming technology, and more particularly to an additive processing forming method suitable for complex parts and molds.
  • additive Manufacturing also known as 3D printing, rapid prototyping technology
  • AM additive Manufacturing
  • 3D printing rapid prototyping technology
  • the rapid prototyping technology of non-metal prototypes such as paraffin and paper
  • the existing metal additive manufacturing methods mainly include a molten material forming method based on a high energy beam to melt a powder, a wire material, and a solid additive forming method based on other energy.
  • the molten additive forming method mainly includes laser rapid prototyping technology, such as Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS) and Laser Engineering NetShaping (LENS); Electron beam rapid prototyping techniques, such as Electron Beam Melting (EBM) and Electron Beam Freeform Fabrication (EBFF); Plasma Fusion Rapid Prototyping, such as Plasma Powder Deposition Manufacturing , PPDM); arc melting rapid prototyping technology, such as Arc Rapid Prototyping Manufacturing (ARPM).
  • laser rapid prototyping technology such as Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS) and Laser Engineering NetShaping (LENS); Electron beam rapid prototyping techniques, such as Electron Beam Melting (EBM) and Electron Beam Freeform Fabrication (EBFF); Plasma Fusion Rapid Prototyping, such as Plasma Powder Deposition Manufacturing , PPDM); arc melting rapid prototyping technology, such as Arc Rapid Prototyping Manufacturing (ARPM).
  • SLM Selective Laser Mel
  • the solid additive forming method mainly includes the "Ultrasonic Additive Manufacturing (UAM)" method developed by the German company Fabrionic, which utilizes the vibration energy of the ultrasonic waves to rub the two surfaces to be joined to form an additive manufacturing process of intermolecular fusion,
  • UAM Ultrasonic Additive Manufacturing
  • Fabrionic which utilizes the vibration energy of the ultrasonic waves to rub the two surfaces to be joined to form an additive manufacturing process of intermolecular fusion
  • the existing metal laminated body manufactures a rapid forming method, which firstly spreads out the sheet material larger than the maximum size of the part, and then uses the laser cutting system to remove most of the waste material, the material utilization rate is low, and the large area paving will make the electrode and the board
  • the contact area of the material is large, so that the resistance welding current density is small, the weldable thickness is small, and the quality is not high.
  • the patent publication No. CN103350321A published on October 16, 2013, discloses a method for manufacturing a metal part additive based on contour features, which uses a layered idea to layer the metal part model.
  • the method controls the feeding trajectory of the sheet by the control command, the sheet material is layered and fed, and the mechanically completes the superposition welding of the layers of the part, which can only control the feeding path of the sheet material.
  • the processing precision is low, and the part forming quality is poor, and thus it is not suitable for forming a part having a complicated inner and outer contour.
  • CN104827155A discloses a solid-melt composite additive forming method suitable for complex parts, which processes layers by layering in layers, and realizes bonding of layers by solder, and then heats to realize solid-melt composite welding forming.
  • Additive forming of complex parts has the advantages of high molding efficiency and high material utilization rate, but further research shows that it still has the following disadvantages:
  • the final part of the bonding process is not stable; the second is to achieve the bonding of the layers through the solder, the inclusion of solder and other materials, so that the overall mechanical properties of the part decline, strength, toughness, micro-cracks, pores and other defects
  • the third is that the solder is added by a certain device when the two layers of materials are separately bonded.
  • the whole process is cumbersome and the requirements on the device mechanism are relatively complicated.
  • Fourth, the whole process is offline, and the various cutting devices are used. After the layer plate is cut according to the contour, it is solidified and solidified after stacking and forming, and the automation is not realized. There are block processing, just layered stacking, which is not suitable for some complex parts with various materials.
  • the present invention provides an additive processing forming method suitable for complex parts and molds, in which a layered manner is adopted according to the inner and outer contour features of the complex part or the mold itself.
  • the layer completes the precise processing of the inner and outer contours of the sheet material, and in particular, can perform stacking stacking on each layer after precision processing, and then layer-by-layer positioning, and finally complete the diffusion connection of each layer sheet by integral diffusion connection, correspondingly
  • It can realize the processing and forming of parts and molds with complex internal and external contours, and overcome the defects of poor process stability, mechanical performance degradation and cumbersome process of the whole parts prepared by the existing molding process, with high molding precision, high molding efficiency and material cost. Low, high molding strength, and good stability of the molding process.
  • the present invention proposes an additive processing forming method suitable for complex parts and molds, which comprises the following steps:
  • Modeling and stratification establishing a CAD geometric model of the formed part or mold to be processed, and extracting the STL model of the part or the mold, and dividing the STL model into a plurality of layers with a preset layer thickness;
  • Layer-by-layer processing the sheet material with the thickness of each layer is selected as the processing object of each layer, and the independent processing object is respectively processed by the cutting device according to the numerical control instruction generated by the step (2) corresponding to each layer processing.
  • the various layers of the sheet are subjected to a cutting process to complete the independent processing of the layers having the inner and outer contours;
  • the layers processed by the layering are stacked and stacked according to their arrangement order to obtain the initial blanks having the inner and outer contours of the formed parts or molds to be processed, or the layers which are layered and processed.
  • Integral diffusion connection the vacuum-diffusion connection of the precisely-positioned initial blanks in a whole form, or the vacuum-diffusion connection of the plurality of precisely-formed primary blanks, respectively, and stacking by block for bulk vacuum diffusion connection In this way, additive forming of complex parts or molds is completed.
  • each step of the step (4) is subjected to an integral electric resistance welding or ultrasonic welding along the upper surface of the layer to achieve pre-bonding with the upper layer.
  • the materials of the layers in the preform are the same or different; the materials of the layers in each of the preforms are the same or different, and the materials used for the respective preforms are the same or different.
  • the layer thicknesses of the layers are the same or different.
