WO2020182098A1 - 液浮粉末床增材制造设备和方法 - Google Patents

液浮粉末床增材制造设备和方法 Download PDF

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Publication number
WO2020182098A1
WO2020182098A1 PCT/CN2020/078446 CN2020078446W WO2020182098A1 WO 2020182098 A1 WO2020182098 A1 WO 2020182098A1 CN 2020078446 W CN2020078446 W CN 2020078446W WO 2020182098 A1 WO2020182098 A1 WO 2020182098A1
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Prior art keywords
liquid
floating
powder
powder bed
forming
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Ceased
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PCT/CN2020/078446
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English (en)
French (fr)
Inventor
林峰
张磊
王东方
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Tsinghua University
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Tsinghua University
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Publication date
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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
    • 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
    • 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
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/64—Treatment of workpieces or articles after build-up by thermal 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B22F12/45—Two or more
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/70—Gas flow means
    • 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
    • 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
    • B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
    • 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 present disclosure relates to the technical field of additive manufacturing, and in particular to a liquid floating powder bed additive manufacturing equipment and a liquid floating powder bed additive manufacturing method.
  • Powder bed fusion based on selective melting of high-energy beams (such as laser, electron beam, etc.) and laser/electron beam cladding deposition manufacturing (CDM) are two typical additive manufacturing processes Compared with the CDM technology that directly feeds the material (powder or wire) into the molten pool, the PBF technology has lower forming efficiency and smaller forming size, but it has great advantages in the three-dimensional forming of complex structures and special materials.
  • the PBF forming process in the related technology involves scanning a pre-laid powder bed with a laser or electron beam, sintering or melting the powder material layer by layer, so that the material is stacked and formed layer by layer, while the three-dimensional parts are buried in the powder layer by layer bed. Therefore, the depth of the powder bed must be greater than the final height dimension of the three-dimensional part, and the horizontal dimension of the powder bed is equivalent to the plane dimension of the forming cylinder.
  • the size of the formed parts is getting larger and larger, the size of the forming cylinder also increases, and the volume of the powder bed increases exponentially.
  • the forming cylinder For a powder bed melting equipment of a certain specification or model, the forming cylinder must be set according to the limit size of the forming part in order to accommodate the largest forming part promised in its parameter index. In the actual use of the equipment, the size or volume of the formed parts is sometimes large and sometimes small, but the existing process requires that the forming cylinder must always be filled with powder to ensure the normal operation of the powder bed melting process.
  • the PBF additive manufacturing equipment needs to design the powder supply system according to the maximum capacity of the forming cylinder, which virtually increases the volume and weight of the equipment; on the other hand, it also makes the equipment users have to purchase far more than the parts to be manufactured.
  • Chinese patents CN20141001119.0, CN20172140150.2, and CN201711025216.3 disclose a device and process for fabricating a forming cylinder layer by layer synchronously with forming parts. This process does not need to set a fixed size forming cylinder, but in the PBF additive manufacturing process, the use of laser cladding deposition or laser selective melting and other methods to simultaneously produce the forming cylinder, and automatically adapt to the top surface of the forming cylinder
  • the powder spreading device of the shape spreads the powder.
  • Chinese patent CN201611194738.1 discloses a powder spreading device with this function. After the forming is completed, the forming cylinder must be destroyed to take out the formed parts.
  • This technology based on the simultaneous production of the forming cylinder, although the fixed size forming cylinder is eliminated, and the amount of powder required to maintain the powder bed is greatly reduced, but the production of the forming cylinder requires some material consumption, and the forming cylinder can only Once used, it is destroyed and discarded, and can no longer be used. In addition, this technical solution does not greatly improve other problems in the PBF process.
  • Chinese patent CN20161021527.2 discloses an additive manufacturing technology for laser selective melting of powder in a suspension composed of liquid and metal powder. Specifically, the powder is melted layer by layer in the suspension close to the surface of the suspension. The purpose is to isolate the air and prevent oxidation. At the same time, the suspension is used for rapid powder transportation to increase the forming speed.
  • This technology eliminates the tangible powder layer (bed), but still requires a large amount of powder and liquid carrier to form a suspension to fill the forming (cylinder) container, and the metal is melted in the suspension, and the laser needs to pass through a certain thickness of the suspension. At the same time, the metal powder will inevitably react and react with the liquid. Therefore, it is difficult to control the chemical composition of the formed part and the molten pool behavior when the powder is melted, and it is difficult to ensure the forming quality.
  • an object of the present disclosure is to provide a liquid floating powder bed additive manufacturing equipment that can reduce the amount of forming powder, increase the utilization rate of forming powder, and reduce the thermal stress of three-dimensional parts. , And meet the needs of multiple forms of composite manufacturing and online inspection.
  • the present disclosure also proposes a liquid floating powder bed additive manufacturing method.
  • a liquid floating powder bed additive manufacturing equipment includes: a forming chamber; a workbench device, where the workbench device is provided in the The forming chamber has a forming area.
  • the workbench device includes at least one forming cylinder configured to contain floating liquid; a powder supply device configured to spread the forming powder on The surface of the floating liquid, the forming powder floats on the surface of the floating liquid under the action of buoyancy to form a powder bed covering the forming area; at least one high-energy beam emission focusing scanning device, the high-energy beam emission focusing scanning device It is configured to emit a high-energy beam to perform a forming process on the powder bed, so that the forming powder is deposited layer by layer to form a three-dimensional part.
  • the liquid floating powder bed additive manufacturing equipment can reduce the amount of forming powder, improve the utilization rate of forming powder, reduce the thermal stress of three-dimensional parts, and meet the needs of multiple forms of composite manufacturing and online inspection.
  • the powder bed has a thickness of 0.01mm-100mm and includes a wet layer and a dry layer, the wet layer is immersed in the floating liquid, and the dry layer is above the floating liquid and Does not contain the floating liquid; wherein the forming area is covered by the dry layer, and the high-energy beam scans the dry layer to heat up, sinter or melt the scanned part of the dry layer, and deposit layer by layer ⁇ The molding area.
  • the forming cylinder is equipped with a heating/cooling device that heats and melts the float material into the float and keeps the float at 50°C-2000°C The predetermined temperature.
  • the density of the floating material is greater than the density of the shaped powder material.
  • the forming cylinder heating/cooling device controls the temperature of the floating liquid to rise or fall to a temperature that maximizes the wetting angle between the floating liquid and the surface of the three-dimensional part .
  • the forming cylinder heating/cooling device controls the temperature of the floating liquid and its rate of change to increase or decrease in accordance with the requirements for heat treatment of the three-dimensional part.
  • the forming cylinder is provided with a liquid inlet and a liquid outlet, the liquid inlet is connected to the heating kettle, and the liquid outlet is provided with a liquid drain valve and is connected to the lower collecting kettle.
  • strainer With strainer.
  • the forming cylinder is equipped with a liquid level detecting device for detecting the height of the floating liquid and a liquid level adjusting device for adjusting the height of the floating liquid.
  • the liquid level adjustment device is a column with constant cross-section that can move up and down; when the column with constant cross-section moves downward and is immersed in the floating liquid, the height of the floating liquid rises; When the equal cross-section cylinder moves upward and is lifted from the floating liquid, the liquid level of the floating liquid decreases.
  • a collection cover is provided in the forming chamber, and the collection cover is arranged above the forming area and avoids the high-energy beam emitted by the high-energy beam emitting and focusing scanning device.
  • An air inlet and an air outlet are provided, and the air outlet is connected with an air extraction device and a purifier.
  • the working platform device includes: a working platform provided at the upper end of the forming cylinder and surrounding the forming cylinder; a lifting platform, the lifting platform is provided on the forming cylinder Inside the cylinder, and drive the three-dimensional parts up and down.
  • the powder supply device includes: a powder supply device configured to store and supply the shaped powder to the working platform; a powder spreader, the powder spreader provided on the working platform A platform, the powder spreader is configured to push the shaped powder to the surface of the floating liquid in the forming cylinder and level the powder bed on the surface of the floating liquid.
  • the forming chamber is provided with at least one of a cladding device, a processing device and a detection device.
