WO2019091086A1 - 基于激光选区熔化的金属精细多孔结构成型方法 - Google Patents

基于激光选区熔化的金属精细多孔结构成型方法 Download PDF

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WO2019091086A1
WO2019091086A1 PCT/CN2018/087872 CN2018087872W WO2019091086A1 WO 2019091086 A1 WO2019091086 A1 WO 2019091086A1 CN 2018087872 W CN2018087872 W CN 2018087872W WO 2019091086 A1 WO2019091086 A1 WO 2019091086A1
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laser
porous structure
forming
powder
molding
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PCT/CN2018/087872
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English (en)
French (fr)
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邹善方
刘睿诚
吴利苹
张志霄
姚圳珠
蒋安琪
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成都优材科技有限公司
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Priority to US16/763,870 priority Critical patent/US20210060646A1/en
Publication of WO2019091086A1 publication Critical patent/WO2019091086A1/zh

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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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1103—Making porous workpieces or articles with particular physical characteristics
    • B22F3/1115—Making porous workpieces or articles with particular physical characteristics comprising complex forms, e.g. honeycombs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
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    • B22F10/20—Direct sintering or melting
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    • B22F3/1003—Use of special medium during sintering, e.g. sintering aid
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    • B22F3/1103—Making porous workpieces or articles with particular physical characteristics
    • 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
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/082—Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
    • 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
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0433—Nickel- or cobalt-based alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/045—Alloys based on refractory metals
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/045—Alloys based on refractory metals
    • C22C1/0458—Alloys based on titanium, zirconium or hafnium
    • 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
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    • B22F12/10—Auxiliary heating means
    • B22F12/17—Auxiliary heating means to heat the build chamber or platform
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B22F12/60—Planarisation devices; Compression devices
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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
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    • B22F2003/1042—Sintering only with support for articles to be sintered
    • B—PERFORMING OPERATIONS; TRANSPORTING
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Definitions

  • the present invention relates to a metal fine porous structure forming method based on laser selective melting.
  • Biological parts of porous structures are often used in the field of orthopedic implants, and traditional processing is difficult to achieve due to the complicated structure.
  • Common metals used in orthopedic implants include titanium alloys and cobalt-chromium alloys. These two alloys have poor machinability and are difficult to cut. In thermal processing, they are very easy to absorb impurities such as hydrogen, oxygen, nitrogen, carbon, etc. The performance is poor and the production process is complicated.
  • the laser bed laser melting process of 3D laser printing is to spread the metal powder on the molding substrate, melt the powder with laser, and then stack the layers to form the final shape.
  • the process usually includes three-dimensional design of biological parts and three-dimensional design after three-dimensional design.
  • the model performs data processing, parameter setting of laser selective sintering, and sintering of selected areas.
  • the process breaks through the limitations of conventional processing at the design end and the processing end, and can form a porous metal structure.
  • the existing powder bed laser melting process also has some technical problems. For example, in the laser printing of fine porous parts, since the powder spreading device uses a hard blade, the fine structure of the part is easily scratched by the blade, and is porous.
  • the thin-walled or hole-shaped support rods of the parts are easy to bond the powder during molding, resulting in rough surface, and the structure of the support rods is not accurate enough during molding, resulting in lower precision of the final parts. Need further grinding and repair in the later stage.
  • the invention provides a metal fine porous structure forming method based on laser selective melting, which can form a high-precision, high-performance metal by using a powder-laying device which does not damage parts when performing laser-dipping metal melting. Biological parts with fine porous structure.
  • the method for forming a metal fine porous structure based on laser selective melting of the invention comprises three-dimensional design, data processing, parameter setting and selective sintering, wherein:
  • the laser scanning parameter setting of the layered processed three-dimensional model is performed, and the global spot compensation is set, the working file is established, and the molding device is introduced into the molding device;
  • a flexible paving device is arranged in the molding apparatus, and the metal powder is placed in the powder silo of the molding apparatus. After the paving device flattens the metal powder from the powder silo onto the forming substrate, the fiber laser emits a laser to form The metal powder on the substrate is melted to form a single layer cross section of the porous structure;
  • the molding substrate is lowered one layer, and after the metal powder is again laid from the powder silo onto the molding substrate, the fiber laser emits laser to melt the metal powder on the molding substrate, and then forms a porous structure.
  • the metal powder is melted and layer by layer until a molded porous structural part is obtained.
  • the support structure is a tree-shaped support structure, wherein the bottom of the trunk is located on the molding substrate.
  • step D before the laser beam is emitted by the fiber laser, the oxygen concentration of the molding chamber is controlled to be 0.01% to 0.09% by charging an inert gas into the molding chamber and the filter chamber of the molding apparatus.
  • step C the parameter of the spot compensation is set to -0.10 to -0.13 mm.
  • the size of the three-dimensional model is scaled to 75% to 80% of the theoretical size in step C.
  • Step C the maximum ratio of the energy of the laser scanning of the upper surface contour and the vertical surface contour of the three-dimensional model to the energy of the laser scanning of the lower surface contour of the three-dimensional model is set to 2.5, and the upper surface contour and vertical of the three-dimensional model are set.
  • the maximum ratio of the laser scanning speed of the surface profile to the laser scanning speed of the lower surface profile of the three-dimensional model is 0.67.
  • a specific arrangement may be that the energy of the laser scanning for the upper surface contour and the vertical surface contour is 140 W to 200 W, the scanning speed is 1000 mm/s to 1200 mm/s, and the energy of the laser scanning for the contour of the lower surface is 80 W. ⁇ 120W, scanning speed is 1800mm / s ⁇ 2000mm / s.