  • the vacuum diffusion connection is specifically to effect molecular diffusion between the layers of the layer in a vacuum environment at a high temperature and high pressure to achieve an overall connection.
  • the high temperature is 0.4 to 0.9 times the melting point of the material, and the high pressure is 0.2 MPa to 100 MPa.
  • the vacuum-diffused green compact or the complex part or mold obtained by final shaping is subjected to laser milling, mechanical milling, grinding or polishing to achieve the dimensional accuracy and surface precision requirements.
  • the invention firstly processes each layer independently based on the complex inner and outer contours of the part or the mold, and stacks the layers on each other and then lays them layer by layer to finally complete the overall positioning and then diffuse the connection in an integrated manner.
  • the complex parts and molds prepared by the overall processing method of the present invention have greatly improved the process stability of the parts and the molds as compared with the parts and molds prepared by the existing methods, and the mechanical properties of the prepared parts and molds are more stable. There are no other materials involved, such as good strength and toughness, and few defects such as micro cracks and pores, which can overcome the problems of poor mechanical properties and process stability of parts and molds caused by solder, and cumbersome process engineering caused by separate soldering between sheets.
  • the invention in particular for parts or molds of different materials or complex shapes, divides the entire part or mold into several pieces, and performs diffusion joint forming in the form of block-by-block accumulation, completing composite materials or gradient materials, or having complex internal cavities.
  • the present invention Prior to the integral diffusion bonding, the present invention performs direct connection welding between the two layers of the accurately positioned obtained by electric resistance welding or ultrasonic welding to pre-bond the layers to obtain a preform having certain process stability.
  • the method of the invention is based on the principle of discrete/stack forming and layer forming, according to the shape complexity and precision requirements of the parts or molds and the contour features, to realize the precise processing of the profile of each layer, and complete the parts or molds layer by layer.
  • the fine processing of the inner and outer contours of the layer, layering and stacking of the parts or molds and diffusion joint forming have the advantages of high forming precision, high molding efficiency, wide applicability and low material cost.
  • the invention is not only suitable for vacuum diffusion forming after layer-by-layer stacking forming under computer control, but also can be used for vacuum diffusion forming after cutting and forming various layers of sheets by various cutting devices under off-line conditions. .
  • the invention is close to solid forming, and the parts or molds do not need to be supported during the forming process, and various parts with complicated shapes and molds can be formed.
  • the present invention directly laminates and stacks and then integrally diffuses the joints to form complex parts.
  • the mold has the advantages of small deformation, stable formability, no arc radiation pollution, and good working conditions.
  • the process of the invention is simple, directly stacked and formed, and accurately positioned layer by layer, finally completes the overall positioning, and then performs overall diffusion to connect, reducing the time required for each two layers of solder alone, improving work efficiency, and being simple and simple.
  • the invention is close to solid forming, and then layered to the whole positioning part or mold layer by layer, which can overcome the complicated environment of space microgravity, high vacuum and easy to lose stability, and can be used for space reorientation to manufacture corresponding parts or molds. .
  • Figure 1 (a) - Figure 1 (f) is a schematic view of a process for forming a metal part having a complex hollow shape in the middle by the method of the present invention
  • FIGS. 2(a) to 2(g) are schematic views showing a process of forming a metal mold having a complex hollow shape in the middle by the method of the present invention
  • 3(a) to 3(b) are schematic views of defects of a metal part having a complicated hollow shape prepared by a conventional method.
  • the invention considers that the structure of the complex shape part or the inner part of the mold is difficult to be machined, and the process stability of the part and the mold is very high, and the layers which have been processed are stacked and precisely positioned according to the arrangement order thereof, and then The whole vacuum diffusion treatment is performed on the stacked and positioned preliminary blanks, that is, the layer-by-layer positioning is realized in the process of layer-by-layer stacking, and then the entire parts or molds which are accurately positioned are integrally vacuum-diffused and integrally connected, so that each The effect of molecular diffusion on the integral connection of the parts or the mold is achieved, and the connection stability is high, and the diffusion and fusion can be completely diffused, and parts and molds having complex internal and external contours with few defects such as good strength and toughness and micro cracks and pores can be prepared.
  • the direct contact between the layers of the layers is carried out, and no other bonding materials are added, and the layers are mutually diffused by diffusion treatment, so that the entire parts are stably connected to
  • Modeling and stratification Establish a CAD geometric model of the formed part or mold to be processed, and extract the STL model of the part or mold based on the CAD geometric model, and divide the STL model into multiple layers with a preset layer thickness.
  • the layer thickness of each layer can be the same or different, which is determined by the processing requirements of the part or mold, and the operator can make reasonable selection and division according to the needs;
  • the layers processed in layers are stacked and stacked according to their arrangement order to obtain the initial blanks having the inner and outer contours of the formed parts or molds, and each layer is accurately positioned once in the stacking process, that is, all layers are Stacking in order according to their order and sequentially positioning, and finally stacking and positioning all layers to obtain a preform having a contour of the inside or outside of the formed part or mold, which is a part or mold to be prepared;
  • the blocks are stacked in blocks, and the combined parts are the parts or molds to be prepared.
  • the parts are divided into upper and lower parts, and the layers in the lower part are stacked and stacked in order. Positioning to form the lower portion of the part, stacking the layers in the upper block in the order in which they are stacked and sequentially positioning to form the upper portion of the part, thereby completing the two inner and outer contours of the shaped part to be processed Stacking and positioning of the primary billet;
  • the plurality of preliminary green blocks that have been accurately positioned are firstly vacuum-diffused and then stacked one by one for the whole vacuum diffusion connection, that is, a plurality of initial positions that have been accurately positioned.
  • Each of the briquettes is separately vacuum-diffused, and then the blocks are stacked on each other in order and then subjected to integral vacuum diffusion bonding.
  • the additive forming of the complex parts or the mold is completed, and the complicated internal cavity of the part or the mold is difficult to process.