  • the lifting platform lifts all or part of the three-dimensional parts on it out of the powder bed, the melting At least one of the coating device, the processing device, and the detection device is moved to a working position, and the three-dimensional part is subjected to cladding deposition manufacturing, cutting processing, drilling processing and/or quality inspection.
  • the lifting platform is connected with at least one lower driving support rod and/or at least one upper driving suspension rod, wherein the lower driving support rod passes upward through the bottom wall of the forming cylinder to be connected to the lifting platform ;
  • the upper driving boom is inserted downward into the floating liquid and connected with the lifting platform.
  • the working platform is configured with a baffle
  • the baffle is located on the side of the upper driving boom facing the powder bed and includes: a horizontal part, the surface of the horizontal part and the working platform The surfaces are parallel and at the same height; the outer vertical portion, the outer vertical portion extends upward from the side of the horizontal portion facing the upper driving boom; the inner vertical portion, the inner vertical portion extends from the The side of the horizontal part facing the powder bed extends downward.
  • the lifting platform is provided with a liquid permeable hole penetrating along its thickness direction.
  • the at least one high-energy beam emission focusing scanning device includes an electron beam emission focusing scanning device and/or a laser beam emission focusing scanning device; the shaping process includes using the electron beam emission focusing scanning device The emitted electron beam and/or the laser beam emitted by the laser beam emission focusing scanning device performs one or a combination of processing of scanning, heating, sintering, melting and cutting on the powder bed.
  • An embodiment according to the second aspect of the present disclosure proposes a liquid floating powder bed additive manufacturing method.
  • the liquid floating powder bed additive manufacturing method includes: heating and melting the floating material into a floating liquid and introducing it into a forming cylinder; The powder is spread on the surface of the floating liquid, so that the shaped powder floats on the surface of the floating liquid under buoyancy to form a powder bed, and at least part of the powder bed is located above the liquid surface of the floating liquid. Containing floating liquid to form a dry layer; using high-energy beams to shape the dry layer in the powder bed, so that the powder bed is deposited layer by layer to form a three-dimensional part.
  • the liquid floating powder bed additive manufacturing method can reduce the amount of forming powder, improve the utilization rate of forming powder, reduce the thermal stress of three-dimensional parts, and meet the needs of multiple forms of composite manufacturing and online inspection.
  • the forming process includes scanning, heating, sintering, and sintering the powder bed by using the electron beam emitted by the electron beam emission focusing scanning device and/or the laser beam emitted by the laser beam emission focusing scanning device.
  • One or a combination of melting and cutting processes are possible.
  • Fig. 1 is a schematic structural diagram of a liquid floating powder bed additive manufacturing equipment according to an embodiment of the present disclosure.
  • Fig. 2 is a schematic structural diagram of a liquid floating powder bed additive manufacturing equipment according to another embodiment of the present disclosure.
  • Fig. 3 is a schematic diagram of a powder bed of a liquid floating powder bed additive manufacturing equipment according to an embodiment of the present disclosure.
  • FIG. 4 is a schematic structural diagram of a forming cylinder of a liquid floating powder bed additive manufacturing equipment and its floating liquid introduction and discharge device according to an embodiment of the present disclosure.
  • Fig. 5 is a schematic diagram of the operation of the liquid floating powder bed additive manufacturing equipment according to an embodiment of the present disclosure during composite manufacturing.
  • Fig. 6 is a partial structural diagram of a lifting platform of a liquid floating powder bed additive manufacturing equipment according to an embodiment of the present disclosure.
  • Fig. 7 is a partial structure diagram of another lifting platform of a liquid floating powder bed additive manufacturing equipment according to an embodiment of the present disclosure.
  • Workbench device 5 work platform 8, lifting platform 15, forming cylinder 10, liquid inlet 30, liquid outlet 31, heating kettle 28, liquid inlet valve 26, drain valve 16, collecting kettle 17, floating liquid material 27, Filter 29, liquid penetration hole 41,
  • Powder supply device 22 powder supply device 6, powder spreader 7,
  • the baffle 40 the horizontal portion 38, the outer vertical portion 34, and the inner vertical portion 37.
  • the present disclosure proposes a liquid floating powder additive manufacturing equipment 1 and a liquid floating powder additive manufacturing method.
  • the equipment and method can reduce the amount of forming powder and improve the forming powder Utilization rate, reduce the thermal stress of three-dimensional parts, and meet the needs of multiple forms of composite manufacturing and online inspection.
  • liquid floating powder additive manufacturing equipment 1 according to an embodiment of the present disclosure will be described below with reference to the drawings.
  • the liquid floating powder additive manufacturing equipment 1 includes a forming chamber 9, a table device 5, a powder supply device 22 and at least one high-energy beam emission focusing scanning device 3.
  • the workbench device 5 is provided in the forming chamber 9, and the workbench device 5 has a forming area.
  • the workbench device 5 includes at least one forming cylinder 10, and the forming cylinder 10 is configured to be suitable for containing the floating liquid 14.
  • the powder supply device 22 is configured to be suitable for spreading the forming powder 20 on the surface of the floating liquid 14.
  • the forming powder 20 floats on the surface of the floating liquid 14 under the action of buoyancy to form a powder bed 35 covering the forming area.
  • At least one high-energy beam emission focusing scanning device 3 is configured to emit high-energy beams to shape the powder bed 35 so that the shaping powder 20 is deposited in the shaping area layer by layer to form a three-dimensional part 21.
  • liquid floating powder bed additive manufacturing method includes:
  • the floating material is heated and melted into floating liquid 14 and introduced into the forming cylinder 10;
  • the dry layer 12 in the powder bed 35 is formed by a high-energy beam, so that the powder bed 35 is deposited layer by layer to form a three-dimensional part 21.
  • the forming cylinder 10 is filled with liquid metal or non-metal (ie floating liquid 14), and the forming powder 20 on the surface is supported by the buoyancy of the liquid metal or non-metal to form the liquid Floating powder bed 35.
  • the liquid-floating powder bed 35 Different from the full solid powder bed in the current PBF technology where the forming cylinder is filled with powder, the liquid-floating powder bed 35 only maintains a certain thickness on the liquid surface, which can not only reduce the amount of powder required when manufacturing large three-dimensional parts, but also does not require complexity.
  • the self-adaptive powder spreading device while controlling the temperature of liquid metal or non-metal (ie floating liquid 14), can well increase and maintain the temperature of the formed three-dimensional part, reduce its thermal stress and control its microstructure.
  • liquid-floating powder bed 35 is supported by buoyancy, can well maintain a certain thickness, and automatically restore the flatness of the surface when disturbed. This will allow the three-dimensional part 21 to lift or translate during the forming process without damaging the integrity of the powder bed 35.
  • This feature allows the three-dimensional part 21 to be separated from the powder bed 35 for other forms of processing (such as another additive manufacturing, cutting, drilling, rolling or surface spraying, etc.) and/or inspection during the powder bed melting process. In order to achieve multiple forms of composite manufacturing and online inspection.
  • the liquid floating powder additive manufacturing equipment 1 and method according to the embodiments of the present disclosure can reduce the amount of forming powder, improve the utilization rate of forming powder, reduce the thermal stress of three-dimensional parts, and implement various forms of composite processing and manufacturing. Online inspection.
  • the powder bed 35 includes a wet layer 11 and a dry layer 12 located above the wet layer 11.
  • the wet layer 11 is immersed in the floating liquid 14, and the dry layer 12 is located between the floating liquid 14. It does not contain floating liquid 14.
  • the forming area is covered by the dry layer 12, and the high-energy beam scans the dry layer 12 to heat up, sinter or melt the scanned part of the dry layer 12. And layer by layer is deposited in the forming area.
  • liquid metal or non-metal with a higher density (specific gravity) is used to form a powder layer with a certain thickness on the surface of the molded powder 20 with a lower density by buoyancy, and high-energy beams such as laser or electron beam are applied to the powder
  • the upper surface of the layer is selectively sintered or melted.
  • the thickness of the powder bed 35 is 0.01 mm-100 mm, preferably 1 mm-50 mm.
  • the forming cylinder 10 is equipped with a heating/cooling device that heats and melts the float material into a float 14 and maintains the float 14 at a predetermined temperature, for example, the The predetermined temperature is 50°C-2000°C.
