WO2020058722A1 - Fabrication additive sur lit de poudre - Google Patents

Fabrication additive sur lit de poudre Download PDF

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Publication number
WO2020058722A1
WO2020058722A1 PCT/GB2019/052645 GB2019052645W WO2020058722A1 WO 2020058722 A1 WO2020058722 A1 WO 2020058722A1 GB 2019052645 W GB2019052645 W GB 2019052645W WO 2020058722 A1 WO2020058722 A1 WO 2020058722A1
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WIPO (PCT)
Prior art keywords
section
powder
light
beams
layer
Prior art date
Application number
PCT/GB2019/052645
Other languages
English (en)
Inventor
Professor William O'NEILL
Dr Martin SPARKES
Original Assignee
Camadd Ltd
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Publication date
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Publication of WO2020058722A1 publication Critical patent/WO2020058722A1/fr

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Classifications

    • 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
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • 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
    • 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
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • 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
    • B22F12/22—Driving means
    • 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
    • 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
    • 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

  • a POWDER BED ADDITIVE MANUFACTURING
  • the present disclosure relates to additive manufacturing and more particularly to the means by which the resolution and surface quality of additively manufacturing parts can be improved compared to those achieved by conventional additive manufacturing systems.
  • AM additively manufactured
  • pre-placed powder bed technology also known as three-dimensional printing
  • AM additively manufactured
  • the widespread application of AM is a result of the ease with which AM users can create products in any particular material in relatively short times compared to conventional subtractive and formative techniques.
  • systems manufacturers across the world that commonly apply the same basic principles of powder bed based AM.
  • successive layers of material are deposited to form the structure which are consolidated in a form as determined by the data defined by a three-dimensional computer model of the object.
  • the material is deposited in powder layers with each layer being consolidated in selective regions by a laser beam (or some other structured light source).
  • SLM Selective Laser Melting
  • LAM Laser Additive Manufacturing Technique
  • the ability to control the edge definition of each melted layer is quite low and often determined by factors such as, but not limited to: the particle size distribution of the powder being employed; the stability of the laser scanning system in defining the melt path; and the optical stability of the laser being employed to melt the powder (i.e: variation in laser beam diameter; laser power stability; laser pointing stability; and other optical changes that result in a variation of melt width).
  • the layer-by-layer approach applied in SLM processes the ability to produce parts with very well-defined surface quality and precision is often quite low and very much below parts produced by subtractive machining operations or formative processes.
  • AM parts produced by SLM techniques have to be post-processed either by subtractive finishing techniques such as machining, de-burring, mechanical polishing, grinding, and/or lapping processes.
  • subtractive finishing techniques such as machining, de-burring, mechanical polishing, grinding, and/or lapping processes.
  • the consequence of this is an increase in part costs and part manufacturing times.
  • Many of the SLM process parameters can be controlled, such as laser power, scan speed, hatch spacing, and powder layer thickness. Optimization of the SLM process parameters is an essential step for controlling material properties and the quality of the fabricated parts.
  • Position dependent surface quality in selective laser melting Positionsabhangige Oberflachenqualitat im selektiven Laserstrahlschmelzen (Hitzler et al Materwiss. Werksttech. 2017, 48, 327-334) have been carried out to investigate the effects of SLM process parameters to improve the density, surface roughness, and dimensional accuracy of SLM parts.
  • Scanning strategy has also been shown to improve part quality through a reduction in part distortion as the built-in thermal stresses are distributed throughout the layers as the part is built (Stress and deformation evaluations of scanning strategy effect in selective laser melting; Cheng et al, Proceedings of the ASME 2016 1 1 th International Manufacturing Science and Engineering Conference, Blacksburg, VA, USA, 27 June-1 July 2016). It is generally well known that part surface quality varies according to the orientation of the surface with respect to layer direction in the part, and to the location of the part on the AM build plate.
  • a method for additive manufacturing comprising: depositing at least one powder material layer onto a powder bed; fusing a first section of the at least one powder material layer by exposing the first section to one or more beams of light from one or more light sources; ablating a second section of the at least one powder material layer by exposing the second section to one or more beams of light, wherein the second section is adjacent to the first section.