  • the complex cavity block can be processed first, such as laser milling, mechanical milling, grinding or polishing, and then stacked and integrated with vacuum diffusion.
  • each layer of the step (4) is subjected to an integral electric resistance welding or ultrasonic welding along the upper surface of the layer, that is, the welding head will be the entire upper layer of the current layer.
  • the surface is swept once so that the lower surface of the current layer is completely conformed to the upper surface of the upper layer, thereby achieving pre-bonding between the two layers.
  • Positioning (1.1) Firstly, the stacked current layers are positioned by using a plurality of positioning rods distributed outside the current layer and attached to the outer surface of the sheet; (1.2) then at the current The next layer is stacked on the layer. After stacking, multiple positioning rods are raised to position all the stacked layers. At this time, the positioning rods are attached to the outer surfaces of all the stacked layers to ensure all stacked sheets.
  • the step (1.2) is repeated until the stacking of all layers is completed, and the whole blank obtained after stacking is accurately positioned.
  • the first layer is stacked on the positioning device, and then positioned by the positioning rod 1; then the second layer is stacked on the first layer that has been positioned, and then the positioning rod is raised to position the first layer and the second layer that have been stacked; Continue to stack the third layer on the second layer that has been positioned, and then position the rod to position the first layer, the second layer, and the third layer that have been stacked, such that the stacking and positioning are repeated until the last layer is stacked, and
  • the positioning rod is raised to realize positioning of all the layers that have been stacked, so that the overall positioning of the primary blanks is realized at the same time that all the layers are stacked, which facilitates the subsequent integral diffusion connection, ensures the relative position between the layers, and thus ensures the entire parts. Overall accuracy.
  • the above is only an exemplary illustration of the positioning method and does
  • the vacuum diffusion connection specifically performs the molecular diffusion between the sheets in a whole form by the high temperature and high pressure method in a vacuum environment to achieve the overall connection of the parts.
  • the high temperature means that the temperature is 0.4-0.9 times the melting point of the material, and the high pressure is 0.2 MPa-100 MPa.
  • the complex parts or molds obtained by final forming can be finished by laser milling, mechanical milling, grinding or polishing until the dimensional accuracy and surface precision are met.
  • the method of the present invention is further illustrated by taking a metal part having a complicated shape at both ends and not being closed at both ends, and the method includes the following steps:
  • the CAD model of the part is created according to the three-dimensional shape and size of the target part, the STL model of the part is extracted, and the layer thickness is selected according to the actual shape and size of the part.
  • the layer thickness can be selected according to actual needs.
  • the layer thickness of each layer can be the same or different.
  • the materials can be the same or different, which is determined by the processing requirements of the parts, and the operator can perform as needed.
  • Reasonable selection and division in this embodiment, the layer thickness of each layer is selected to be 1.5 mm; see Figure 1 (b)
  • the STL model is performed by the layered slicing software in units of 1.5 mm. It is divided into a plurality of layers each having a thickness of 1.5 mm, and the materials selected for each layer are determined by the process requirements of the parts, and the same layer is selected for each layer in this embodiment;
  • the same forming sheet with a thickness of 1.5 mm is selected as the processing object of each layer, and the numerical control instruction corresponding to the current layer processing generated by the cutting device according to the step (2) is used to respectively follow the contour trajectory of the current layer.
  • the layer performs the cutting process, thereby realizing the processing of the inner and outer contours of the current layer, and simultaneously positioning the current layer by using a plurality of positioning rods in the positioning device, thereby realizing precise positioning and trimming processing of the current layer, as shown in FIG. 1 . (c);
  • step (3) that is, the second layer is cut and the second layer is stacked on the first layer that has been positioned, and then the positioning rod is raised to position the two layers that have been stacked, or two layers are respectively Perform resistance welding or ultrasonic welding directly for pre-treatment.
  • step (3) that is, the second layer is cut and the second layer is stacked on the first layer that has been positioned, and then the positioning rod is raised to position the two layers that have been stacked, or two layers are respectively Perform resistance welding or ultrasonic welding directly for pre-treatment.
  • Step 3 Cycle through until the complete integral stacking or pre-processing of the entire part is completed to obtain a preform with certain process stability. See Figure 1 for details. );
  • the accurately positioned whole parts obtained by the step (4) are vacuum-diffused and composited, and molecular diffusion molding between the layers of the entire part is completed, and the required conditions are obtained.
  • Target part As shown in Fig. 1(f), the accurately positioned whole parts obtained by the step (4) are vacuum-diffused and composited, and molecular diffusion molding between the layers of the entire part is completed, and the required conditions are obtained.
  • Target part As shown in Fig. 1(f), the accurately positioned whole parts obtained by the step (4) are vacuum-diffused and composited, and molecular diffusion molding between the layers of the entire part is completed, and the required conditions are obtained.
  • the outer contour has some burrs left by the positioning device, it can be machined step by step at the same working position to further improve the precision of the parts.
  • the method of the present invention is further illustrated by taking a metal mold having a complicated shape at both ends in the middle as an example, and the method includes the following steps:
  • the mold CAD geometric model is established according to the three-dimensional shape and size of the target mold, the STL model of the mold is extracted, and the layer thickness is selected according to the actual shape and size of the mold, in actual operation.
  • the layer thickness can be selected according to actual needs.
  • the layer thickness of each layer can be the same or different, and the materials can be the same or different, which is determined by the processing requirements of the mold, and the operator
  • the embodiment first performs the layering and then layering, and divides the mold into two upper and lower parts, wherein the thickness of the upper layer is 1.5 mm, below.
  • the thickness of each layer is 2.0mm.
  • the STL model is divided into multiple layers by the layering slicing software in units of 1.5mm and 2.0mm.
  • the materials selected for each layer are determined by the mold process requirements.