  • the maximum ratio of the laser energy of the scanning upper skin and the inner portion to the laser energy of the scanning lower skin is set to 3.75, and the scan speed of the upper epidermis and the inner surface is scanned.
  • the maximum ratio of scanning speed to scanning the epidermis is 0.67.
  • the laser energy of the upper epidermis and the inner surface is scanned from 250 W to 300 W, the scanning speed is from 1000 mm/s to 1200 mm/s, and the laser energy of the scanning epidermis is 80 W to 120 W, and the scanning speed is 1800mm/s to 2000mm/s.
  • the three-dimensional model is a porous structure having a self-supporting structure, the hanging angle of the self-supporting rod in the porous structure is greater than 30° and less than 90°, and the diameter of the self-supporting rod is 0.2-0.4 mm.
  • the molding substrate is preheated by 30 ° C to 40 ° C before the powder spreading device flattens the metal powder on the molding substrate.
  • the flexible powder spreading device in step D comprises a carbon fiber brush and/or a silicone rubber structure.
  • the metal powder described in the step D is a titanium alloy powder or a cobalt chromium alloy powder.
  • the titanium alloy powder or the cobalt chromium alloy powder has a particle diameter of 15 to 45 ⁇ m.
  • the metal fine porous structure forming method based on laser selective melting of the invention realizes the molding of the fine porous structure by providing a flexible powder laying device in the molding apparatus, and the fine porous structure formed has high precision and does not damage the porous structure.
  • the fine part, the porous structure has a smooth surface, can be effectively applied to orthopedic implantation, and can form a variety of porous structures, and can form dozens of porous structures simultaneously on one substrate, and the molding efficiency is very high.
  • FIG. 1 is a flow chart of a method for forming a metal fine porous structure based on laser selective melting in the present invention.
  • Example 2 is a schematic view showing a fine porous structure of a titanium alloy of Example 1.
  • Figure 3 is a porous structure formed in accordance with Figure 2.
  • Example 4 is a schematic view showing a fine porous structure of a cobalt-chromium alloy of Example 2.
  • Figure 5 is a porous structure formed in accordance with Figure 4.
  • Fig. 6 is a schematic view showing the fine porous structure of a titanium alloy of Example 3.
  • Figure 7 is a porous structure formed in accordance with Figure 6.
  • the method for forming a metal fine porous structure based on laser selective melting of the invention comprises three-dimensional design, data processing, parameter setting and selective sintering, wherein:
  • a three-dimensional model of a fine porous structure is formed by three-dimensional design.
  • the parameters of the laser scanning of the layered processed three-dimensional model are set, and the global spot compensation is set, and the working file is established and imported into the molding device.
  • the spot compensation is set because there is a heat affected zone during laser scanning, so that the size of the actually printed part is larger than the theoretical design size, so setting the spot compensation will ensure the accuracy of the final part size.
  • the spot compensation value and the diameter of the rod in the porous structure are an order of magnitude. When the spot compensation value is twice the rod diameter, after the spot compensation is set, the laser will not scan the rod, and when When the rod diameter is slightly larger than twice the spot compensation value, the laser scanning area is narrow and the rod is not easily formed.
  • the parameter of the spot compensation in step C is preferably set to -0.10 to -0.13 mm, and at the same time, the size of the three-dimensional model is scaled to 75% of the theoretical size in order to ensure the dimensional accuracy of the molded part due to the thermal expansion during the molding process. 80%;
  • a flexible paving device is arranged in the molding apparatus, and the metal powder is placed in the powder silo of the molding apparatus. After the paving device flattens the metal powder from the powder silo onto the forming substrate, the fiber laser emits a laser to form The metal powder on the substrate melts to form a single layer cross section of the porous structure.
  • the metal powder may be a titanium alloy powder or a cobalt chromium alloy powder having a particle diameter of 15 to 45 ⁇ m.
  • the molding substrate is lowered one layer, and after the metal powder is again laid from the powder silo onto the molding substrate, the fiber laser emits laser to melt the metal powder on the molding substrate, and then forms a porous structure.
  • the single-layer cross section judge whether the porous structure of the part has been formed, if it has been formed, terminate the molding operation, and take out the porous structural molded part; otherwise, lower the molded substrate by one layer, and repeat steps D-E according to the working file established in step C.
  • the metal powder is melted and layer by layer until a molded porous structural part is obtained.
  • the method of the present invention realizes the molding of the fine porous structure by providing a flexible powder laying device in the molding apparatus, and the fine porous structure formed is high in precision, does not damage the minute portion of the porous structure, and smoothes the surface of the porous structure.
  • the porous structure of the three-dimensional model is mutually staggered by the support rods of adjacent holes in the porous structure to form a self-supporting porous structure, so that the entire porous structure can be smoothly formed without collapse without forming support during the molding process, and will not collapse.
  • the support rods of the respective holes preferably have a hanging angle of between 30° and 90°, and the diameter of the support rod is 0.2 to 0.4 mm.
  • the support structure is added to the three-dimensional model as a tree-shaped support structure, and the tree-shaped support has a trunk connected to the molding substrate and a branch supporting the porous structure, wherein the trunk and the branch are either cylindrical or conical or round. Table shape.
  • the tree-shaped support can provide sufficient support area and strength to the porous structure, while occupying less area on the substrate, and is also easy to remove after the product is formed.