  • the second section may be contiguous to the first section.
  • the method may further comprise melting at least one region of the second section by exposing said at least one region of the second section to one or more beams of light.
  • the at least one region of the second section may comprise an edge of the second section contiguous to the first section.
  • a same one or more beams of light may perform at least two of the steps of fusing, ablating and melting.
  • the one or more beams of light may be controlled by at least one of moving (i) an optical head on a Cartesian robot; and (ii) moving the one or more beams through a galvanometer moving mirror scanner.
  • the one or more light sources of the one or more beams of light may comprise at least one of laser diodes, fibre lasers, disk lasers and phased array lasers.
  • the one or more light sources may each have a total power output of between about 100W and about 100 kW.
  • the one or more light sources may collectively have a total power output of about 100W to about 100kW.
  • the one or more beams of light may utilise vector scanning techniques.
  • the one or more beams of light may utilise raster scanning techniques.
  • the powder material layer may comprise a metal powder.
  • the metal powder may comprise at least one of a nickel-based superalloy powder, a titanium powder, a titanium alloy powder and a nickel-chromium based superalloy powder. It will be appreciated that the disclosure is not restricted to the list of metal powders above. Other suitable metal powders can be used.
  • the one or more beams of light may have a diameter of about 10 micron to about 10mm.
  • the second section forms a perimeter around the first section.
  • the ablating the second section ablates the second section of the powder material layer to a depth equal to or greater than the depth of the fused first section of the powder material layer.
  • Melting a region of the second section may melt the region to a depth equal to or greater than a maximum peak to trough roughness of the second section.
  • an additive manufacturing system comprising: a powder bed support system; a powder delivery system; one or more light sources; and a control system configured to control the additive manufacturing system to: deposit at least one powder material layer from the powder deliver system onto the powder bed support system; fuse a first section of the at least one powder material layer by exposing the first section to one or more beams of light from the one or more light sources; and ablate a second section of the at least one powder material layer by exposing the second section to one or more beams of light from the one or more light sources, wherein the second section is adjacent to the first section.
  • control system may be further configured to control the additive manufacturing system to melt at least one region of the second section by exposing said at least one region of the second section to one or more beams of light from the one or more light sources.
  • the control system may further comprise one or more optical heads, wherein the one or more optical heads are configured to do at least one of: produce one or more light beams from the one or more light sources; control the movement of the one or more light beams; and control the beam diameter of the one or more light beams.
  • a power of each of the one or more light sources may be configured to melt, ablate or heat each of the plurality of powder material layers.
  • the control system may be configured to receive at least one build file defining a set of instructions for controlling the additive manufacturing system.
  • the set of instructions may comprise instructions for at least one of: fusing the first section of the at least one powder layer; ablating the second section of the at least one powder layer; melting the at least one region of the second section; controlling a thickness of each powder material layer; controlling an angle of a point of the second section with respect to a plane of the at least one powder layer; and controlling an angle of a point of the region of the second section with respect to a plane of the at least one powder layer.
  • a method for additive manufacturing of a three-dimensional structure formed by a plurality of build layers comprising: use of single or multiple beams of light to expose layers of powder material in selected regions until the powder fuses to form voxels, which form build layers of a three- dimension structure.
  • the light may be generated from selected light sources and delivered to an optical head such that single or multiple beams are directed toward different locations on each of the powder layers.
  • the single or multiple beams may be used for melting the powder, ablating the edge of the melted layer, and re-melting the edge of the ablated layer.
  • the single or multiple beams may be moved using various techniques (e.g.
  • the single or multiple beams may provide distributed exposures forming a distributed exposure pattern including beams that used for melting, ablating and surface finishing according to various scan patterns such that a plurality of exposures on a single layer forms each build layer.
  • the method may further comprise single or multiple light beams for each process sequence are adjusted accordingly to melt, ablate, and re-melt the edge of each fused layer in order to improve the edge quality of the layer and subsequent layers within the three-dimensional object.
  • the light sources may comprise laser diodes, fibre lasers, disk lasers, and phased array laser sources.
  • the light sources may have total power outputs of 100W to 100 kW.
  • the light sources may further perform the melting, ablating and re-melting of the fused edges using vector scanning of the beams or raster scanning of the beams.