  • the forming cylinder 10 with heating and heat preservation functions can heat the floating liquid material with higher density to a liquid state and maintain the temperature at a preset temperature higher than the melting point during the entire forming process.
  • the density (specific gravity) of the metallic or non-metallic material as the floating liquid 14 is greater than the density (specific gravity) of the forming powder 20, and will not cause any chemical reaction with the forming powder 20 and the three-dimensional parts 21. Reaction, unless the reaction that occurs is conducive to improving the usability of the formed three-dimensional part 21.
  • the forming cylinder heating/cooling device controls the temperature of the floating liquid 14 to rise or fall to make the floating liquid 14 and the surface of the three-dimensional part 21 wetting angle Maximum temperature.
  • the forming cylinder heating/cooling device controls the temperature of the floating liquid 14 and its rate of change to increase in accordance with the requirements for heat treatment of the three-dimensional part 21 Or drop.
  • the forming cylinder 10 is equipped with a liquid level detection device and a liquid level adjustment device.
  • the liquid level detection device is used to detect the liquid level of the floating liquid 14, and the liquid level adjustment device is used to adjust the liquid level of the floating liquid 14, thereby maintaining and adjusting the height of the liquid level of the floating liquid 14 in the forming cylinder 10 .
  • the liquid level adjusting device is an equal cross-section cylinder 13 that can move up and down, and the equal cross-section cylinder 13 may be made of a high temperature resistant material.
  • the equal-section column 13 moves down and immerses into the floating liquid 14, the height of the floating liquid 14 rises; when the equal-section column 13 moves upward and lifts from the floating liquid 14, the height of the floating liquid 14 decreases .
  • the forming cylinder 10 is provided with a liquid inlet 30 and a liquid outlet 31.
  • the liquid inlet 30 may be arranged on the side wall of the forming cylinder 10 and adjacent to the upper edge.
  • the liquid port 31 may be provided on the bottom wall of the forming cylinder 10.
  • the liquid inlet 30 is connected to the heating kettle 28 and the liquid inlet 30 is provided with a liquid inlet valve 26, and the liquid outlet 31 is provided with a liquid discharge valve 16 and a liquid outlet 31
  • a collection kettle 17 is provided below, and a filter mesh 29 is provided in the collection kettle 17.
  • the floating liquid material 27 with higher density can be melted and heated to a predetermined temperature by the heating kettle 28, and then introduced into the forming cylinder 10 through the liquid inlet 30.
  • the discharge valve 16 of the discharge port 31 is opened, and after a part of the floating liquid 14 is discharged
  • the drain valve 16 is closed, and the liquid level adjustment device adjusts the liquid level.
  • the liquid discharge valve 16 of the liquid discharge port 31 is opened, and all the floating liquid 14 is discharged into the collecting tank 17.
  • the collection kettle 17 is equipped with a filter screen 29 to filter out the forming powder 20 in the discharged floating liquid 14.
  • the filtered forming powder 20 can be recycled and reused, and the remaining liquid can be cooled and waited for the next forming, or passed into the liquid
  • the port 30 is reintroduced into the forming cylinder 10 for new forming.
  • the forming chamber 9 A collection cover 18 may be provided inside, the collection cover 18 is arranged above the forming area, and the collection cover 18 avoids the high-energy beam emitted by the high-energy beam emission focusing scanning device 3, and the collection cover 18 is provided with an air inlet 25 and an air outlet 36, The air outlet 36 is connected with an air extraction device 19 and a purifier 23. After the gas is processed by the purifier 23 to remove heavy metals and harmful substances, it can be discharged to the atmosphere, or introduced into the forming chamber 9, or enters the collection cover 18 through the air inlet 25 .
  • the work platform device 5 includes a work platform 8 and a lifting platform 15.
  • the working platform 8 is arranged at the upper end of the forming cylinder 10 and is arranged around the forming cylinder 10.
  • the forming area can be formed on the upper surface of the lifting platform 15 and can be covered by the scanning range of the high energy beam.
  • the lifting platform 15 is arranged in the forming cylinder 10 and drives the three-dimensional part 21 to rise and fall.
  • the lifting platform 15 melts layer by layer with the powder bed 35 Or sintering and gradually sinking and driving the formed three-dimensional part 21 to gradually immerse into the floating liquid 14.
  • the lifting platform 15 is provided with a liquid permeable hole 41 penetrating the lifting platform 15.
  • the liquid permeable hole 41 penetrating the lifting platform 15 in the vertical direction is provided.
  • the powder supply device 22 includes a powder supplier 6 and a powder spreader 7.
  • the powder feeder 6 is configured to store and feed the molded powder 20 to the work platform 8.
  • the powder spreader 7 is provided on the working platform 8, and the powder spreader 7 is configured to push the forming powder 20 to the surface of the floating liquid 14 in the forming cylinder 10 and level the powder bed 35 on the surface of the floating liquid 14.
  • the forming chamber 9 is provided with at least one of a cladding device 32, a processing device and a detection device.
  • the lifting platform 15 removes the three-dimensional parts 21 on it
  • the cladding device 32, the processing device and the detection device is moved to the working position to perform cladding deposition manufacturing, cutting processing, and drilling on the three-dimensional part 21 Processing and/or quality inspection.
  • the lifting platform 15 can be lifted to lift all or part of the three-dimensional parts 21 out of the powder bed 35, and the cladding device 32 (such as laser cladding head, electron beam fuse head)
  • the cladding device 32 such as laser cladding head, electron beam fuse head
  • the formed three-dimensional parts 21 are cladding with the same or different materials for cladding deposition manufacturing; processing devices (such as milling heads, drills) can also be used to cut or drill the formed three-dimensional parts 21; also The formed three-dimensional parts 21 are inspected by using inspection devices (such as laser scanning, contact probes, ultrasonic probes, X-ray probes).
  • the lifting platform 15 is lowered, and the three-dimensional part 21 is re-immersed in the floating liquid 14 and the powder bed 35.
  • the powder spreader 7 re-levels the powder bed 35, the high-energy beam powder is continued. Bed melt forming manufacturing.
  • At least one lower driving support rod 39 and/or at least one upper driving suspension rod 33 is connected to the lifting platform 15.
  • the lower driving support rod 39 passes upward through the bottom wall of the forming cylinder 10 and is connected to the lifting platform 15 (as shown in FIGS. 1, 2 and 4); the upper driving suspension rod 33 is inserted downward into the floating liquid 14 and It is connected to the lifting platform 15 (as shown in Figs. 6 and 7), wherein Fig. 6 shows an example of using a single-sided upper driving boom 33, and Fig. 7 shows an example of using a double-sided upper driving boom 33, Suitable for the manufacture of large and heavy parts.
  • the working platform 8 is configured with a baffle 40, which is located on the side of the upper driving boom 33 facing the powder bed 35, and the baffle 40 includes a horizontal portion 38 and an outer vertical portion. Straight portion 34 and inner vertical portion 37.
  • the surface of the horizontal portion 38 is parallel to the surface of the work platform 8 and is located at the same height.
  • the outer vertical portion 34 extends upward from the side of the horizontal portion 38 that faces the upward driving boom 33.
  • the inner vertical portion 37 extends downward from the side of the horizontal portion 38 facing the powder bed 35, and the depth (the dimension in the vertical direction) of the inner vertical portion 37 is greater than the maximum thickness of the powder bed 35.
  • the function of the outer vertical part 34 is to confine the forming powder 20 in the horizontal part 38 when the powder spreader 7 spreads powder; and the function of the inner vertical part 37 is to constrain the powder bed 35 to form a stable wet layer 11 and a dry layer. 12.
  • the at least one high-energy beam emission focusing scanning device 3 includes an electron beam emission focusing scanning device and/or a laser beam emission focusing scanning device.
  • FIG. 1 shows an example in which a laser beam emission focusing and scanning device is used alone
  • FIG. 2 shows an example in which an electron beam emission focusing and scanning device is used alone.
  • the laser beam emission focusing scanning device and the electron beam emission focusing scanning device can be used to perform compound scanning for selective melting, so as to combine the advantages of electron beam selective melting and laser selective melting.