  • the contour refers to the contour of each layer in the 3D printing process, and has an upper surface contour, a vertical surface contour and a lower surface contour in each layer, wherein the upper contour and the vertical contour design parameters mainly consider the melting uniformity and the surface quality. It is better, so it will set higher laser energy and lower scanning speed.
  • the parameters of the lower surface it is necessary to consider the laser to penetrate the surface, causing the powder under the surface to bond, causing the slag phenomenon, so it will be set lower. Laser energy and high scanning speed.
  • the internal entities are also divided into the upper skin, the inner and the lower skin, and the parameter settings correspond to the upper contour, the vertical contour and the lower contour, respectively. Therefore, correspondingly, the maximum ratio of the energy of the laser scanning of the upper surface contour and the vertical surface contour of the three-dimensional model to the energy of the laser scanning of the lower surface contour of the three-dimensional model is set in this step, and the upper surface contour of the three-dimensional model is The maximum ratio of the laser scanning speed of the vertical surface profile to the laser scanning speed of the lower surface profile of the three-dimensional model is 0.67.
  • the upper and vertical contour laser energy can be set to 140W to 200W, the scanning speed can be set to 1000mm/s to 1200mm/s, the lower contour laser energy can be set to 80W to 120W, and the scanning speed can be set to 1800mm/s to 2000mm/ s; in the internal physical process parameters, set the laser scanning parameters of the internal entity of the three-dimensional model, set the maximum ratio of the laser energy of the scanning epidermis and the internal laser to the scanning of the epidermis to 3.75, scan the upper epidermis and the inner The maximum ratio of the scanning speed to the scanning speed of the scanning epidermis is 0.67.
  • the upper skin and internal laser energy can be set to 250W ⁇ 300W, the scanning speed can be set to 1000mm / s ⁇ 1200mm / s, the lower skin laser energy can be set to 80W ⁇ 120W, the scanning speed can be set to 1800mm / s ⁇ 2000mm / s .
  • the molded substrate is preheated at 30 ° C to 40 ° C before lamination to reduce the damage of the powdered device to the upper layer of sintered metal powder.
  • the present invention is based on a laser selective zone melting metal fine porous structure forming method, which has three-dimensional design, data processing, parameter setting and selective sintering, wherein:
  • the support rod 3 has a diameter of 0.2 mm.
  • the tree-supported trunk 1 and the branch 2 are respectively a truncated cone or a conical shape.
  • the average diameter of the trunk 1 is 1.0 mm, and the diameter of the portion of the branch 2 in contact with the porous structure is 0.6 mm.
  • the contour parameter setting of the three-dimensional model includes: the upper and the vertical contours have a laser energy of 150 W, the scanning speed is 1100 mm/s, the lower contour has a laser energy of 100 W, and the scanning speed is 1800 mm/s; the parameters of the internal physical process include: The upper and inner laser energy is 250W, the scanning speed is 1000mm/s, the laser energy of the lower epidermis is 80W, the scanning speed is 2000mm/s, and the spot compensation parameter is set to -0.10mm, ensuring that the support rod 3 in the porous unit is not It cannot be scanned because of spot compensation; at the same time, the size of the 3D model is scaled to 75% of the theoretical size in order to ensure the dimensional accuracy of the molded part due to the thermal expansion during the molding process.
  • a flexible powder spreading device comprising a carbon fiber brush or a silicone rubber or the like is disposed in the molding apparatus, and a titanium alloy powder having a particle diameter of 15 to 45 ⁇ m is placed in a powder chamber of the molding apparatus, and then into the molding chamber and the filter chamber.
  • the inert gas was charged and the oxygen concentration of the molding chamber was controlled to be in the range of 0.05%.
  • the powder spreading device flattens the titanium alloy powder from the powder silo onto the molding substrate, and the laser light emitted by the fiber laser passes through the collimating mirror, the beam expanding mirror, the galvanometer and the F- ⁇ . The mirror is focused on the molded substrate to melt the titanium alloy powder on the molded substrate to form a single layer cross section of the porous structure.
  • the molding substrate is lowered one layer, and after the metal powder is again laid from the powder silo onto the molding substrate, the fiber laser emits laser to melt the metal powder on the molding substrate, and then forms a porous structure.
  • the single-layer cross section judge whether the porous structure of the part has been formed, and if it has been formed, terminate the molding operation and take out the porous structural molded part. Otherwise, the formed substrate is lowered by one layer, and according to the working file established in step C, steps D to E are repeated to melt and accumulate the metal powder layer by layer until the formed porous structural part is obtained.
  • the present invention is based on a laser selective zone melting metal fine porous structure forming method, which has three-dimensional design, data processing, parameter setting and selective sintering, wherein:
  • the support rod 3 has a diameter of 0.3 mm.
  • the tree-supported trunk 1 and the branch 2 are respectively a truncated cone or a conical shape.
  • the trunk 1 has an average diameter of 1.1 mm
  • the diameter of the contact portion of the branch 2 with the porous structure is 0.7 mm.
  • the contour parameter setting of the three-dimensional model includes: upper and vertical contour laser energy is 180W, scanning speed is 1200mm/s, lower contour laser energy is 120W, scanning speed is 1900mm/s; internal physical process parameters are: upper epidermis and The internal laser energy is 270W, the scanning speed is 1100mm/s, the laser energy of the lower epidermis is 100W, the scanning speed is 1900mm/s, and the global spot compensation parameter is set to -0.12mm, ensuring that the support rod 3 in the porous unit will not be compensated by the spot. It cannot be scanned; at the same time, the size of the 3D model is scaled to 78% of the theoretical size in order to ensure the dimensional accuracy of the molded part due to the thermal expansion during the molding process.