  • the powder layer may comprise at least one of a metal powder, a nickel-based superalloy powder, a titanium powder, a titanium alloy powder, and a nickel-chromium based superalloy powder.
  • the optical head may deliver beam spots with a diameter in the range of about 10 micron to about 10mm.
  • a method for multiple beam additive manufacturing of a three- dimensional structure formed by a plurality of build layers comprising: delivering a powder layer of powder material to a powder support system; forming a build layer by fusing powder regions to produce fused regions that form the build layer, wherein the perimeters of the fused regions are further exposed to a light source such that an ablated region is created around the perimeter of the fused regions and to a depth equal to or greater than the depth of the fused layer; and a further light source traverses the ablated edge of the fused layer such that the edge is further melted such that the depth of the melt on the edge is equal to or greater than the maximum peak to trough roughness of the ablated edge; and repeating this three stage process for each successive build layer in the powder layer to form each of the build layers for the three-dimensional structure.
  • a single or multiple beam additive manufacturing system comprising: a powder bed support system for supporting the powder bed and three- dimensional structure formed therein and for moving the powder bed vertically and incrementally to accommodate multiple powder layers of powder material; a powder delivery system for delivering each powder layer on the powder bed; an single source or multiple light sources; an optical head for delivering the single or multiple light sources; an optical head for controlling the direction of scanning; an optical head for controlling the beam diameter of a single or multiple light sources; a control system for controlling the single or multiple light sources, the powder dispensing system, the power of the light source or sources, the x-y-z position of the light sources within the additive manufacturing system.
  • the light sources may have their optical power defined to produce melting or ablation or heating.
  • control system may further be instructed by a build file defining the instructions to fuse each layer of the three-dimensional part.
  • control system may further be instructed by a build file defining the instructions to ablate the edge of each fused layer of the three-dimensional part.
  • control system may further be instructed by a build file defining the instructions to re-melt the edge of each ablated layer of the three-dimensional part.
  • the ablation edge may be substantially vertical or non vertical between each layer as defined by the surface geometry of the three-dimensional part to be built.
  • control system may further be instructed by a build file defining the instructions to select the thickness of each layer.
  • control system may further be instructed by a build file defining the instructions to select an angle of the ablated region with respect to the position around the perimeter of the fused layer.
  • control system may further be instructed by a build file defining the instructions to select the angle of the re-melted region with respect to the position around the perimeter of the ablated layer.
  • Figure 1 is a schematic illustration showing the effect that un-melted powder has on the accuracy and quality of the surface of a part made by known additive manufacturing techniques
  • Figure 2a) and b) are schematic illustrations of a laser ablating the edge of the melted layer in order to produce a layer with the required edge definition
  • Figure 3 shows an exemplary process for performing a method according to an aspect of the present disclosure
  • Figure 4 shows an exemplary process for forming a build layer according to another aspect of the present disclosure.
  • Figure 5 is a schematic illustration of the process for re-melting the edge in order to improve surface roughness of each layer.
  • the method comprises: providing a light source, or an array of light sources coupled to a motion system that may be driven by Cartesian robot or two-or three dimensional optical galvanometer mirror based scanning system; delivering powder layers of powder material on a powder bed support system that moves vertically and incrementally to accommodate each powder layer; forming build layers of the three-dimensional structure in each of the powder layers of powder materials, where the formation of each layer comprises single or multiple laser beam exposures to selectively fuse the corresponding regions of the powder material, wherein each beam of light is directed with sufficient power and duration to melt the powder material in the corresponding regions to form fused regions; on formation of the fused regions in the layer a light source, or an array of light sources coupled to a motion system that may be driven by Cartesian robot or two-or three dimensional optical galvanometer based
  • the method may further comprises providing a light source or an array of light sources coupled to a motion system that may be driven by Cartesian robot or two-or three dimensional optical galvanometer mirror based scanning system, wherein each beam of light is directed with sufficient power and duration such that the edge of the a well defined vertical or near vertical edge of the ablated region is re-melted to a depth greater than or equivalent to the peak to trough surface roughness of the vertical or near vertical edge, wherein the re-melted surface of the vertical or near vertical edge of the newly formed fused layer is further improved through the effects of surface tension and solidification.