  • the scanning electron beam 2 emitted by the electron beam emission focusing scanning device and the scanning laser beam 4 emitted by the laser beam emission focusing scanning device can be used to scan the forming area, preheat the forming powder bed 35 and control the cooling process , Make the temperature field of the forming area in an appropriate range, control the temperature gradient, and reduce the thermal stress; Scan the section of the three-dimensional part 21 and its inner and outer contours, so that the materials in the section will gradually heat up, sinter and melt, forming a clear, continuous and complete section and its contour In order to obtain high-performance and high-precision three-dimensional parts 21.
  • the forming process includes scanning, heating, sintering, melting and cutting the powder bed 35 using the electron beam 2 emitted by the electron beam emission focusing scanning device and/or the laser beam 4 emitted by the laser beam emission focusing scanning device.
  • One treatment or a combination of several, in addition, the cooling process of the three-dimensional part 21 and the powder bed 35 can be controlled.
  • the forming chamber 9 (as shown in FIG. 2) that uses the electron beam 2 to control the powder bed 35 for preheating, sintering, melting deposition and cooling is equipped with a vacuum system and an inert gas backfill system to prevent the electron beam 2 from being transmitted.
  • the power is excessively attenuated, and considering the evaporation of the high-temperature floating liquid 14 and the powder bed 35 during melting and deposition, the inert gas can be backfilled, and the vacuum degree is maintained between 10 -4 Pa and 10 Pa; while for the laser beam 4 to the powder bed 35
  • the forming chamber 9 (as shown in Figure 1) for preheating, sintering, melting deposition and cooling control is equipped with air extraction and inflation devices. After the pumping-inflating cycle, the forming chamber 9 needs to be filled with inert gas, the pressure is equal to or greater than 1 atmosphere ( ⁇ 0.1013 MPa) and the oxygen content is reduced to below 0.1%.
  • a liquid floating powder additive manufacturing equipment 1 which uses liquid buoyancy to support a powder bed, that is, spreads powder on the surface of a liquid with a higher density (specific gravity) to form a liquid floating powder bed, and then uses laser or electron beam The high-energy beam preheats, sinters or melts and deposits the powder layer by layer to manufacture three-dimensional parts.
  • the denser metal or non-metal (floating liquid material 27) is heated and melted to form the floating liquid 14.
  • the floating liquid 14 is introduced into the forming cylinder 10 with heating/cooling and heat preservation functions in the forming chamber 9, and the temperature of the floating liquid 14 Keep at a predetermined temperature (50°C-2000°C).
  • the powder spreader 7 in the forming chamber 9 spreads the smaller-density forming powder 20 on the floating liquid 14 to form a powder bed 35 with a certain thickness (0.01 mm-100 mm).
  • the powder bed 35 floats on the surface of the floating liquid 14 and includes a wet layer 11 immersed in the floating liquid 14 and a dry layer 12 on the floating liquid 14.
  • the high-energy beam emission focusing scanning device 3 emits the laser beam 4 and/or the electron beam 2, scanning the powder bed 35 for heating, and scanning a certain area to sinter or melt and deposit the powder bed 35 to form the required part section, and compare it with the following
  • the formed three-dimensional parts 21 or the lifting platform 15 are connected.
  • the lifting platform 15 drops a layer of thick height
  • the liquid level detection device and the liquid level control device connected with the forming cylinder 10 measure and adjust the liquid level to return to the preset liquid level position
  • the powder spreader 7 pushes the forming powder 20 to