  • a flexible paving device comprising a structure such as a carbon fiber brush or a silicone rubber is disposed in the molding apparatus, and a cobalt chromium alloy powder having a particle diameter of 15 to 45 ⁇ m is placed in a powder silo of the molding apparatus, and then to the molding chamber and the filter chamber. It is filled with an inert gas and controls the oxygen concentration of the molding chamber to be within 0.02%.
  • the paving device flattens the cobalt chromium alloy powder from the powder silo onto the forming substrate, and the laser light emitted by the fiber laser passes through the collimating mirror, the beam expander mirror, the galvanometer and the F- The ⁇ mirror focuses on the molded substrate to melt the cobalt-chromium alloy powder on the molded substrate to form a single-layer cross section of the porous structure.
  • the molding substrate is lowered one layer, and after the metal powder is again laid from the powder silo onto the molding substrate, the fiber laser emits laser to melt the metal powder on the molding substrate, and then forms a porous structure.
  • the single-layer cross section judge whether the porous structure of the part has been formed, and if it has been formed, terminate the molding operation and take out the porous structural molded part. Otherwise, the formed substrate is lowered by one layer, and according to the working file established in step C, steps D to E are repeated to melt and accumulate the metal powder layer by layer until the formed porous structural part is obtained.
  • the method for forming a metal fine porous structure based on laser selective melting has the three-dimensional design, data processing, parameter setting and selective sintering, wherein:
  • the tree-supported trunk 1 and the branch 2 are respectively a truncated cone or a conical shape.
  • the trunk 1 has an average diameter of 1.2 mm, and the diameter of the contact portion of the branch 2 with the porous structure is 0.8 mm. Layering the 3D model.
  • the contour parameter settings of the three-dimensional model include: upper and vertical contour laser energy is 140W, scanning speed is 1200mm/s, lower contour laser energy is 80W, scanning speed is 1900mm/s; internal physical process parameters are: upper epidermis and The internal laser energy is 280W, the scanning speed is 1200mm/s, the laser energy of the lower epidermis is 80W, the scanning speed is 1900mm/s, and the global spot compensation parameter is set to -0.12mm, ensuring that the support rod 3 in the porous unit is not compensated by the spot. It cannot be scanned; at the same time, due to the thermal expansion during the molding process, the size of the three-dimensional model is scaled to 80% of the theoretical size in order to ensure the dimensional accuracy of the molded part.