  • an additive manufacturing system comprising a control system for controlling the position and motion of the light source or an array of light sources, the powder bed support system, the powder layering system in coordination to form build layers.
  • the control system may be configured to control the light source or an array of light sources to generate light from the selected sources such that light emitted from the sources is directed to specific regions of each of the powder layers to fuse the powder regions that form the volume elements of the three-dimensional object.
  • the control system may be configured to control the light source or an array of light sources to generate light from the selected sources such that light emitted from the sources is directed to the edge regions of each of the fused powder layers to ablate the edges of the fused layer regions such that a well-defined vertical or near vertical edge of the newly formed fused layer is created.
  • the control system may be configured to control the light source or an array of light sources to generate light from the selected sources such that light emitted from the sources is directed to the edge regions of well-defined vertical or near vertical edge of the newly formed fused layer to re-melt the newly formed edge such that a further refinement of the roughness of newly formed edge is created by surface tension and solidification.
  • the above system may implement a method for additive manufacturing, consistent with the present disclosure, comprising the use of single or multiple beams of light (e.g. laser light) to expose layers of powder material in selected regions until the powder fuses to form voxels, which form build layers of a three dimensional structure.
  • the light may be generated from selected light sources and delivered to an optical head such that the single or multiple beams are directed toward different locations on each of the powder layers.
  • the single or multiple beams may be used for melting the powder, ablating the edge of the melted layer, or melting the edge of the ablated layer.
  • the single or multiple beams may be moved using various techniques (e.g.
  • the single or multiple beams may provide distributed exposures forming a distributed exposure pattern, and may comprise beams used for melting, ablating or surface finishing according to various scan patterns, such that a plurality of exposures on a single layer may form each build layer.
  • the single or multiple beams additive manufacturing system and method may increase the build quality, build accuracy, and surface finish of the part built through multiple layers.
  • the additive manufacturing system may be used to produce three- dimensional structures from a wide range of materials.
  • the powder materials may comprise, without limitation and merely for example, one or more of powdered Ti-6AI-4V, Inconel 718 (and other nickel based super alloys), stainless steels, cobalt chrome, aluminum and its alloys.
  • the powdered material may additionally or alternatively comprise any other powder-based materials known for use in powder bed fusion additive manufacturing.
  • the single or multiple beam additive manufacturing systems and methods may be used with powders having asymmetrical powder distribution including powder sizes in the range of approximately 5 pm to approximately 300 pm.
  • the single or multiple beam additive manufacturing systems and methods may additionally or alternatively be used with powders having powder sizes in less than 5 pm.
  • the light source or array of light sources may comprise high power fibre coupled diode lasers, high power continuous wave or pulsed fibre lasers,
  • the output power of the light source or array of light sources may be changed during each exposure of the powder layer, for example, to produce ablation effects, melting effects, or preheating affects.
  • the energy delivered by the light source or array of light sources may be changed during each exposure of the powder layer, for example, by changing the exposure duration or beam diameter (spot size).
  • the light source or array of light sources may comprise fiber lasers with up to about 50 kW continuous output power, or quasi-continuous lasers with output powers up to about 10 kW
  • the trajectory of the laser beam may be angled with respect to the vertical surface normal of the layers to enable the ablation process to create sloped sides in regions when the part has significant curvature. [0060] The trajectory of the laser beam may be angled with respect to the surface normal of the ablated layers to enable the laser to directly impact the ablated edge at non glancing angles for more efficient melting operations.
  • “exposure” refers to an exposure of light for a defined period of time.
  • “powder material” refers to a material in the form of particles.
  • “fuse” refers to combining particles together as single structure through melting or sintering.
  • “ablate” refers to evaporating material to form a void or loss of material at a particular location.
  • “melt” refers to changing the state of material from a solid to a liquid.
  • the term“laser” refers generally to a category of optical devices that emit a spatially and temporally coherent beam of light otherwise known as a laser beam.
  • laser refers to conventional lasers (such as CO2, YAG, and fiber lasers), as well as laser diodes.
  • “voxel” refers to a unit measure of a“fused region” but is not necessarily the same size as a“fused region”, for example, a fused region may be comprised of multiple voxels.