  • the upper part of this embodiment is The layer is made of a kind of sheet material such as aluminum alloy, and the other layer of the lower layer is made of another kind of sheet material such as copper;
  • the formed sheet material of aluminum alloy with thickness of 1.5mm is selected as the processing object of each layer, and the numerical control instruction corresponding to the current layer processing generated by the cutting device according to step (2) is used along the contour trajectory of the current layer respectively.
  • step (3) that is, the second layer is cut and the second layer is stacked on the first layer that has been positioned, and then the positioning rod is raised to position the two layers that have been stacked, or two layers are respectively Conductive welding or ultrasonic welding is directly connected to the pretreatment, and the cycle is repeated until the complete integral stacking or pretreatment of the above primary green block is completed, and a preliminary green block having a certain process stability is obtained, as shown in Fig. 2(d);
  • the formed sheet material of copper material with a thickness of 2.0 mm is selected as the processing object of each layer, and the numerical control instruction corresponding to the current layer processing generated by the cutting device according to step (2) is used along the contour trajectory of the current layer respectively.
  • the current layer performs a cutting process, thereby realizing the processing of the inner and outer contours of the current layer, and simultaneously positioning the current layer by using a plurality of positioning rods in the positioning device, thereby realizing precise positioning and trimming processing of the current layer;
  • step (5) that is, the second layer is cut and the second layer is stacked on the first layer that has been positioned, and then the positioning rod is raised to position the two layers that have been stacked, or two layers are respectively Conductive welding or ultrasonic welding is directly connected to the pretreatment, and the cycle is repeated until the complete stacking or pre-processing of the following initial briquette block is completed, and the first briquette block 2 with certain process stability is obtained, as shown in Fig. 2(e);
  • the outer contour has some burrs left by the positioning device, it can be machined step by step at the same working position to further improve the precision of the mold.
  • Metal parts with complex shapes and high precision of inner and outer contours are formed by adding solder between each two layers.