  • a flexible powder spreading device comprising a carbon fiber brush or a silicone rubber or the like is disposed in the molding apparatus, and a titanium alloy powder having a particle diameter of 15 to 45 ⁇ m is placed in a powder chamber of the molding apparatus, and then into the molding chamber and the filter chamber.
  • the inert gas was charged and the oxygen concentration of the molding chamber was controlled to be within 0.06%.
  • the powder spreading device flattens the titanium alloy powder from the powder silo onto the molding substrate, and the laser light emitted by the fiber laser passes through the collimating mirror, the beam expanding mirror, the galvanometer and the F- ⁇ The mirror is focused on the molded substrate to melt the titanium alloy powder on the molded substrate to form a single layer cross section of the porous structure.
  • the molding substrate is lowered one layer, and after the metal powder is again laid from the powder silo onto the molding substrate, the fiber laser emits laser to melt the metal powder on the molding substrate, and then forms a porous structure.
  • the single-layer cross section judge whether the porous structure of the part has been formed, and if it has been formed, terminate the molding operation and take out the porous structural molded part. Otherwise, the formed substrate is lowered by one layer, and according to the working file established in step C, steps D to E are repeated to melt and accumulate the metal powder layer by layer until the formed porous structural part is obtained.

Abstract

一种基于激光选区熔化的金属精细多孔结构成型方法，包括：三维设计、数据处理、参数设置和选区烧结，具体为：A.设计精细多孔结构的三维模型；B.添加支撑结构，并进行分层处理；C.激光扫描的参数设置，设置光斑补偿；D.成型设备中设置柔性铺粉装置，铺粉装置将金属粉末平铺到成型基板上后，光纤激光器发射激光将金属粉末熔化，形成多孔结构的单层截面；E.成型基板下降一层，重复步骤D～E，使金属粉末逐层熔化堆积，直到获得多孔结构零件。该成型方法能够成型精细的多孔结构，不会破坏多孔结构的细微部分，且成型的多孔结构表面光滑，能够有效应用于骨科植入中。

Description

基于激光选区熔化的金属精细多孔结构成型方法 技术领域
本发明涉及基于激光选区熔化的金属精细多孔结构成型方法。
背景技术
多孔结构的生物零件常被用于骨科植入领域，由于结构复杂，传统加工很难实现。骨科植入常用的金属包括有钛合金和钴铬合金，这两种合金的可加工性能差，切削加工困难，在热加工中，非常容易吸收氢、氧、氮、碳等杂质，造成抗磨性差，而且生产工艺复杂。
3D激光打印的粉末床激光熔化工艺是将金属粉末平铺在成型基板上，用激光熔化粉末，再层层堆积，最终成型，其工艺通常包括对生物零件的三维设计、对三维设计后的三维模型进行数据处理、激光选区烧结的参数设置、选区烧结等步骤。该工艺突破了传统加工在设计端和加工端的限制，可成型金属多孔结构。但是，现有的粉末床激光熔化工艺也存在一些技术问题，例如在精细的多孔零件的激光打印中，由于铺粉装置采用的是硬质刮刀，因此零件的微细结构容易被刮刀刮坏，多孔零件的薄壁或孔的支撑杆，特别是各孔的边缘部分，在成型时容易粘结粉末，造成表面粗糙，支撑杆等结构在成型时精度不够等，从而造成最终加零件的精度较低，需要后期的进一步打磨修复。
发明内容
本发明提供了一种基于激光选区熔化的金属精细多孔结构成型方法，在进行激光选区融化金属的铺粉时采用不会对零件产生损伤的铺粉装置，可成型出高精密、高性能的金属精细多孔结构的生物零件。
本发明的基于激光选区熔化的金属精细多孔结构成型方法，包括有三维设计、数据处理、参数设置和选区烧结，其中：
A.通过三维设计形成精细多孔结构的三维模型；
B.在数据处理软件中对所述的三维模型添加支撑结构，并对三维模型进行分层处理；
C.在工艺控制软件中对分层处理后的三维模型进行激光扫描的参数设置，并对全局的光斑补偿进行设置，建立工作文件，导入成型设备中；
D.成型设备中设置柔性的铺粉装置，将金属粉末置入成型设备的粉末仓中，所述的铺粉装置将金属粉末从粉末仓平铺到成型基板上后，光纤激光器发射激光将成型基板上的金属粉末熔化，形成多孔结构的单层截面；