  • the powder bed 35 is pushed up and flattened to form a flat surface of the powder bed 35.
  • the high-energy beam emission focusing scanning device 3 scans the powder bed 35 again for heating, sintering or melting to deposit a new layer, and so on, until the additive manufacturing of the entire three-dimensional part 21 is completed.
  • the lifting platform 15 can be lowered to completely submerge the three-dimensional part 21 in the floating liquid 14 and adjust the temperature and holding time of the floating liquid 14 to heat the formed three-dimensional part 21.
  • the temperature of the floating liquid 14 can be adjusted to a temperature at which the surface tension of the floating liquid 14 is large, or the contact angle (wetting angle) between the floating liquid 14 and the surface of the three-dimensional component 21 is large. In order to better ensure the separation of the floating liquid 14 and the three-dimensional parts 21.
  • the way to take out the three-dimensional parts 21 can be to lift the three-dimensional parts 21 out of the floating liquid 14 and the powder bed 35 by the lifting platform 15 or by opening the drain valve 16 at the bottom of the forming cylinder 10 to discharge the floating liquid 14 to gradually expose the three-dimensional parts 21
  • the floating liquid 14 and the powder bed 35 separate the three-dimensional part 21 from the floating liquid 14 and the powder bed 35.
  • liquid floating powder additive manufacturing equipment 1 Other configurations and operations of the liquid floating powder additive manufacturing equipment 1 according to the embodiments of the present disclosure are known to those of ordinary skill in the art, and will not be described in detail here.

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Abstract

一种液浮粉末床增材制造设备，包括成形室(9)；工作台装置(5)，工作台装置设于成形室且具有成形区域，工作台装置至少包括一个成形缸(10)，成形缸被构造成适于盛装浮液(14)；粉末供给装置(22)，粉末供给装置被构造成适于将成形粉末(20)铺展于浮液的表面，成形粉末在浮力的作用下浮于浮液表面以形成覆盖成形区域的粉末床(35)；至少一个高能束发射聚焦扫描装置(3)，高能束发射聚焦扫描装置被构造成发射高能束对粉末床进行成形处理，以使成形粉末逐层沉积而形成三维零件。以及一种液浮粉末床增材制造方法。采用上述液浮粉末床增材制造设备能够减少成形粉末的用量、提高成形粉末的利用率、降低三维零件的热应力，且满足多种形式的复合加工制造和在线检验的需要。

Description

液浮粉末床增材制造设备和方法
相关申请的交叉引用
本公开基于申请号为201910185600.2，申请日为2019年3月12日的中国专利申请提出，并要求该中国专利申请的优先权，该中国专利申请的全部内容在此引入本公开作为参考。
技术领域
本公开涉及增材制造技术领域，具体而言，涉及一种液浮粉末床增材制造设备和一种液浮粉末床增材制造方法。
背景技术
基于高能束(如激光、电子束等)选区熔化的粉末床熔融(powder bed fusion，PBF)和激光/电子束的熔覆沉积制造(cladding deposition manufacturing，CDM)是两种典型的增材制造工艺，相对于将材料(粉末或丝材)直接送入熔池的CDM技术，PBF技术虽然成形效率较低、成形尺寸较小，但在复杂结构和特殊材料的三维成形方面具有很大的优势。
相关技术中的PBF成形工艺，其过程为用激光或电子束扫描预先铺设好的粉末床，逐层烧结或熔化粉末材料，使材料逐层堆积成形，而三维零件则逐层地被埋入粉末床。因此粉末床的深度，必须大于三维零件最终的高度尺寸，而粉末床的水平尺寸则与成形缸的平面尺寸相当。然而，随着粉末床熔融工艺的不断成熟和需求的增长，成形零件的尺寸越来越大，成形缸的尺寸也随之增大，粉末床的容积则随之成指数倍的增长。
对于一定规格或型号的粉末床熔融设备而言，其成形缸必须按其成形零件的极限尺寸设置，以便容纳其参数指标中所承诺的最大成形零件。而在设备的实际使用过程中，成形零件的尺寸或体积时大时小，但现有的工艺要求成形缸必须始终被填满粉末，才能保证粉末床熔融工艺的正常运行。
鉴于此，一方面造成PBF增材制造设备必要按成形缸的最大容量设计粉末供给系统，无形中增大了设备的体积和重量；另一方面也使设备用户必须采购远远超出所要制造零件的体积或重量的粉末材料，以填充成形缸。虽然成形后未烧结或未熔化的粉末可以被循环再使用，但研究和实践表明，超过一定次数(约10次)循环使用后，因氧化和流动性下降， 粉末不能再使用，必须更换新粉末，因此造成极大的浪费，这使得增材制造技术所具有的近净成形及材料利用率高的优势受到严重的挑战和质疑。由于粉末价格较高(是同等重量块材价格的10-20倍)，对于致力于将增材制造技术规模化应用的企业，需要投入和消耗大量资金，购买填充粉末床的粉末，这将严重影响企业的经济效益和资金循环。
对于基于激光的粉末床熔融增材制造技术(SLM)，还存在粉末床温度较低(一般不高于200℃)、导致三维零件热应力大、易开裂、无法成形塑性较差的材料等不足。虽然可以通过底板加热，但只能对接近底板的低层粉末有加热作用，改善高度较低零件的热应力情况，而无法加热高层粉末。随着零件成形高度的增加，上层粉末的温度会越来越低，热应力改善的效果会越来越弱，因此无法彻底解决SLM工艺热应力大的问题。
此外，粉末床在受到扰动时无法保证平整性，因此三维零件在成形过程中进行升降或平移会破坏粉末床的完整性，这样导致在粉末床熔融工艺过程中三维零件无法脱离粉末床而进行其它形式的加工，不能满足多种形式的复合加工制造和在线检验的需要。
中国专利CN20141001119.0、CN20172140150.2和CN201711025216.3公开了一种与成形零件同步地逐层制作随形成形缸的装置及工艺。这种工艺不需要设置固定尺寸的成形缸，而是在PBF增材制造过程中利用激光熔覆沉积或激光选区熔化等方法同步制作随形成形缸，并通过能够自动适应随形成形缸顶面形状的铺粉装置进行铺粉。中国专利CN201611194738.1公开了一种具有这种功能的铺粉装置。在成形完成后，要破坏随形成形缸，以取出成形的零件。
这种基于同步制作随形成形缸的技术，虽然取消了固定尺寸的成形缸，大幅减少了维持粉末床需要的粉末量，但制作随形成形缸需要消耗部分材料，而且随形成形缸只能使用一次就被破坏并抛弃，无法再使用。另外，这一技术方案对PBF工艺中的其它问题没有太大的改善。
中国专利CN20161021527.2公开了一种在液体和金属粉末组成的悬浮液中进行激光选择性熔化粉末的增材制造技术。具体是在接近悬浮液表面的悬浮液中逐层地熔化粉末，目的是隔绝空气、防止氧化，同时利用悬浮液进行快速粉末输送，提高成形速度。该技术消除了有形的粉末层(床)，但仍然需要大量的粉末与液体载体组成悬浮液填充成形(缸)容器，而且金属在悬浮液中熔化，激光需透过一定厚度的悬浮液，能量会损失，同时金属粉末还不可避免地会与液体发生作用和反应，因此难以控制成形零件的化学成分和粉末熔化时的熔池行为，难以保证成形质量。