  • the method has the following problems when forming parts: 1) as shown in Fig. 3(a), the resistor The welding connects the materials, the overall process stability and integrity of the parts are not good, and there will be partial non-fusion. 2) As shown in Figure 3(b), the layers are realized by solder (A in Figure 3(b)). Bonding, the overall mechanical properties of the part are reduced, including reduced strength toughness, micro-cracks, pores and other defects (B in Figure 3 (b)); 3) solder is added to each layer of the sheet separately The whole process is cumbersome.

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Abstract

一种适用于复杂零件和模具的增材加工成形方法，包括如下步骤：建立零件或模具的CAD几何模型，提取STL模型，以预设分层厚度将STL模型划分为多个层；分别提取多个层的内外轮廓点以形成内外轮廓轨迹，基于内外轮廓轨迹生成与各层加工对应的数控指令；选用厚度为各分层厚度的板料作为各层的加工对象，通过切割装置按照与各层加工对应的数控指令对各层板料进行切割；将各层按照排列次序进行叠层堆积获得初坯或初坯块，叠层堆积时每堆积一层进行一次精准定位，之后将初坯进行真空扩散连接或将初坯块先进行真空扩散连接再堆叠最后再进行真空扩散连接。该方法成型效率高、成型精度高、材料成本低、成型稳定性好。

Description

一种适用于复杂零件和模具的增材加工成形方法 [技术领域]
本发明属于增材成形技术领域，更具体地，涉及一种适用于复杂零件和模具的增材加工成形方法。
[背景技术]
增材制造(Additive Manufacturing，AM，亦称3D打印、快速原型制造)技术，起源于20世纪80年代末，由于其原理的独特之处和工艺上的优势，已从初试时功能验证的塑料、石蜡、纸等非金属原型快速成形技术，到直接或间接制备各种模具的快速制造技术，再到目前的金属零件或模具的快速制造技术，AM技术取得了快速的发展和实际的应用。现有的金属增材制造方法，主要有基于高能束以熔化粉末、丝材的熔融增材成形方法和基于其它能量的固态增材成形方法。
熔融增材成形方法，主要包括激光快速成型技术，如选区激光熔融(Selective Laser Melting，SLM)、直接金属激光烧结(Direct Metal Laser Sintering，DMLS)和激光近形制造(Laser Engineering NetShaping，LENS)；电子束快速成形技术，如电子束熔融(Electron Beam Melting，EBM)和电子束实体自由成形(Electron Beam Freeform Fabrication，EBFF)；等离子熔积快速成形技术，如等离子熔积直接制造(Plasma Powder Deposition Manufacturing，PPDM)；电弧熔积快速成形技术，如电弧制造技术(Arc Rapid Prototyping Manufacturing，ARPM)。不同的熔融增材方法各有优劣，如激光快速成形技术，由于全部材料都要经过固-液-固相变过程，导致体积变化大，残余应力和变形大且需要大功率激光器设备，成本较高，熔积效率低；电子束快速成形技术，由于电子束对粉末的冲击大，不利于成形，而且成形过程须在真空室内进行，对硬件的要求高，运 行成本高；激光束、等离子束、电弧成形的零件无支撑，复杂度受限；此外，由于制造精度不高且有弧光辐射，因此，限制了其工业化应用范围。固态增材成形方法，主要有德国Fabrisonic公司开发的“超声波增材制造(UAM)”方法，该方法利用超声波的振动能量使两个需连接表面摩擦，形成分子间融合的增材制造工艺，具有变形小、精度高等优势，但其仍然存在以下问题：当制备的零件需达到高精度的要求时，其除了需要超声波成形装置外，还需要设置三轴数控铣床以在超声波增材成形之后对零件进行机械加工，如此增加了设备重量、制造周期和成本，目前该方法只能用于低熔点金属的增材成形。
现有的金属叠层实体制造快速成形方法，其先以大于零件最大尺寸的板料整体铺出而后利用激光切割系统剔除大部分废料，材料利用率低，且大面积铺料会使电极与板料的接触面积大而致使电阻焊合电流功率密度较小，可焊合厚度很小、质量不高。而申请公布号CN103350321A，公布日2013年10月16日的专利文献公开了一种基于轮廓特征的金属零件增材制造方法，该方法虽然采用了分层的思想对金属零件的模型进行分层切片处理，但其依然存在以下问题：该方法通过控制指令控制板料的送料轨迹，板料分层送进，机械的完成零件各层的叠加焊合，其只能对板料的送料路径进行控制，而无法对各层板料的内外轮廓进行精确加工，加工精度低，零件成形质量差，因而并不适用于具有复杂内外轮廓的零件的成形。CN104827155A公开了一种适用于复杂零件的固熔复合增材成形方法，该方法采用分层方式逐层加工各层，并通过焊料实现各层的粘合，然后加热实现固熔复合熔接成形以完成复杂零件的增材成形，其具有成型效率高、材料利用率高的优点，但是进一步研究表明，其仍然存在以下缺点：一是通过焊料实现零件每两层之间连接，粘合可靠性不高，最终得到的零件粘合工艺稳定性不好；二是通过焊料实现各层的粘合，参杂钎料等材料，使得零件整体的机械性能下降，强度、韧性降低，微小裂纹、气孔等缺陷增加； 三是每两层板料之间单独粘合时要通过一定装置加入焊料，整个工艺过程繁琐，对装置机构要求比较复杂；四是整个过程处于离线情况下，通过各种切割设备将各层板材按轮廓切割好后堆积成形之后进行固熔复合，并没有实现自动化；五是整个过程没有分块处理，只是分层堆叠，对于某些各部分材料多样化的复杂零件不适用。
[发明内容]