E.完成一层单层截面后，成型基板下降一层，再次将金属粉末从粉末仓平铺到成型基板上后，光纤激光器发射激光将成型基板上的金属粉末熔化，再形成一层多孔结构的单层截面； 判断零件的多孔结构是否已成型，若已成型，则结束成型操作，取出多孔结构成型件；否则将成型基板下降一层，根据步骤C建立的工作文件，重复步骤D～E，使金属粉末逐层熔化堆积，直到获得成型的多孔结构零件。
优选的，所述的支撑结构为树形支撑结构，其中树干的底部位于成型基板上。
进一步的，步骤D中，在光纤激光器发射激光前，通过向成型设备的成型室和过滤仓中充入惰性气体，控制成型室的氧浓度为0.01％～0.09％。
进一步的，步骤C中将光斑补偿的参数设置为－0.10～－0.13mm。
进一步的，在步骤C中将三维模型的大小缩放至理论尺寸的75％～80％。
进一步的，步骤C中设置对三维模型的上表面轮廓和垂直表面轮廓的激光扫描的能量与对三维模型下表面轮廓的激光扫描的能量的最大比值为2.5，对三维模型的上表面轮廓和垂直表面轮廓的激光扫描速度与对三维模型下表面轮廓的激光扫描速度的最大比值为0.67。
具体的一种设置可以为，所述对上表面轮廓和垂直表面轮廓的激光扫描的能量为140W～200W，扫描速度为1000mm/s～1200mm/s；对下表面轮廓的激光扫描的能量为80W～120W，扫描速度为1800mm/s～2000mm/s。
进一步的，步骤C中对三维模型的内部实体进行激光扫描的设置中，设置扫描上表皮和内部的激光能量与对扫描下表皮的激光能量的最大比值为3.75，扫描上表皮和内部的扫描速度与扫描下表皮的扫描速度的最大比值为0.67。
具体的，在所述的激光扫描设置中，扫描上表皮和内部的激光能量为250W～300W，扫描速度为1000mm/s～1200mm/s，扫描下表皮的激光能量为80W～120W，扫描速度为1800mm/s～2000mm/s。
进一步的，所述的三维模型为具有自支撑结构的多孔结构，多孔结构中的自支撑杆的悬垂角大于30°且小于90°，自支撑杆的直径为0.2～0.4mm。
进一步的，步骤D中，在铺粉装置将金属粉末平铺在成型基板之前，先将成型基板预热30℃～40℃。
可选的，步骤D中所述柔性的铺粉装置包括碳纤维毛刷和/或硅橡胶结构。
进一步的，步骤D中所述的金属粉末为钛合金粉末或钴铬合金粉末。
优选的，所述钛合金粉末或钴铬合金粉末的粒径为15～45μm。
本发明的基于激光选区熔化的金属精细多孔结构成型方法，通过在成型设备中设置柔性的铺粉装置，实现了精细多孔结构的成型，并且成型的精细多孔结构精度高，不会破坏多孔结构的细微部分，多孔结构的表面光滑，能够有效应用于骨科植入中，而且能够成型多种多孔结构，且在一块基板上可同时成型数十个多孔结构，成型效率非常高。
以下结合实施例的具体实施方式，对本发明的上述内容再作进一步的详细说明。但不应将此理解为本发明上述主题的范围仅限于以下的实例。在不脱离本发明上述技术思想情况下，根据本领域普通技术知识和惯用手段做出的各种替换或变更，均应包括在本发明的范围内。
附图说明
图1为本发明基于激光选区熔化的金属精细多孔结构成型方法的流程图。
图2为实施例1的一种钛合金精细多孔结构示意图。
图3为根据图2成型后的多孔结构。
图4为实施例2的一种钴铬合金精细多孔结构示意图。
图5为根据图4成型后的多孔结构。
图6为实施例3的一种钛合金精细多孔结构示意图。
图7为根据图6成型后的多孔结构。
具体实施方式
本发明的基于激光选区熔化的金属精细多孔结构成型方法，包括有三维设计、数据处理、参数设置和选区烧结，其中：
A.通过三维设计形成精细多孔结构的三维模型。
B.在数据处理软件中对所述的三维模型添加支撑结构，并对三维模型进行分层处理；
C.在工艺控制软件中对分层处理后的三维模型进行激光扫描的参数设置，并对全局的光斑补偿进行设置，建立工作文件，导入成型设备中。设置光斑补偿是因为激光扫描时会有热影响区，使得实际打印出来的零件尺寸大于理论设计的尺寸，因此设置光斑补偿会保证最终零件尺寸的精度。但对于精细的多孔结构来说，光斑补偿值和多孔结构中的杆的直径在一个数量级，当光斑补偿值的两倍大于杆直径时，设置光斑补偿后，激光将不会扫描杆，而当杆直径略大于光斑补偿值的两倍时，激光扫描的区域较窄，杆不易成型。因此步骤C中的光斑补偿的参数优选设置为－0.10～－0.13mm，同时，由于成型过程中的热膨胀影响，为了保证成型零件的尺寸精度，将三维模型的大小缩放至理论尺寸的75％～80％；
D.成型设备中设置柔性的铺粉装置，将金属粉末置入成型设备的粉末仓中，所述的铺粉装置将金属粉末从粉末仓平铺到成型基板上后，光纤激光器发射激光将成型基板上的金属粉末熔化，形成多孔结构的单层截面。其中所述的金属粉末可以为钛合金粉末或钴铬合金粉末，其粒径为15～45μm。
E.完成一层单层截面后，成型基板下降一层，再次将金属粉末从粉末仓平铺到成型基板上后，光纤激光器发射激光将成型基板上的金属粉末熔化，再形成一层多孔结构的单层截面；判断零件的多孔结构是否已成型，若已成型，则结束成型操作，取出多孔结构成型件；否则 将成型基板下降一层，根据步骤C建立的工作文件，重复步骤D～E，使金属粉末逐层熔化堆积，直到获得成型的多孔结构零件。
本发明的方法通过在成型设备中设置柔性的铺粉装置，实现了精细多孔结构的成型，并且成型的精细多孔结构精度高，不会破坏多孔结构的细微部分，使多孔结构的表面光滑。
其中三维模型的多孔结构是通过多孔结构中各相邻孔的支撑杆相互交错，形成自支撑的多孔结构，使整个多孔结构在成型过程中不需要添加支撑也能顺利成型，不会垮塌。其中各孔的支撑杆优选的悬垂角为30°～90°之间，支撑杆的直径为0.2～0.4mm。
在数据处理软件中对三维模型添加支撑结构为树形支撑结构，树形支撑具有与成型基板相连的树干和支撑多孔结构的树枝，其中树干和树枝既可为圆柱形，也可为圆锥或圆台形。树形支撑能够对多孔结构提供足够的支撑面积和强度的同时，在基板上也占用更少的面积，而且在产品成型后也易于去除。