发明内容
本公开旨在至少解决现有技术中存在的技术问题之一。为此，本公开的一个目的在 于提出一种液浮粉末床增材制造设备，该液浮粉末床增材制造设备能够减少成形粉末的用量、提高成形粉末的利用率、降低三维零件的热应力，且满足多种形式的复合加工制造和在线检验的需要。
本公开还提出一种液浮粉末床增材制造方法。
根据本公开的第一方面的实施例提出一种液浮粉末床增材制造设备，所述液浮粉末床增材制造设备包括：成形室；工作台装置，所述工作台装置设于所述成形室且具有成形区域，所述工作台装置至少包括一个成形缸，所述成形缸被构造成适于盛装浮液；粉末供给装置，所述粉末供给装置被构造成适于将成形粉末铺展于所述浮液的表面，所述成形粉末在浮力的作用下浮于所述浮液表面以形成覆盖所述成形区域的粉末床；至少一个高能束发射聚焦扫描装置，所述高能束发射聚焦扫描装置被构造成发射高能束对所述粉末床进行成形处理，以使所述成形粉末逐层沉积而形成三维零件。
根据本公开实施例的液浮粉末床增材制造设备能够减少成形粉末的用量、提高成形粉末的利用率、降低三维零件的热应力，且满足多种形式的复合加工制造和在线检验的需要。
根据本公开的一些具体实施例，所述粉末床的厚度为0.01mm-100mm且包括湿层和干层，所述湿层浸入所述浮液，所述干层在所述浮液之上且不含有所述浮液；其中，所述成形区域由所述干层覆盖，所述高能束扫描所述干层以使所述干层的被扫描的部分升温、烧结或熔化，并逐层沉积于所述成型区域。
根据本公开的一些具体实施例，所述成形缸配置有加热/冷却装置，所述加热/冷却装置将浮液材料加热熔化成所述浮液且将所述浮液保持在50℃-2000℃的预定温度。
进一步地，所述浮液材料的密度大于所述成形粉末材料的密度。
进一步地，在但不限于所述三维零件制造完成后，所述成形缸加热/冷却装置控制所述浮液温度上升或下降到使所述浮液与所述三维零件表面润湿角最大的温度。
进一步地，在但不限于所述三维零件制造完成后，所述成形缸加热/冷却装置按照对所述三维零件进行热处理的要求，控制所述浮液的温度及其变化率上升或下降。
进一步地，所述成形缸设有进液口和排液口，所述进液口与加热釜相连，所述排液口设有排液阀且与下方的收集釜相连，所述收集釜内设有滤网。
根据本公开的一些具体实施例，所述成形缸配置有用于检测所述浮液液面高度的液面高度检测装置和用于调节所述浮液液面高度的液面高度调节装置。
进一步地，所述液面高度调节装置为可上下移动的等截面柱体；当所述等截面柱体向下移动而向所述浮液浸入时，所述浮液的液面高度上升；当所述等截面柱体向上移动而从所述浮液提起时，所述浮液的液面高度降低。
根据本公开的一些具体示例，所述成形室内设有收集罩，所述收集罩设于所述成形区域的上方且避让开所述高能束发射聚焦扫描装置发射的高能束，所述收集罩设有进气口和出气口，所述出气口连接有抽气装置和净化器。
根据本公开的一些具体实施例，所述工作台装置包括：工作平台，所述工作平台设于所述成形缸上端且围绕所述成形缸设置；升降台，所述升降台设于所述成形缸内，且带动所述三维零件升降。
进一步地，所述粉末供给装置包括：粉末供给器，所述粉末供给器被构造成将所述成形粉末储存并供给至所述工作平台；粉末铺设器，所述粉末铺设器设于所述工作平台，所述粉末铺设器被构造成将所述成形粉末推送至所述成形缸内浮液的表面并将所述浮液表面的所述粉末床铺平。
进一步地，所述成形室内设有熔覆装置、加工处理装置和检测装置中的至少一种，当所述升降台将其上的三维零件全部或部分提升出所述粉末床时，所述熔覆装置、所述加工处理装置和所述检测装置中的至少一种移动到工作位置，对所述三维零件进行熔覆沉积制造、切削加工、钻孔加工和/或质量检测。
进一步地，所述升降台连接有至少一个下驱动支撑杆和/或至少一个上驱动吊杆，其中，所述下驱动支撑杆向上穿过所述成形缸的底壁而与所述升降台相连；所述上驱动吊杆向下插入所述浮液而与所述升降台相连。
进一步地，所述工作平台构造有挡板，所述挡板位于所述上驱动吊杆的朝向所述粉末床的一侧且包括：水平部，所述水平部的表面与所述工作平台的表面平行且位于同一高度；外竖直部，所述外竖直部从所述水平部的朝向所述上驱动吊杆的一侧向上延伸；内竖直部，所述内竖直部从所述水平部的朝向所述粉末床的一侧向下延伸。
根据本公开的一些具体示例，所述升降台设有沿其厚度方向贯通的透液孔。
根据本公开的一些具体实施例，所述至少一个高能束发射聚焦扫描装置包括电子束发射聚集扫描装置和/或激光束发射聚集扫描装置；所述成形处理包括利用所述电子束发射聚集扫描装置发射的电子束和/或所述激光束发射聚集扫描装置发射的激光束对所述粉末床进行扫描、加热、烧结、熔化和切割加工中的一种或几种组合处理。
根据本公开的第二方面的实施例提出一种液浮粉末床增材制造方法，所述液浮粉末床增材制造方法包括：将浮液材料加热熔化为浮液并导入成形缸；将成形粉末铺展于所述浮液的表面，使所述成形粉末在浮力的作用下浮于所述浮液表面以形成粉末床，且至少有部分所述粉末床位于所述浮液的液面以上而不含有浮液，形成干层；利用高能束对所述粉末床中的干层进行成形处理，以使所述粉末床逐层沉积而形成三维零件。
根据本公开实施例的液浮粉末床增材制造方法能够减少成形粉末的用量、提高成形 粉末的利用率、降低三维零件的热应力，且满足多种形式的复合加工制造和在线检验的需要。
根据本公开的一些具体实施例，所述成形处理包括利用电子束发射聚集扫描装置发射的电子束和/或激光束发射聚集扫描装置发射的激光束对所述粉末床进行扫描、加热、烧结、熔化和切割加工中的一种或几种组合处理。
本公开的附加方面和优点将在下面的描述中部分给出，部分将从下面的描述中变得明显，或通过本公开的实践了解到。
附图说明
本公开的上述和/或附加的方面和优点从结合下面附图对实施例的描述中将变得明显和容易理解，其中：
图1是根据本公开实施例的液浮粉末床增材制造设备的结构示意图。
图2是根据本公开另一个实施例的液浮粉末床增材制造设备的结构示意图。
图3是根据本公开实施例的液浮粉末床增材制造设备的粉末床的结构示意图。
图4是根据本公开实施例的液浮粉末床增材制造设备的成形缸及其浮液导入与排出装置的结构示意图。
图5是根据本公开实施例的液浮粉末床增材制造设备进行复合加工制造时的工作示意图。
图6是根据本公开实施例的液浮粉末床增材制造设备的一种升降台局部结构示意图。
图7是根据本公开实施例的液浮粉末床增材制造设备的另一种升降台局部结构示意图。
附图标记：
液浮粉末增材制造设备1、激光束4、电子束2、三维零件21、
成形室9、
工作台装置5、工作平台8、升降台15、成形缸10、进液口30、排液口31、加热釜28、进液阀26、排液阀16、收集釜17、浮液材料27、滤网29、透液孔41、
粉末供给装置22、粉末供给器6、粉末铺设器7、
高能束发射聚焦扫描装置3、
浮液14、
成形粉末20、粉末床35、湿层11、干层12、
等截面柱体13、
收集罩18、进气口25、出气口36、抽气装置19、净化器23、
熔覆装置32、
上驱动吊杆33、
下驱动支撑杆39、
挡板40、水平部38、外竖直部34、内竖直部37。
具体实施方式
下面详细描述本公开的实施例，所述实施例的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的，仅用于解释本公开，而不能理解为对本公开的限制。
在本公开的描述中，需要理解的是，术语“上”、“下”、“竖直”、“水平”、“顶”、“底”、“内”、“外”、等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本公开和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本公开的限制。
考虑相关技术中增材制造技术的现状，本公开提出一种液浮粉末增材制造设备1和一种液浮粉末增材制造方法，该设备和方法能够减少成形粉末的用量、提高成形粉末的利用率、降低三维零件的热应力，且满足多种形式的复合加工制造和在线检验的需要。
下面参考附图描述根据本公开实施例的液浮粉末增材制造设备1。
如图1-图7所述，根据本公开实施例的液浮粉末增材制造设备1包括成形室9、工作台装置5、粉末供给装置22和至少一个高能束发射聚焦扫描装置3。
工作台装置5设于成形室9，且工作台装置5具有成形区域，工作台装置5至少包括一个成形缸10，成形缸10被构造成适于盛装浮液14。粉末供给装置22被构造成适于将成形粉末20铺展于浮液14的表面，成形粉末20在浮力的作用下浮于浮液14表面以形成覆盖所述成形区域的粉末床35。至少一个高能束发射聚焦扫描装置3，高能束发射聚焦扫描装置3被构造成发射高能束对粉末床35进行成形处理，以使成形粉末20逐层沉积于所述成型区域而形成三维零件21。
下面描述根据本公开实施例的液浮粉末床增材制造方法，所述液浮粉末床增材制造方法包括：
将浮液材料加热熔化为浮液14并导入成形缸10；
将成形粉末20铺展于浮液14的表面，使成形粉末20在浮力的作用下浮于浮液14 表面以形成粉末床35，且至少有部分粉末床35位于浮液14的液面以上而不含有浮液14，形成干层12；