  • One aspect of the present disclosure is, in general, directed to providing an additive manufacturing process that addresses the main disadvantage of conventional additive manufacturing, namely the accuracy or the manufactured part, quality of the manufactured part and the surface finish of the manufactured part.
  • a further advantage of aspects of the present disclosure is a high processing speed of up to several hundred metres per minute.
  • Figure 1 shows a cross section of a single fused layer 1 under normal conditions of additive manufacturing with powder beds using existing techniques.
  • the outer limits 2 of fused layer 1 are shown some distance from the required limits 4 of fused layer 1 .
  • the required limit 4 may define a desired profile of fused layer 1 .
  • the un-melted powder 3 within the powder layer impart an uneven surface to the edge of the part and result in a part that is not accurate and has high surface roughness.
  • an aspect of the present disclosure relates to a method of producing a part or plurality of parts within an AM system (such as a SLM machine) for manufacturing of a three-dimensional structure or structures formed by a plurality of build layers.
  • an ablated region 7 is formed using light beam 5.
  • the ablation of material in this region may form a substantially vertical or near vertical edge region 8 between ablated region 7 and fused region 1 .
  • the ablation region 7 may form a perimeter or perimeters 6 around the required limit 4 of fused region 1 , separating fused region 1 from un-melted loose powder 9.
  • FIG. 3 shows an exemplary process 300 for a method of manufacturing according to an aspect of the present disclosure.
  • one or more powder layers comprising powder material are delivered or deposited on to a powder bed support.
  • the powder bed support may be a component of a powder bed support system.
  • the power bed support system may move incrementally in two or three dimensions to receive each powder layer.
  • build layers of the three-dimensional structure are formed in each of the powder layers or alternatively a single build layer may be formed in several powder layers.
  • one or more further powder layers comprising powder material are delivered onto the powder bed support system and/or existing build layers. The process of step 304 may then be repeated for the new powder layers.
  • FIG. 4 shows an exemplary process 400 for forming the build layers in each of the powder layers.
  • a light source provides at least one light beam, for example a laser.
  • the one or more beams of light may be provided by a plurality of light sources, such as an array of light sources.
  • the one or more light sources may be coupled to a motion system.
  • the motion system may be driven by, for example, a Cartesian robot. Additionally or alternatively, the motion system may be driven by a two- or three-dimensional optical galvanometer based scanning system.
  • a first region, or section, of the powder layer is fused to form at least one fused region 1 .
  • the fused region may be formed by exposure to a single or multiple beams of light.
  • Each beam of light is directed with sufficient power and duration to melt the powder material in the corresponding regions to form fused regions 1 . This allows the process to selectively fuse the corresponding selected regions 1 of the powder material.
  • one or more light beams 5 may be used to ablate powder material in a second region 7 or section of the powder layer. This ablated region may be adjacent to or contiguous to one or more fused region 1 , or may partially overlap one or more fused regions 1 .
  • the ablated section 7 may be adjacent to or contiguous to the required limits 4 of fused region 1 .
  • the one or more light beams 5 may be provided by the same light source, or array of light sources as the one or more beams 5 used to produce the fused region 1 .
  • the one or more light beams 5 used to ablate the material in the second section 7 may be provided by a different one or more light sources. In this case, these sources may also be coupled to a motion system, driven in the same way or a different way to the first set of sources.
  • Material in the ablated region 7 may be ablated to a depth substantially equal to, or greater than, the depth of the fused first region 1 . The ablation of this region 7 may create an edge 8 substantially perpendicular or near perpendicular to the plane of the powder layer.
  • This edge may be around the whole or part of the perimeter 4 of fused region 1 , or around whole or part of isolated regions of fused layer 1 .
  • the ablated region 7 may form a separation between loose or unfused powder 3 and the edge 8 of the fused region 1 .
  • the edge of the ablated region adjacent to the fused region may be re-melted or re-fused.
  • Figure 5 shows an exemplary schematic illustration of the process for re-melting an edge of the ablated region.
  • FIG. 7 shows an exemplary schematic illustration of the process for re-melting an edge of the ablated region.