在对多孔结构的三维模型进行所述的激光扫描的参数设置时，主要分为轮廓和内部实体的工艺参数。轮廓指的是3D打印过程中每一层的轮廓，在每一层中分别具有上表面轮廓、垂直表面轮廓和下表面轮廓，其中上轮廓和垂直轮廓设计参数时主要考虑熔化充分均匀，表面质量较优，因此会设置较高的激光能量和较低的扫描速度，下表面轮廓设计参数时要考虑激光易穿透表面，引起表面下方粉末粘结，造成挂渣现象，因此会设置较低的激光能量和较高的扫描速度。内部实体也分为上表皮、内部和下表皮，参数设置分别对应上轮廓、垂直轮廓和下轮廓。因此相应的，该步骤中设置对三维模型的上表面轮廓和垂直表面轮廓的激光扫描的能量与对三维模型下表面轮廓的激光扫描的能量的最大比值为2.5，对三维模型的上表面轮廓和垂直表面轮廓的激光扫描速度与对三维模型下表面轮廓的激光扫描速度的最大比值为0.67。其中上轮廓和垂直轮廓激光能量可以设为140W～200W，扫描速度可以设为1000mm/s～1200mm/s，下轮廓激光能量可以设为80W～120W，扫描速度可以设为1800mm/s～2000mm/s；在内部实体工艺参数中，设置对三维模型的内部实体的激光扫描参数，设置扫描上表皮和内部的激光能量与对扫描下表皮的激光能量的最大比值为3.75，扫描上表皮和内部的扫描速度与扫描下表皮的扫描速度的最大比值为0.67。其中上表皮和内部激光能量可以设为250W～300W，扫描速度可以设为1000mm/s～1200mm/s，下表皮激光能量可以设为80W～120W，扫描速度可以设为1800mm/s～2000mm/s。
在铺粉时，需要先向成型设备的成型室和过滤仓中充入惰性气体来控制成型室的氧浓度在0.01％～0.09％，以对烧结的金属粉末进行保护。在通过柔性的铺粉装置铺粉前，还要先将成型基板预热30℃～40℃后再进行铺粉，以减少铺粉装置对上一层已烧结金属粉末的损害。
实施例1：
如图1至图3所示本发明基于激光选区熔化的金属精细多孔结构成型方法，有三维设计、数据处理、参数设置和选区烧结，其中：
A.在三维设计中形成精细多孔结构的三维模型，在所述的三维模型中包括具有支撑杆3的自支撑结构，所述支撑杆3的悬垂角(与水平面的夹角)为45°，支撑杆3的直径为0.2mm。
B.在Magics数据处理软件中对所述的三维模型添加树形支撑，树形支撑的树干1和树枝2分别为圆台或圆锥形。其中树干1的平均直径为1.0mm，树枝2的与多孔结构接触部分的直径为0.6mm。对三维模型进行分层处理。
C.在工艺控制软件中对分层处理后的三维模型的轮廓参数、填充线参数进行设置，主要包括激光能量、扫描速度，并对全局的光斑补偿进行设置，建立工作文件，导入成型设备中。所述三维模型的轮廓参数设置包括：上轮廓和垂直轮廓的激光能量为150W，扫描速度为1100mm/s，下轮廓的激光能量为100W，扫描速度为1800mm/s；内部实体工艺的参数包括：上表皮和内部的激光能量为250W，扫描速度为1000mm/s，下表皮的激光能量为80W，扫描速度为2000mm/s；光斑补偿参数设置为－0.10mm，保证多孔单元中的支撑杆3不会因为光斑补偿而无法被扫描；同时，由于成型过程中的热膨胀影响，为了保证成型零件的尺寸精度，将三维模型的大小缩放至理论尺寸的75％。
D.在成型设备中设置包含碳纤维毛刷或硅橡胶等结构的柔性铺粉装置，将粒径为15～45μm的钛合金粉末置入成型设备的粉末仓中，然后向成型室和过滤仓中充入惰性气体，并控制成型室的氧浓度在0.05％范围内。将成型基板预热至30℃后，所述的铺粉装置将钛合金粉末从粉末仓平铺到成型基板上，光纤激光器发射的激光经准直镜、扩束镜、振镜和F-θ镜，聚焦于成型基板上，将成型基板上的钛合金粉末熔化，形成多孔结构的单层截面。
E.完成一层单层截面后，成型基板下降一层，再次将金属粉末从粉末仓平铺到成型基板上后，光纤激光器发射激光将成型基板上的金属粉末熔化，再形成一层多孔结构的单层截面；判断零件的多孔结构是否已成型，若已成型，则结束成型操作，取出多孔结构成型件。否则将成型基板下降一层，根据步骤C建立的工作文件，重复步骤D～E，使金属粉末逐层熔化堆积，直到获得成型的多孔结构零件。
实施例2：
如图1、图4和图5所示本发明基于激光选区熔化的金属精细多孔结构成型方法，有三维设计、数据处理、参数设置和选区烧结，其中：
A.在三维设计中形成精细多孔结构的三维模型，在所述的三维模型中包括具有支撑杆3 的自支撑结构，所述支撑杆3的悬垂角(与水平面的夹角)为45°，支撑杆3的直径为0.3mm。
B.在Magics数据处理软件中对所述的三维模型添加树形支撑，树形支撑的树干1和树枝2分别为圆台或圆锥形。其中树干1的平均直径为1.1mm，树枝2的与多孔结构接触部分的直径为0.7mm。对三维模型进行分层处理。
C.在工艺控制软件中对分层处理后的三维模型的轮廓参数、填充线参数进行设置，主要包括激光能量、扫描速度，并对全局的光斑补偿进行设置，建立工作文件，导入成型设备中。所述三维模型的轮廓参数设置包括：上轮廓和垂直轮廓激光能量为180W，扫描速度为1200mm/s，下轮廓激光能量为120W，扫描速度为1900mm/s；内部实体工艺参数为：上表皮和内部激光能量为270W，扫描速度为1100mm/s，下表皮激光能量为100W，扫描速度为1900mm/s；全局光斑补偿参数设置为－0.12mm，保证多孔单元中的支撑杆3不会因为光斑补偿而无法被扫描；同时，由于成型过程中的热膨胀影响，为了保证成型零件的尺寸精度，将三维模型的大小缩放至理论尺寸的78％。
D.在成型设备中设置包含碳纤维毛刷或硅橡胶等结构的柔性铺粉装置，将粒径为15～45μm的钴铬合金粉末置入成型设备的粉末仓中，然后向成型室和过滤仓中充入惰性气体，并控制成型室的氧浓度在0.02％范围内。将成型基板预热至40℃后，所述的铺粉装置将钴铬合金粉末从粉末仓平铺到成型基板上，光纤激光器发射的激光经准直镜、扩束镜、振镜和F-θ镜，聚焦于成型基板上，将成型基板上的钴铬合金粉末熔化，形成多孔结构的单层截面。
E.完成一层单层截面后，成型基板下降一层，再次将金属粉末从粉末仓平铺到成型基板上后，光纤激光器发射激光将成型基板上的金属粉末熔化，再形成一层多孔结构的单层截面；判断零件的多孔结构是否已成型，若已成型，则结束成型操作，取出多孔结构成型件。否则将成型基板下降一层，根据步骤C建立的工作文件，重复步骤D～E，使金属粉末逐层熔化堆积，直到获得成型的多孔结构零件。
实施例3：
如图1、图6和图7所示本发明基于激光选区熔化的金属精细多孔结构成型方法，有三维设计、数据处理、参数设置和选区烧结，其中：
A.在三维设计中形成精细多孔结构的三维模型，在所述的三维模型中包括具有支撑杆3的自支撑结构，所述支撑杆3的悬垂角(与水平面的夹角)为45°，支撑杆3的直径为0.4mm。
B.在Magics数据处理软件中对所述的三维模型添加树形支撑，树形支撑的树干1和树枝2分别为圆台或圆锥形。其中树干1的平均直径为1.2mm，树枝2的与多孔结构接触部分的直径为0.8mm。对三维模型进行分层处理。