利用高能束对粉末床35中的干层12进行成形处理，以使粉末床35逐层沉积而形成三维零件21。
根据本公开实施例的液浮粉末增材制造设备1及方法，利用液态金属或非金属(即浮液14)填充成形缸10，利用液体金属或非金属的浮力支撑表面的成形粉末20形成液浮式的粉末床35。不同于目前PBF技术中全部用粉末填充成形缸的全固态粉末床，液浮式的粉末床35只在液面上保持一定厚度，不但可以减少制造大型三维零件时需要的粉末量，而且无需复杂的自适应铺粉装置，同时通过控制液体金属或非金属(即浮液14)的温度，可以很好地提高和保持成形三维零件的温度，降低其热应力并控制其微观组织。
并且，液浮式的粉末床35有浮力支持，能够很好地保持一定的厚度，并在受到扰动时自动恢复表面的平整性。这将可以允许三维零件21在成形过程中进行升降或平移，而不破坏粉末床35的完整性。此特点使得在粉末床熔融工艺过程中三维零件21可以脱离粉末床35进行其它形式的加工(如另一种增材制造、切削加工、钻孔、辊压或表面喷涂等)和/或检测，以实现多种形式的复合加工制造和在线检验。
因此，根据本公开实施例的液浮粉末增材制造设备1及方法，能够减少成形粉末的用量、提高成形粉末的利用率、降低三维零件的热应力，且实施多种形式的复合加工制造和在线检验。
在本公开的一些具体实施例中，如图3所示，粉末床35包括湿层11和位于湿层11上方的干层12，湿层11浸入浮液14，干层12在浮液14之上且不含有浮液14。其中，所述成形区域由干层12覆盖，所述高能束扫描干层12以使干层12的被扫描的部分升温、烧结或熔化。并逐层沉积于所述成型区域。
由此，利用密度(比重)较大的液态金属或非金属(浮液14)，将密度较小的成形粉末20通过浮力在表面形成一定厚度的粉末层，激光或电子束等高能束在粉末层上表面进行选择性的烧结或熔化，虽然与目前的SLM工艺一样需要对成形室9内的气氛进行控制，限制氧含量，但避免了浮液14对熔池的干扰和不利影响。
其中，粉末床35的厚度为0.01mm-100mm，优选为1mm-50mm。
在本公开的一些具体实施例中，成形缸10配置有加热/冷却装置，所述加热/冷却装置将浮液材料加热熔化成浮液14且将浮液14保持在预定温度，例如，所述预定温度为50℃-2000℃。设置具有加热和保温功能的成形缸10，可以将密度较大的浮液材料加热至液态并在整个成形过程中保持温度处于预先设置的、高于熔点的预定温度。
本领域的技术人员需要理解地是，作为浮液14的金属或非金属材料的密度(比重)比 成形粉末20的密度(比重)大，并且不会与成形粉末20和三维零件21发生任何化学反应，除非所发生的反应有利于改进所成形三维零件21的使用性能。
在本公开的一些具体实施例中，在但不限于三维零件21制造完成后，所述成形缸加热/冷却装置控制浮液14温度上升或下降到使浮液14与三维零件21表面润湿角最大的温度。
在本公开的一些具体实施例中，在但不限于三维零件21制造完成后，所述成形缸加热/冷却装置按照对三维零件21进行热处理的要求，控制浮液14的温度及其变化率上升或下降。
在本公开的一些具体实施例中，如图1、图2和图4所示，成形缸10配置有液面高度检测装置和液面高度调节装置。液面高度检测装置用于检测浮液14的液面高度，液面高度调节装置用于调节浮液14的液面高度，由此可以保持和调整成形缸10中浮液14的液面的高度。
可选地，所述液面高度调节装置为可上下移动的等截面柱体13，等截面柱体13可由耐高温材料制成。当等截面柱体13向下移动而向浮液14浸入时，浮液14的液面高度上升；当等截面柱体13向上移动而从浮液14提起时，浮液14的液面高度降低。
在本公开的一些具体实施例中，如图4所示，成形缸10设有进液口30和排液口31，进液口30可以设置在成形缸10的侧壁且邻近上沿，排液口31可以设置在成形缸10的底壁，所述进液口30相连加热釜28且进液口30设有进液阀26，排液口31设有排液阀16且排液口31下方设有收集釜17，收集釜17内设有滤网29。
具体地，成形开始前，可用加热釜28将密度较大的浮液材料27熔化并加热至预定温度，通过进液口30导入成形缸10。在成形过程中，随着三维零件21下沉体积的增大，当液面高度调节装置无法调整液面处于预设高度时，排液口31的排液阀16打开，排出一部分浮液14后排液阀16关闭，液面高度调节装置进行液面高度调整。当成形结束后，排液口31的排液阀16打开，排出全部浮液14到收集釜17中。收集釜17中设有滤网29，滤除排出浮液14中的成形粉末20，滤出的成形粉末20可回收再利用，而剩下的液体则可冷却等待下一次成形，或通过进液口30重新导入成形缸10进行新的成形。
在本公开的一些具体示例中，如图1所示，为更充分地收集成形缸10中高温浮液14的挥发物和成形粉末20在高能束扫描下产生的蒸发物或飞溅，成形室9内可以设有收集罩18，收集罩18设于成形区域的上方，且收集罩18避让开高能束发射聚焦扫描装置3发射的高能束，收集罩18设有进气口25和出气口36，出气口36连接有抽气装置19和净化器23，气体经净化器23处理去除其中的重金属和有害物质后，可以排向大气，或导入成形室9，或通过进气口25进入收集罩18。
在本公开的一些具体实施例中，如图1和图2所示，工作台装置5包括工作平台8和升降台15。
工作平台8设于成形缸10上端且围绕成形缸10设置。所述成形区域可形成于升降台15的上表面且可被高能束扫描范围覆盖，升降台15设于成形缸10内且带动三维零件21升降，升降台15随着粉末床35的逐层熔化或烧结而逐渐下沉并带动已成形的三维零件21逐渐浸入浮液14中。
其中，为了方便升降台15升降时浮液14的流动，升降台15设有贯通升降台15的透液孔41，例如，透液孔41沿上下方向贯通升降台15。
在本公开的一些具体示例中，如图1和图2所示，粉末供给装置22包括粉末供给器6和粉末铺设器7。
粉末供给器6被构造成将成形粉末20储存并供给至工作平台8。粉末铺设器7设于工作平台8，粉末铺设器7被构造成将成形粉末20推送至成形缸10内浮液14的表面并将浮液14表面的粉末床35铺平。
在本公开的一些具体实施例中，如图5所示，成形室9内设有熔覆装置32、加工处理装置和检测装置中的至少一种，当升降台15将其上的三维零件21全部或部分提升出粉末床35时，熔覆装置32、所述加工处理装置和所述检测装置中的至少一种移动到工作位置，对三维零件21进行熔覆沉积制造、切削加工、钻孔加工和/或质量检测。
在逐层制造三维零件21的过程中，可以提升升降台15，将三维零件21全部或部分提升出粉末床35，利用熔覆装置32(如激光熔覆头、电子束熔丝头)在已成形的三维零件21基础上熔覆相同或不同材料，进行熔覆沉积制造；也可以利用加工处理装置(如铣削头、钻头)对已成形的三维零件21进行切削或钻孔等加工；还可以利用检测装置(如激光扫描、触点探头、超声探头、X射线探头)对已成形的三维零件21进行检测。
上述熔覆沉积、切削加工或检测完成后，下降升降台15，将三维零件21重新浸入浮液14和粉末床35中，粉末铺设器7将粉末床35重新铺平后，继续进行高能束粉末床熔融成形制造。
在本公开的一些具体示例中，升降台15连接有至少一个下驱动支撑杆39和/或至少一个上驱动吊杆33。
具体而言，下驱动支撑杆39向上穿过成形缸10的底壁而与升降台15相连(如图1、图2和图4所示)；上驱动吊杆33向下插入浮液14而与升降台15相连(如图6和图7所示)，其中，图6示出了采用单侧上驱动吊杆33的示例，图7示出了采用双侧上驱动吊杆33的示例，适用于大型、较重零件的制造。
进一步地，如图6和图7所示，工作平台8构造有挡板40，挡板40位于上驱动吊 杆33的朝向粉末床35的一侧，且挡板40包括水平部38、外竖直部34和内竖直部37。
水平部38的表面与工作平台8的表面平行且位于同一高度。外竖直部34从水平部38的朝向上驱动吊杆33的一侧向上延伸。内竖直部37从水平部38的朝向粉末床35的一侧向下延伸，内竖直部37的深度(上下方向上的尺寸)大于粉末床35的最大厚度。外竖直部34的作用是在粉末铺设器7铺粉时将成形粉末20限制在水平部38内；而内竖直部37的作用是约束粉末床35以形成稳定的湿层11和干层12。
在本公开的一些具体实施例中，所述至少一个高能束发射聚焦扫描装置3包括电子束发射聚集扫描装置和/或激光束发射聚集扫描装置。图1示出了单独采用激光束发射聚集扫描装置的示例，图2示出了单独采用电子束发射聚集扫描装置的示例。
当然，也可以同时结合激光束发射聚集扫描装置和电子束发射聚集扫描装置。将电子束-激光束结合起来进行复合扫描进行选区熔化，以将电子束选区熔化和激光选区熔化的优点结合。具体而言，所述电子束发射聚集扫描装置发射的扫描电子束2和所述激光束发射聚集扫描装置发射的扫描激光束4均可用于扫描成形区域，预热成形粉末床35和控制降温过程，使成形区域温度场处于适当范围，控制温度梯度，降低热应力；扫描三维零件21截面及其内外轮廓，使截面内材料逐步升温、烧结、熔化，形成清晰、连续、完整的截面及其轮廓，从而可以获得高性能和较高精度的三维零件21。
所述成形处理包括利用所述电子束发射聚集扫描装置发射的电子束2和/或所述激光束发射聚集扫描装置发射的激光束4对粉末床35进行扫描、加热、烧结、熔化和切割加工中的一种处理或几种组合，此外还可以控制三维零件21和粉末床35的降温过程。