  • the one or more beams of light 5 may be used to re-melt the whole or part of the ablated region 7.
  • the one or more beams of light 5 may be from the same or a different one or more light sources as those used for fusing and/or ablating the corresponding regions 1 and 7 of the powder layer.
  • the light beams 5 may be directed around the perimeter or perimeters 10 of ablated region 7. This perimeter 10 may be the edge of the ablated region adjacent to the fused region 1 .
  • the re-melted or re-fused region or regions of ablated region 7 may be re-melted to a depth substantially equal to or greater than the maximum peak to trough surface roughness of the surface of the ablated section 7. This process may result in a reduced surface roughness of the re-melted region.
  • the perimeter 10 may comprise the substantially perpendicular or vertical edge 8’, and the re-melting of the region may result in a lower surface roughness of re-melted edge 8’ relative to the substantially perpendicular edge 8.
  • a laser polished surface may have a roughness of less than 5um Rz.
  • a method for providing a light source, or an array of light sources 5 coupled to a motion system that may be driven by Cartesian robot or two-or three dimensional optical galvanometer based scanning system delivering powder layers of powder material on a powder bed support system that moves vertically and incrementally to accommodate each powder layer; forming build layers of the three-dimensional structure in each of the powder layers of powder materials, where the formation of each layer comprises single or multiple laser beam exposures to selectively fuse the corresponding regions of the powder material, wherein each beam of light is directed with sufficient power and duration to melt the powder material in the corresponding regions to form fused regions 1 ; on formation of the fused regions in the layer a light source, or an array of light sources 5 coupled to a motion system that may be driven by Cartesian robot or two-or three dimensional optical galvanometer based scanning system, is directed around the perimeter or perimeters 10 of the ablated regions wherein each beam of light is directed with sufficient power and duration such that the edge of the

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  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
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  • Plasma & Fusion (AREA)
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  • Toxicology (AREA)
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Abstract

L'invention concerne un procédé et un système permettant une fabrication additive destinée à la production de pièces tridimensionnelles, comprenant une source de lumière ou de multiples sources de lumière en vue d'exposer des couches de matériau en poudre dans des régions spécifiques en vue de fusionner la poudre en couches fondues. Les sources de lumière ou multiples sources de lumière peuvent en outre être utilisées en vue d'ablater sélectivement les périmètres des couches fondues en vue de fournir une grande précision de dimensions de couches fondues. Les sources de lumière ou multiples sources de lumière peuvent en outre être utilisées en vue de faire fondre sélectivement le bord des couches ayant subi une ablation en vue d'améliorer la finition de surface des couches fondues. Les sources de lumière ou multiples sources de lumière peuvent en outre être utilisées en vue de répéter les multiples étapes de processus de fusion, d'ablation et de finition couche par couche jusqu'à ce que l'objet soit achevé.
PCT/GB2019/052645 2018-09-20 2019-09-20 Fabrication additive sur lit de poudre WO2020058722A1 (fr)

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US201862734041P 2018-09-20 2018-09-20
US62/734,041 2018-09-20

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113828794A (zh) * 2020-06-24 2021-12-24 郑芳田 积层制造方法
CN112807493A (zh) * 2020-12-31 2021-05-18 山东第一医科大学附属省立医院(山东省立医院) 一种胆道植入体及其制作方法
CN113458594A (zh) * 2021-07-22 2021-10-01 哈尔滨电气动力装备有限公司 核主泵定心块激光熔敷钴基合金粉末焊接方法
CN114160809A (zh) * 2021-11-09 2022-03-11 南京晨光集团有限责任公司 一种高功率大层厚选区激光熔化成形方法
WO2023160955A1 (fr) * 2022-02-28 2023-08-31 Trumpf Laser- Und Systemtechnik Gmbh Procédé de fabrication additive avec réduction de la rugosité de surface d'un article façonné produit dans le procédé de fabrication
CN114713848A (zh) * 2022-06-10 2022-07-08 西安赛隆金属材料有限责任公司 一种提升增材制造零件表面质量的方法及增材制造设备
CN114713848B (zh) * 2022-06-10 2022-09-23 西安赛隆增材技术股份有限公司 一种提升增材制造零件表面质量的方法及增材制造设备
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