C.在工艺控制软件中对分层处理后的三维模型的轮廓参数、填充线参数进行设置，主要包括激光能量、扫描速度，并对全局的光斑补偿进行设置，建立工作文件，导入成型设备中。所述三维模型的轮廓参数设置包括：上轮廓和垂直轮廓激光能量为140W，扫描速度为1200mm/s，下轮廓激光能量为80W，扫描速度为1900mm/s；内部实体工艺参数为：上表皮和内部激光能量为280W，扫描速度为1200mm/s，下表皮激光能量为80W，扫描速度为1900mm/s；全局光斑补偿参数设置为－0.12mm，保证多孔单元中的支撑杆3不会因为光斑补偿而无法被扫描；同时，由于成型过程中的热膨胀影响，为了保证成型零件的尺寸精度，将三维模型的大小缩放至理论尺寸的80％。
D.在成型设备中设置包含碳纤维毛刷或硅橡胶等结构的柔性铺粉装置，将粒径为15～45μm的钛合金粉末置入成型设备的粉末仓中，然后向成型室和过滤仓中充入惰性气体，并控制成型室的氧浓度在0.06％范围内。将成型基板预热至35℃后，所述的铺粉装置将钛合金粉末从粉末仓平铺到成型基板上，光纤激光器发射的激光经准直镜、扩束镜、振镜和F-θ镜，聚焦于成型基板上，将成型基板上的钛合金粉末熔化，形成多孔结构的单层截面。
E.完成一层单层截面后，成型基板下降一层，再次将金属粉末从粉末仓平铺到成型基板上后，光纤激光器发射激光将成型基板上的金属粉末熔化，再形成一层多孔结构的单层截面；判断零件的多孔结构是否已成型，若已成型，则结束成型操作，取出多孔结构成型件。否则将成型基板下降一层，根据步骤C建立的工作文件，重复步骤D～E，使金属粉末逐层熔化堆积，直到获得成型的多孔结构零件。

Claims (14)

  1. 基于激光选区熔化的金属精细多孔结构成型方法，包括有三维设计、数据处理、参数设置和选区烧结，其特征为：
    A.通过三维设计形成精细多孔结构的三维模型；
    B.在数据处理软件中对所述的三维模型添加支撑结构，并对三维模型进行分层处理；
    C.在工艺控制软件中对分层处理后的三维模型进行激光扫描的参数设置，并对全局的光斑补偿进行设置，建立工作文件，导入成型设备中；
    D.成型设备中设置柔性的铺粉装置，将金属粉末置入成型设备的粉末仓中，所述的铺粉装置将金属粉末从粉末仓平铺到成型基板上后，光纤激光器发射激光将成型基板上的金属粉末熔化，形成多孔结构的单层截面；
    E.完成一层单层截面后，成型基板下降一层，再次将金属粉末从粉末仓平铺到成型基板上后，光纤激光器发射激光将成型基板上的金属粉末熔化，再形成一层多孔结构的单层截面；判断零件的多孔结构是否已成型，若已成型，则结束成型操作，取出多孔结构成型件；否则将成型基板下降一层，根据步骤C建立的工作文件，重复步骤D～E，使金属粉末逐层熔化堆积，直到获得成型的多孔结构零件。
  2. 如权利要求1所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：所述的支撑结构为树形支撑结构，其中树干的底部位于成型基板上。
  3. 如权利要求1所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：步骤D中，在光纤激光器发射激光前，通过向成型设备的成型室和过滤仓中充入惰性气体，控制成型室的氧浓度为0.01％～0.09％。
  4. 如权利要求1所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：步骤C中将光斑补偿的参数设置为－0.10～－0.13mm。
  5. 如权利要求4所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：在步骤C中将三维模型的大小缩放至理论尺寸的75％～80％。
  6. 如权利要求1所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：步骤C中设置对三维模型的上表面轮廓和垂直表面轮廓的激光扫描的能量与对三维模型下表面轮廓的激光扫描的能量的最大比值为2.5，对三维模型的上表面轮廓和垂直表面轮廓的激光扫描速度与对三维模型下表面轮廓的激光扫描速度的最大比值为0.67。
  7. 如权利要求6所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：所述对上表面轮廓和垂直表面轮廓的激光扫描的能量为140W～200W，扫描速度为1000mm/s～ 1200mm/s；对下表面轮廓的激光扫描的能量为80W～120W，扫描速度为1800mm/s～2000mm/s。
  8. 如权利要求1所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：步骤C中对三维模型的内部实体进行激光扫描的设置中，设置扫描上表皮和内部的激光能量与对扫描下表皮的激光能量的最大比值为3.75，扫描上表皮和内部的扫描速度与扫描下表皮的扫描速度的最大比值为0.67。
  9. 如权利要求8所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：在所述的激光扫描设置中，扫描上表皮和内部的激光能量为250W～300W，扫描速度为1000mm/s～1200mm/s，扫描下表皮的激光能量为80W～120W，扫描速度为1800mm/s～2000mm/s。
  10. 如权利要求1所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：所述的三维模型为具有自支撑结构的多孔结构，多孔结构中的自支撑杆的悬垂角大于30°且小于90°，自支撑杆的直径为0.2～0.4mm。
  11. 如权利要求1所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：步骤D中，在铺粉装置将金属粉末平铺在成型基板之前，先将成型基板预热30℃～40℃。
  12. 如权利要求1至11之一所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：步骤D中所述柔性的铺粉装置包括碳纤维毛刷和/或硅橡胶结构。
  13. 如权利要求1至11之一所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：步骤D中所述的金属粉末为钛合金粉末或钴铬合金粉末。
  14. 如权利要求13所述的基于激光选区熔化的金属精细多孔结构成型方法，其特征为：所述钛合金粉末或钴铬合金粉末的粒径为15～45μm。
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