针对现有技术的上述缺点和/或改进需求，本发明提供了一种适用于复杂零件和模具的增材加工成形方法，其中根据复杂零件或模具自身的内外轮廓特征，采用分层的方式逐层完成板料的内外轮廓的精确加工，并尤其能够对精确加工后的各层依次执行叠层堆积，然后逐层定位，最后以整体扩散连接的方式完成各层板料的扩散连接，相应的能够实现具有复杂内外轮廓的零件和模具的加工成型，并可克服现有成型工艺制备的整体零件工艺稳定性差、机械性能下降、工艺过程繁琐的缺陷，具有成型精度高、成型效率高、材料成本低、成型强度高、成型工艺稳定性好等优点。
为实现上述目的，本发明提出了一种适用于复杂零件和模具的增材加工成形方法，其包括如下步骤：
(1)建模与分层：建立待加工成形零件或模具的CAD几何模型，并提取零件或模具的STL模型，以预设的分层厚度将所述STL模型划分为多个层；
(2)提取分层轮廓：分别提取所述多个层的内外轮廓点以形成内外轮廓轨迹，然后基于所述内外轮廓轨迹生成与各层加工相对应的数控指令；
(3)逐层加工：选用厚度为各分层厚度的板料作为各层的加工对象，通过切割装置按照步骤(2)生成的与各层加工相对应的数控指令，分别对各个独立加工对象的各层板料进行切割处理，从而完成具有内外轮廓的各层的独立加工；
(4)叠层堆积与定位：将分层加工出来的各层按照其排列次序进行叠 层堆积，以获得具有待加工成形零件或模具内外轮廓的初坯，或者将分层加工出来的各层按照其排列次序以分块的形式进行叠层堆积，以获得具有待加工成形零件或模具内外轮廓的多个初坯块，在上述叠层堆积过程中每堆积一层进行一次精准定位；
(5)整体扩散连接：将已精准定位的初坯以整体的形式进行整体真空扩散连接，或将已精准定位的多个初坯块先分别进行真空扩散连接再逐块堆叠进行整体真空扩散连接，以此方式，完成复杂零件或模具的增材加工成形。
作为进一步优选地，所述步骤(4)中每堆积一层沿着该层的上表面进行一次整体电阻焊或超声波焊，以使其与上一层之间实现预结合。
作为进一步优选地，所述初坯中各层的材料相同或不同；每个所述初坯块中各层的材料相同或不同，各个初坯块所用的材料相同或不同。
作为进一步优选地，所述各层的分层厚度相同或不同。
作为进一步优选地，所述真空扩散连接具体为在真空环境下以高温高压的方式使各层板料间进行分子扩散，达到整体连接的效果。
作为进一步优选地，所述高温为材料熔点的0.4-0.9倍，所述高压为0.2MPa-100MPa。
作为进一步优选地，对经真空扩散的初坯块或最终成形获得的复杂零件或模具采用激光铣削、机械铣削、研磨或抛光方式进行精整加工直至达到其尺寸精度和表面精度的要求。
总体而言，通过本发明所构思的以上技术方案与现有技术相比，主要具备以下的技术优点：
1.本发明首先基于零件或模具的复杂内外轮廓以分层的思想独立加工制备各个层，并使各层相互叠层堆积然后将其逐层定位最终完成整体定位后以整体的方式进行扩散连接，以本发明整体处理的方式制备的复杂零件和模具相对于采用现有方式制备的零件及模具而言，零件及模具整体的工 艺稳定性得到很大提高，制备的零件及模具机械性能更稳定，没有参杂其他材料，强度、韧性好，微小裂纹、气孔等缺陷少，可克服由焊料导致零件及模具机械性能和工艺稳定性差以及由板料间单独加焊料处理导致工艺工程繁琐等问题。
2.本发明特别是对于不同材料或复杂形状的零件或模具，将整个零件或模具分成数块，以逐块堆积的形式进行扩散连接成形，完成复合材料或梯度材料、或具有复杂内腔的零件及模具的整体增材成形。
3.本发明在整体扩散连接之前，将获得的准确定位的每两层之间进行电阻焊或超声波焊直接连接预处理，使各层之间预结合以获得具有一定工艺稳定性的初坯。
4.本发明方法基于离散/堆积成形及分层成形原理，根据零件或模具的形状复杂度和精度的要求以及轮廓特征，实现各层板料轮廓的精确加工，逐层的完成零件或模具各层的内外轮廓的精细加工，分层完成零件或模具的叠加堆积和扩散连接成形，具有成形精度高、成型效率高、适用性广、材料成本低的优点。
5.本发明不仅适用于在计算机控制下在线逐层堆积成形后真空扩散成形，而且也可用于在离线情况下，通过各种切割设备将各层板材按轮廓切割好后堆积成形之后真空扩散成形。
6.本发明为接近于固体成形，成形过程中零件或模具不需要进行支撑，可实现各种具有复杂形状的零件及模具的成形，本发明直接叠层堆积再整体扩散连接的方式成形复杂零件及模具，具有变形小、成形性稳定、无弧光辐射污染、劳动条件好等优点。
7.本发明工艺过程简单，直接堆叠成型，并逐层进行准确定位，最终完成整体定位，再进行整体扩散来连接，少了每两层单独加焊料所需时间，提高工作效率，同时简单简易，极大节约成本；本发明接近于固体成形，再逐层定位至整体定位零件或模具，可克服空间微重力、高真空、易失稳 的复杂环境，可用于空间再轨制造相应零件或模具。
[附图说明]
图1(a)-图1(f)是采用本发明的方法成形中间具有复杂中空形状金属零件的过程示意图；
图2(a)-图2(g)是采用本发明的方法成形中间具有复杂中空形状金属模具的过程示意图；
图3(a)-图3(b)是采用现有方法制备的中间具有复杂中空形状的金属零件的缺陷示意图。
[具体实施方式]
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。此外，下面所描述的本发明各个实施方式中所涉及到的技术特征只要彼此之间未构成冲突就可以相互组合。
本发明考虑到复杂形状零件或模具内部的结构难以进行机械加工，且对零件及模具工艺稳定性要求很高，通过对已经加工出来的各层按照其排列次序逐层堆叠并进行精确定位，然后对堆叠好的并已定位的初坯进行整体真空扩散处理，即逐层堆叠的过程中实现逐层定位，然后将精准定位后的整个零件或模具以整体的方式进行真空扩散整体连接，使得各层板料间通过分子扩散达到零件或模具整体连接的效果，连接稳定性很高，可完全扩散熔合，可制备强度韧性好，微小裂纹气孔等缺陷少的具有复杂内外轮廓的零件及模具。本发明中各层板料之间直接接触，不用添加其他粘合材料，通过扩散处理使得各层间相互分子扩散，使整个零件各层之间稳定连接，达到整体扩散连接的效果。
本发明实施例提供的一种适用于复杂零件和模具的增材加工成形方法，其包括如下步骤：
(1)建模与分层：建立待加工成形零件或模具的CAD几何模型，并基于CAD几何模型提取零件或模具的STL模型，以预设的分层厚度将STL模型划分为多个层，每层的分层厚度可以相同或不同，其由零件或模具的加工工艺要求决定，操作人员可以根据需要进行合理的选择与划分；
(2)提取分层轮廓：分别提取多个层的内外轮廓点以形成内外轮廓轨迹，然后基于内外轮廓轨迹生成与各层加工相对应的数控指令；
