WO2021232298A1 - 增材制造方法 - Google Patents

增材制造方法 Download PDF

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Publication number
WO2021232298A1
WO2021232298A1 PCT/CN2020/091329 CN2020091329W WO2021232298A1 WO 2021232298 A1 WO2021232298 A1 WO 2021232298A1 CN 2020091329 W CN2020091329 W CN 2020091329W WO 2021232298 A1 WO2021232298 A1 WO 2021232298A1
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WIPO (PCT)
Prior art keywords
additive manufacturing
support
material powder
print
printing
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PCT/CN2020/091329
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English (en)
French (fr)
Inventor
李长鹏
张卿卿
斯维纳连科·卡特瑞娜
陈国锋
Original Assignee
西门子股份公司
西门子（中国）有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by 西门子股份公司, 西门子（中国）有限公司 filed Critical 西门子股份公司
Priority to CN202080099240.5A priority Critical patent/CN115443198A/zh
Priority to PCT/CN2020/091329 priority patent/WO2021232298A1/zh
Priority to US17/925,616 priority patent/US20230173581A1/en
Priority to EP20936574.1A priority patent/EP4137253A4/en
Publication of WO2021232298A1 publication Critical patent/WO2021232298A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
    • B22F10/43—Structures for supporting workpieces or articles during manufacture and removed afterwards characterised by material
    • 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
    • B22F10/30—Process control
    • B22F10/32—Process control of the atmosphere, e.g. composition or pressure in a building chamber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • 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
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • 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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • 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
    • B22F10/68—Cleaning or washing
    • 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
    • B22F2201/00—Treatment under specific atmosphere
    • B22F2201/10—Inert gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • 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 invention relates to the field of 3D printing, in particular to an additive manufacturing method.
  • Additive Manufacturing is now one of the rapidly developing advanced manufacturing technologies in the world, and it shows broad application prospects.
  • SLM Selected Laser Melting
  • additive manufacturing is a type of additive manufacturing (Additive manufacturing) technology, which can quickly manufacture the same parts as the CAD model by means of laser selective melting.
  • the selective laser melting process has been widely used. Different from the traditional material removal mechanism, additive manufacturing is based on the completely opposite principle of materials incremental manufacturing (philosophy). Among them, selective laser melting uses high-power lasers to melt metal powder, and input layer by layer through 3D CAD. The components/components can be built in order to successfully manufacture components with complex internal channels. Additive manufacturing technology can provide a unique potential for arbitrarily manufacturing complex structural components, such complex components usually cannot be easily manufactured by traditional manufacturing processes.
  • Fig. 1 is a schematic diagram of the thermal deformation of the material due to the rapid melting and solidification process when performing 3D printing, resulting in the final printed piece P 1 that is deformed compared to the initial CAD design.
  • the print P 1 does not have a solid support structure and a sufficiently high heat conduction channel, printing defects will occur.
  • the drawing shows that during the printing process of the 3D printing device, the high-temperature laser is generally vertically downward, so it will bring vertical heat H from the top to the bottom, so the entire sample P 1
  • the surface temperature is very high.
  • the laser heating direction T 1 extends from the middle of the sample P 1 to the edge, and part of the area expands. Therefore, the entire sample P 1 has a vertical downward pulling force F 1 , and the print P 1 will produce the following
  • the edge portion shown in the left image of FIG. 1 is deformed downward.
  • the cooling heat-like P 1 T 2 of a tendency to shrink, so that the entire sample P 1 receives an upward stress F 2, as shown in FIG. 1 and therefore will produce The edge part shown on the right is deformed upward.
  • the prior art usually uses a support between the printing base and the printed part. Its function is an anchor structure, which is sufficiently powerful. The mechanical support force to resist the residual stress, so as to avoid material deformation.
  • the support will also act as a solid support and serve as a heat conduction channel under the overhang structure to avoid printing defects that may be caused by local overheating. Based on the operation manual of the 3D printing device, if the print has an inclination angle of less than 45 degrees and a protruding size greater than 1 mm, it is necessary to set the support during the printing process, and remove the print after the printing is completed.
  • the step of removing the support after the printing is completed will cause extra work and cost, and will also affect the surface quality of the print, which will reduce the surface fluid characteristics and significantly reduce the fatigue life. Therefore, it is often after the support is removed. It is necessary to perform additional surface polishing on the part of the print that borders the support.
  • the support member S 1 2 typically prints P 1 and the connecting portion between the support member S 1 is designed as a lattice or zigzag shape to reduce the print P 1 and support a contact area between the element S 1.
  • sawtooth shaped support member S 1 sometimes can not provide a sufficiently high mechanical support to overcome the force of the thermal deformation or residual stress, even be damaged and deformed prints P in a sawtooth portion.