其中，对于采用电子束2对粉末床35进行预热、烧结、熔化沉积和降温控制的成形室9(如图2所示)，配置有真空系统和惰性气体回填系统，为防止电子束2传输过程中功率过度衰减，并考虑高温浮液14和粉末床35熔化沉积时的蒸发，可回填惰性气体，真空度保持在10 -4Pa至10Pa之间；而对于采用激光束4对粉末床35进行预热、烧结、熔化沉积和降温控制的成形室9(如图1所示)，配置有抽气和充气装置。经过抽气-充气循环后，所述成形室9需充满惰性气体，气压等于或大于1个大气压(≥0.1013MPa)并将氧含量降低到0.1％以下。
根据本公开的实施例提出一种液浮粉末增材制造设备1，利用液体浮力支撑粉末床，即在密度(比重)较大的液体表面铺展粉末形成液浮粉末床，再利用激光或电子束等高能束对粉末进行逐层预热、烧结或熔化沉积，以制造三维零件。
下面举例描述根据本公开实施例的液浮粉末增材制造设备1的工作过程。
将密度较大的金属或非金属(浮液材料27)加热熔化作为浮液14，将浮液14导入成形室9内具有加热/冷却和保温功能的成形缸10，并使浮液14的温度保持在预定温度 (50℃-2000℃)。成形室9内的粉末铺设器7将密度较小的成形粉末20铺展在浮液14上，形成一定厚度(0.01mm-100mm)的粉末床35。粉末床35漂浮在浮液14表面，包括浸入浮液14的湿层11和浮液14之上的干层12。高能束发射聚焦扫描装置3发射激光束4和/或电子束2，扫描粉末床35进行加热，以及扫描一定区域对粉末床35进行烧结或熔化沉积以形成所需的零件截面，并与下面已成形的三维零件21或升降台15连接。升降台15下降一层厚高度，与成形缸10连通的液面高度检测装置与液面高度控制装置测量并调整液面回复到预设的液面高度位置，粉末铺设器7推送成形粉末20至粉末床35上并推平，形成粉末床35平整的表面。高能束发射聚焦扫描装置3再次扫描粉末床35进行加热、烧结或熔化沉积新层，如此反复，直到完成整个三维零件21的增材制造。
当完成三维零件21的增材制造后，升降台15可下降，将三维零件21完全没入浮液14中，调整浮液14的温度和保温时间，对成形的三维零件21进行热处理。而在取出三维零件21之前，可将浮液14的温度调整到使其表面张力较大，或使浮液14与三维零件21表面的接触角(润湿角)较大的温度。以便更好地保证浮液14与三维零件21的分离。
取出三维零件21的方式可以通过升降台15上升将三维零件21提升出浮液14和粉末床35，也可以通过打开成形缸10底部的排液阀16，排出浮液14使三维零件21逐步露出浮液14和粉末床35，从而将三维零件21与浮液14和粉末床35分离。
根据本公开实施例的液浮粉末增材制造设备1的其它构成以及操作对于本领域普通技术人员而言都是已知的，这里不再详细描述。
在本说明书的描述中，参考术语“具体实施例”、“具体示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本公开的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不一定指的是相同的实施例或示例。
尽管已经示出和描述了本公开的实施例，本领域的普通技术人员可以理解：在不脱离本公开的原理和宗旨的情况下可以对这些实施例进行多种变化、修改、替换和变型，本公开的范围由权利要求及其等同物限定。

Claims (19)

  1. 一种液浮粉末床增材制造设备，其特征在于，包括：
    成形室；
    工作台装置，所述工作台装置设于所述成形室且具有成形区域，所述工作台装置至少包括一个成形缸，所述成形缸被构造成适于盛装浮液；
    粉末供给装置，所述粉末供给装置被构造成适于将成形粉末铺展于所述浮液的表面，所述成形粉末在浮力的作用下浮于所述浮液表面以形成覆盖所述成形区域的粉末床；
    至少一个高能束发射聚焦扫描装置，所述高能束发射聚焦扫描装置被构造成发射高能束对所述粉末床进行成形处理，以使所述成形粉末逐层沉积而形成三维零件。
  2. 根据权利要求1所述的液浮粉末床增材制造设备，其特征在于，所述粉末床的厚度为0.01mm-100mm且包括湿层和干层，所述湿层浸入所述浮液，所述干层在所述浮液之上且不含有所述浮液；
    其中，所述成形区域由所述干层覆盖，所述高能束扫描所述干层以使所述干层的被扫描的部分升温、烧结或熔化，并逐层沉积于所述成型区域。
  3. 根据权利要求1所述的液浮粉末床增材制造设备，其特征在于，所述成形缸配置有加热/冷却装置，所述加热/冷却装置将浮液材料加热熔化成所述浮液且将所述浮液保持在50℃-2000℃的预定温度。
  4. 根据权利要求3所述的液浮粉末床增材制造设备，其特征在于，所述浮液材料的密度大于所述成形粉末材料的密度。
  5. 根据权利要求3所述的液浮粉末床增材制造设备，其特征在于，在但不限于所述三维零件制造完成后，所述成形缸加热/冷却装置控制所述浮液温度上升或下降到使所述浮液与所述三维零件表面润湿角最大的温度。
  6. 根据权利要求3所述的液浮粉末床增材制造设备，其特征在于，在但不限于所述三维零件制造完成后，所述成形缸加热/冷却装置按照对所述三维零件进行热处理的要求，控制所述浮液的温度及其变化率上升或下降。
  7. 根据权利要求3所述的液浮粉末床增材制造设备，其特征在于，所述成形缸设有进液口和排液口，所述进液口与加热釜相连，所述排液口设有排液阀且与下方的收集釜相连，所述收集釜内设有滤网。
  8. 根据权利要求1所述的液浮粉末床增材制造设备，其特征在于，所述成形缸配置有用于检测所述浮液液面高度的液面高度检测装置和用于调节所述浮液液面高度的 液面高度调节装置。
  9. 根据权利要求8所述的液浮粉末床增材制造设备，其特征在于，所述液面高度调节装置为可上下移动的等截面柱体；
    当所述等截面柱体向下移动而向所述浮液浸入时，所述浮液的液面高度上升；
    当所述等截面柱体向上移动而从所述浮液提起时，所述浮液的液面高度降低。
  10. 根据权利要求1所述的液浮粉末床增材制造设备，其特征在于，所述成形室内设有收集罩，所述收集罩设于所述成形区域的上方且避让开所述高能束发射聚焦扫描装置发射的高能束，所述收集罩设有进气口和出气口，所述出气口连接有抽气装置和净化器。
  11. 根据权利要求1-10中任一项所述的液浮粉末床增材制造设备，其特征在于，所述工作台装置包括：
    工作平台，所述工作平台设于所述成形缸上端且围绕所述成形缸设置；
    升降台，所述升降台设于所述成形缸内，且带动所述三维零件升降。
  12. 根据权利要求11所述的液浮粉末床增材制造设备，其特征在于，所述粉末供给装置包括：
    粉末供给器，所述粉末供给器被构造成将所述成形粉末储存并供给至所述工作平台；
    粉末铺设器，所述粉末铺设器设于所述工作平台，所述粉末铺设器被构造成将所述成形粉末推送至所述成形缸内浮液的表面并将所述浮液表面的所述粉末床铺平。
  13. 根据权利要求11所述的液浮粉末床增材制造设备，其特征在于，所述成形室内设有熔覆装置、加工处理装置和检测装置中的至少一种，当所述升降台将其上的三维零件全部或部分提升出所述粉末床时，所述熔覆装置、所述加工处理装置和所述检测装置中的至少一种移动到工作位置，对所述三维零件进行熔覆沉积制造、切削加工、钻孔加工和/或质量检测。
  14. 根据权利要求11所述的液浮粉末床增材制造设备，其特征在于，所述升降台连接有至少一个下驱动支撑杆和/或至少一个上驱动吊杆，其中，
    所述下驱动支撑杆向上穿过所述成形缸的底壁而与所述升降台相连；
    所述上驱动吊杆向下插入所述浮液而与所述升降台相连。
  15. 根据权利要求14所述的液浮粉末床增材制造设备，其特征在于，所述工作平台构造有挡板，所述挡板位于所述上驱动吊杆的朝向所述粉末床的一侧且包括：
    水平部，所述水平部的表面与所述工作平台的表面平行且位于同一高度；
    外竖直部，所述外竖直部从所述水平部的朝向所述上驱动吊杆的一侧向上延伸；
    内竖直部，所述内竖直部从所述水平部的朝向所述粉末床的一侧向下延伸。
  16. 根据权利要求11所述的液浮粉末床增材制造设备，其特征在于，所述升降台设有沿其厚度方向贯通的透液孔。
  17. 根据权利要求1-10中任一项所述的液浮粉末床增材制造设备，其特征在于，所述至少一个高能束发射聚焦扫描装置包括电子束发射聚集扫描装置和/或激光束发射聚集扫描装置；
    所述成形处理包括利用所述电子束发射聚集扫描装置发射的电子束和/或所述激光束发射聚集扫描装置发射的激光束对所述粉末床进行扫描、加热、烧结、熔化和切割加工中的一种或几种组合处理。
  18. 一种液浮粉末床增材制造方法，其特征在于，包括：
    将浮液材料加热熔化为浮液并导入成形缸；
    将成形粉末铺展于所述浮液的表面，使所述成形粉末在浮力的作用下浮于所述浮液表面以形成粉末床，且至少有部分所述粉末床位于所述浮液的液面以上而不含有浮液，形成干层；
    利用高能束对所述粉末床中的干层进行成形处理，以使所述粉末床逐层沉积而形成三维零件。
  19. 根据权利要求18所述的液浮粉末床增材制造方法，其特征在于，所述成形处理包括利用电子束发射聚集扫描装置发射的电子束和/或激光束发射聚集扫描装置发射的激光束对所述粉末床进行扫描、加热、烧结、熔化和切割加工中的一种或几种组合处理。
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