(3)逐层加工与叠层堆积：选用厚度为各分层厚度的板料作为各层的加工对象，通过切割装置按照步骤(2)生成的与各层加工相对应的数控指令，分别对各个作为独立加工对象的各层板料进行切割处理，从而完成具有内外轮廓的各层的独立加工，各层选用的板料相同或不同；
(4)叠层堆积与定位：
将分层加工出来的各层按照其排列次序进行叠层堆积，以获得具有待加工成形零件或模具内外轮廓的初坯，在叠层堆积过程中每堆积一层进行一次精准定位，即将所有层按照其顺序依次堆叠且依次定位，最后完成所有层的堆叠并定位，以获得具有待加工成形零件或模具内外轮廓的初坯，该初坯即为所需制备的零件或模具；
或者对于具有复杂内腔且后续难以加工的零件或模具而言，则以分块的形式进行叠层堆积，同样在叠层堆积过程中每堆积一层进行一次精准定位，即将零件或模具分成多块并按块进行堆积，多块组合而成的零件即为所需制备的零件或模具，例如将零件分成上下两块，将下面一块中的各层按照其排列次序依次进行叠层堆积并依次进行定位以形成该零件的下部分，将上面一块中的各层按照其排列次序依次进行叠层堆积并依次进行定位以形成该零件的上部分，以此完成两块具有待加工成形零件内外轮廓的初坯块的堆积与定位；
(5)整体扩散连接：
将已精准定位的初坯以整体的形式进行整体真空扩散连接，以此方式， 完成复杂零件或模具的增材加工成形；
或者对于具有复杂内腔且后续难以加工的零件而言，将已精准定位的多个初坯块先分块进行真空扩散连接再逐块堆叠进行整体真空扩散连接，即将已精准定位的多个初坯块各自先分别进行真空扩散连接，然后将各个块按顺序彼此堆叠再进行整体真空扩散连接，以此方式，完成复杂零件或模具的增材加工成形，由于零件或模具复杂内腔后续难以加工，在各个初坯块各自完成真空扩散连接后，可对复杂内腔块先进行加工处理，例如激光铣削、机械铣削、研磨或抛光，然后再堆叠并进行整体真空扩散连接
为了进一步提高整体扩散焊的工艺稳定性和适用性，所述步骤(4)中每堆积一层沿着该层的上表面进行一次整体电阻焊或超声波焊，即焊头将当前层的整个上表面扫掠一遍，以使当前层的下表面与上一层的上表面之间完全贴合，从而实现两层之间的预结合。
对于精准定位的方式其可以采用现有技术中任何一种可实现精准定位的装置或方法进行定位，本发明不做限定均在保护范围之内，例如可采用具有多个定位杆的定位装置进行定位：(1.1)首先利用多个定位杆对已堆叠的当前层进行定位，该多个定位杆分布在当前层板料的外部，并与板料的外表面贴合；(1.2)然后在当前层上堆叠下一层，堆叠好后使多个定位杆上升对已堆叠的所有层进行定位，此时定位杆与已堆叠的所有层的外表面贴合，以此保证所有已堆叠的板料均实现精准定位，使得已堆叠的各层板料之间不发生相对位移；(1.3)重复步骤(1.2)直至完成所有层的堆积，并使得堆积后获得的初坯整体得到准确定位。即将第一层堆叠到定位装置上，然后用定位杆1进行定位；再在已经定位的第一层上堆叠第二层，然后定位杆上升对已经堆叠的第一层和第二层进行定位；继续在已经定位的第二层上堆叠第三层，然后定位杆上升对已经堆叠的第一层、第二层和第三层进行定位，如此循环堆叠与定位，直至最后一层堆叠完毕，并使定位杆上升对已经堆叠的所有层实现定位，如此在所有层堆叠完成的同时，实现初坯 的整体定位，便于后续的整体扩散连接，保证各层之间的相对位置，进而保证整个零件的整体精度。上述内容只是对定位方式的一种示例性说明，不构成对本发明的限定。
具体的，所述真空扩散连接具体为在真空环境下通过高温高压方式使已整体准确定位的初坯以整体的形式进行板料间的分子扩散，达到零件整体连接的效果。具体的，高温指温度为材料熔点的0.4-0.9倍，高压为0.2MPa-100MPa。
此外，可采用激光铣削、机械铣削、研磨或抛光方式对最终成形获得的复杂零件或模具进行精整加工直至达到其尺寸精度和表面精度的要求。
以下为本发明的实施例：
实施例1
本实施例以中间具有复杂形状两端不封闭的金属零件为例，对本发明的方法进行进一步的阐述，其包括如下步骤：
(1)参见图1(a)，根据目标零件的三维形状和尺寸建立零件CAD几何模型，提取零件的STL模型，根据零件实际的成形形状和尺寸选择分层厚度，在实际操作过程中，该分层厚度可以根据实际需要进行选择，根据零件的形状和复杂程度，每层的分层厚度可以相同或不同，材料可以相同或不同，其由零件的加工工艺要求决定，操作人员可以根据需要进行合理的选择与划分，本实施例中，选择各层的分层厚度均为1.5mm；参见图1(b)根据STL模型以及分层厚度，由分层切片软件以1.5mm为单位将STL模型分为多个厚度均为1.5mm的层，各层选用的材料由零件工艺要求决定，本实施例中的各层选用同一种板料；
(2)提取各层的STL模型的内外轮廓点，然后基于这些内外轮廓点生成对应内外轮廓轨迹，由计算机根据这些轮廓轨迹生成与各层加工相对应的数控指令；
(3)选用厚度为1.5mm的相同的成形板料作为各层的加工对象，采用 切割装置按照步骤(2)生成的与当前层加工相对应的数控指令，沿当前层的轮廓轨迹分别对当前层进行切割处理，由此实现对当前层的内外轮廓的加工，同时利用定位装置中的多个定位杆对当前层进行多点定位，从而实现当前层的精确定位和修整处理，具体参见图1(c)；
(4)重复步骤(3)，即切割完成第二层，并将第二层堆叠到已经定位的第一层上，然后定位杆上升对已经堆叠好的两层进行定位，或将每两层间进行电阻焊或超声波焊直接连接预处理，具体参见图1(d)，依次循环直至完成整个零件的准确整体堆叠定位或预处理，获得具有一定工艺稳定性初坯，具体参见图1(e)；
(5)如图1(f)所示将通过步骤(4)获得的精准定位好的整个零件进行真空扩散复合，完成整个零件中各层板料间的分子扩散成形，得到所需的满足条件的目标零件。
在上述整体扩散连接后，若外轮廓有部分因定位装置留下来的毛刺，可在同工位上逐段的进行机械加工，以进一步提高零件的精度。
实施例2
本实施例以中间具有复杂形状两端封闭的金属模具为例，对本发明的方法进行进一步的阐述，其包括如下步骤：
(1)参见图2(a)-(b)，根据目标模具的三维形状和尺寸建立模具CAD几何模型，提取模具的STL模型，根据模具实际的成形形状和尺寸选择分层厚度，在实际操作过程中，该分层厚度可以根据实际需要进行选择，根据模具的形状和复杂程度，每层的分层厚度可以相同或不同，材料可以相同或不同，其由模具的加工工艺要求决定，操作人员可以根据需要进行合理的选择与划分，如图2(c)所示，本实施例先进行分块再进行分层，将模具分成上下两块，其中上面一块各层的厚度为1.5mm，下面一块各层的厚度为2.0mm，由分层切片软件以1.5mm、2.0mm为单位将STL模型分为多个层，各层选用的材料由模具工艺要求决定，本实施例中的上面一块 各层选用一种板料如铝合金，下面一块各层选用另一种板料如紫铜；
(2)提取各层的STL模型的内外轮廓点，然后基于这些内外轮廓点生成对应内外轮廓轨迹，由计算机根据这些轮廓轨迹生成与各层加工相对应的数控指令；
(3)选用厚度为1.5mm的铝合金材质的成形板料作为各层的加工对象，采用切割装置按照步骤(2)生成的与当前层加工相对应的数控指令，沿当前层的轮廓轨迹分别对当前层进行切割处理，由此实现对当前层的内外轮廓的加工，同时利用定位装置中的多个定位杆对当前层进行多点定位，从而实现当前层的精确定位和修整处理；
(4)重复步骤(3)，即切割完成第二层，并将第二层堆叠到已经定位的第一层上，然后定位杆上升对已经堆叠好的两层进行定位，或将每两层间进行电阻焊或超声波焊直接连接预处理，依次循环直至完成上面一块初坯块的准确整体堆叠定位或预处理，获得具有一定工艺稳定性初坯块一，具体参见图2(d)；
(5)选用厚度为2.0mm的紫铜材质的成形板料作为各层的加工对象，采用切割装置按照步骤(2)生成的与当前层加工相对应的数控指令，沿当前层的轮廓轨迹分别对当前层进行切割处理，由此实现对当前层的内外轮廓的加工，同时利用定位装置中的多个定位杆对当前层进行多点定位，从而实现当前层的精确定位和修整处理；
(6)重复步骤(5)，即切割完成第二层，并将第二层堆叠到已经定位的第一层上，然后定位杆上升对已经堆叠好的两层进行定位，或将每两层间进行电阻焊或超声波焊直接连接预处理，依次循环直至完成下面一块初坯块准确整体堆叠定位或预处理，获得具有一定工艺稳定性的初坯块二，具体参见图2(e)；
(7)将通过步骤(4)和步骤(6)获得的精准定位好的两个初坯块分别进行真空扩散复合使得每个初坯块中各层板料间进行分子扩散实现连 接，真空扩散后的两个初坯块如图2(f)-(g)所示，然后将真空扩散后的两个初坯块内腔进行精加工，再使两个初坯块彼此堆叠最后进行整体真空扩散，使两个初坯块之间的板料进行分子扩散，得到所需的满足条件的目标模具，整体真空扩散的温度等于熔点较低材料的0.4-0.9倍，压力在0.2-100MPa之间。
在上述整体扩散连接后，若外轮廓有部分因定位装置留下来的毛刺，可在同工位上逐段的进行机械加工，以进一步提高模具的精度。
对比实施例3：
采用每两层之间添加焊料的方式成形中间具有复杂形状且内外轮廓形貌精度要求较高的金属零件，该方法成型零件时会出现如下问题：1)如图3(a)所示，电阻焊对材料进行连接，零件整体工艺稳定性和完整性不好，会出现局部不融合情况；2)如图3(b)所示，通过焊料(图3(b)中的A)实现各层的粘合，使得零件整体的机械性能下降，包括强度韧性降低，出现微小裂纹、气孔等缺陷(图3(b)中的B)；3)每层板料之间单独粘合时要加入焊料，整个工艺过程繁琐。
本领域的技术人员容易理解，以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。

Claims (7)

  1. 一种适用于复杂零件和模具的增材加工成形方法，其特征在于，包括如下步骤：
    (1)建模与分层：建立待加工成形零件或模具的CAD几何模型，并提取零件或模具的STL模型，以预设的分层厚度将所述STL模型划分为多个层；
    (2)提取分层轮廓：分别提取所述多个层的内外轮廓点以形成内外轮廓轨迹，然后基于所述内外轮廓轨迹生成与各层加工相对应的数控指令；
    (3)逐层加工：选用厚度为各分层厚度的板料作为各层的加工对象，通过切割装置按照步骤(2)生成的与各层加工相对应的数控指令，分别对各个独立加工对象的各层板料进行切割处理，从而完成具有内外轮廓的各层的独立加工；
    (4)叠层堆积与定位：将分层加工出来的各层按照其排列次序进行叠层堆积，以获得具有待加工成形零件或模具内外轮廓的初坯，或者将分层加工出来的各层按照其排列次序以分块的形式进行叠层堆积，以获得具有待加工成形零件或模具内外轮廓的多个初坯块，在上述叠层堆积过程中每堆积一层进行一次精准定位；
    (5)整体扩散连接：将已精准定位的初坯以整体的形式进行整体真空扩散连接，或将已精准定位的多个初坯块先分别进行真空扩散连接再逐块堆叠进行整体真空扩散连接，以此方式，完成复杂零件或模具的增材加工成形。
  2. 如权利要求1所述的适用于复杂零件和模具的增材加工成形方法，其特征在于，所述步骤(4)中每堆积一层可沿着该层的上表面进行一次整体电阻焊或超声波焊，以使其与上一层之间实现预结合。
  3. 如权利要求1所述的一种适用于复杂零件和模具的增材加工成形方 法，其特征在于，所述初坯中各层的材料相同或不同；每个所述初坯块中各层的材料相同或不同，各个初坯块所用的材料相同或不同。
  4. 如权利要求1所述的一种适用于复杂零件和模具的增材加工成形方法，其特征在于，所述各层的分层厚度相同或不同。
  5. 如权利要求1-4任一项所述的适用于复杂零件和模具的增材加工成形方法，其特征在于，所述真空扩散连接具体为在真空环境下以高温高压的方式使各层板料间进行分子扩散，达到整体连接的效果。
  6. 如权利要求5所述的适用于复杂零件和模具的增材加工成形方法，其特征在于，所述高温为材料熔点的0.4-0.9倍，所述高压为0.2MPa-100MPa。
  7. 如权利要求1-6任一项所述的适用于复杂零件和模具的增材加工成形方法，其特征在于，对经真空扩散的初坯块或最终成形获得的复杂零件或模具采用激光铣削、机械铣削、研磨或抛光方式进行精整加工直至达到其尺寸精度和表面精度的要求。
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CN105290739A (zh) * 2015-11-24 2016-02-03 中国航空工业集团公司北京航空制造工程研究所 基于扩散连接的异型结构钛合金构件的铺层增材制造方法
WO2017114104A1 (zh) * 2015-12-30 2017-07-06 北京航科精机科技有限公司 一种片层叠加增材制造复杂金属零件的方法及系统
CN107457404A (zh) * 2017-08-02 2017-12-12 华中科技大学 一种适用于复杂零件和模具的增材加工成形方法

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