  • the zigzag support S 1 will also significantly reduce the thermal conductivity, thus affecting the overall 3D printing capability.
  • the present invention provides an additive manufacturing method, which includes the following steps: generating a support model based on the shape of the print model, wherein at least a part of the support is in contact with at least a part of the print underneath, and the support At least a part of the upper surface of the printed part has a nitride layer; the inert gas is continuously introduced into the additive manufacturing printing device, and the first material powder is spread in the forming cylinder of the additive manufacturing printing device.
  • the first material powder is scanned by laser, so that the first material powder is melted, and the printed part and the supporting part contacting a part of the printed part below are formed layer by layer based on the printed part model; in additive manufacturing Ammonia gas is introduced into the printing device, the first material powder is spread in the forming cylinder of the additive manufacturing printing device, and the first material powder is scanned by laser, so that the first material powder is melted and based on the
  • the support model forms a nitride layer on the upper surface of the support.
  • the step of introducing ammonia gas in the additive manufacturing printing device further includes the following steps: partitioning the ammonia gas input according to the additive manufacturing printing area, and only for the area where the nitride layer of the support member is located. The partitions are fed with a second gas in the additive manufacturing printing device.
  • the density of the supporting member is less than the density of the printed member.
  • non-nitriding layer region of the support member and the printed member are arranged at intervals.
  • the additive manufacturing method further includes the step of: removing the support from the printed part by applying an external force to the nitride layer of the support.
  • the removing step adopts a high-energy vibration process or a sandblasting and polishing process.
  • the first gas is nitrogen or ammonia.
  • the thickness of the nitride layer ranges from 10 micrometers to 1000 micrometers.
  • the additive manufacturing mechanism provided by the present invention can obtain a support that has sufficient strength and is easy to remove after the additive manufacturing is completed, ensures good 3D printing quality, and has a low cost.
  • the nitride layer provided by the present invention has a sufficiently high contact area, can avoid thermal deformation of the material, and achieves good thermal conductivity.
  • the additive manufacturing mechanism provided by the present invention and the nitrided support together also include a surface hardening step, and the printed parts have high wear resistance requirements.
  • Figure 1 is a schematic diagram of the thermal deformation of the material due to the rapid melting and curing process when performing 3D printing
  • Figure 2 is a schematic diagram of the connection between the print and the support
  • Fig. 3 is a schematic diagram of a selective laser melting device according to a specific embodiment of the present invention.
  • Fig. 4 is a schematic diagram of the structure of a printing member and a supporting member according to a specific embodiment of the present invention.
  • the additive manufacturing mechanism provided by the present invention can obtain a support member that is sufficiently strong and easy to remove after the additive manufacturing is completed, and does not affect the contact surface of the printing member and the support member, and can also improve the support due to residual Due to the deformation of the material caused by the stress, the printed part after removing the support still has a high surface quality.
  • the additive manufacturing mechanism provided by the present invention is implemented in a selective laser device.
  • Figure 3 is a schematic diagram of a selective laser melting device.
  • the selective laser melting device 100 includes a laser source 110, a mirror scanner 120, a prism 130, a powder feeding cylinder 140, a forming cylinder 150 and a recovery cylinder 160.
  • the laser source 110 is arranged above the selective laser melting device 100 and serves as a heating source for the metal powder, that is, the metal powder is melted for 3D printing.
  • first piston (not shown) that can move up and down at the lower part of the powder feeding cylinder 140.
  • a spare metal powder is placed in the cavity space above the first piston of the powder feeding cylinder 140, and it follows the movement of the first piston. Moving up and down sends the metal powder from the powder feeding cylinder 140 into the forming cylinder 150.
  • a 3D printed part placement table 154 is provided in the forming cylinder 150, a 3D printed part is clamped above the placement table 154, and a second piston 152 is fixed below the placement table 154, wherein the second piston 152 is perpendicular to the placement table 154 set up.
  • the second piston 152 moves from top to bottom to form a printing space in the molding cylinder 220.
  • the laser source 110 for laser scanning should be set above the forming cylinder 150 of the selective laser melting equipment.
  • the mirror scanner 120 adjusts the position of the laser by adjusting the angle of a prism 130, and determines which area of the laser melts the metal by adjusting the prism 130. powder.
  • the powder feeding cylinder 140 further includes a roller (not shown).
  • the metal powder is stacked on the upper surface of the first piston.
  • the first piston moves vertically from bottom to top to transfer the metal powder to the upper part of the powder feeding cylinder 140.
  • the roller may roll on the metal powder to send the metal powder to the forming cylinder 150. Therefore, the laser scanning is continuously performed on the metal powder to decompose the metal powder into a powder matrix, and the laser scanning of the powder matrix is continued until the powder matrix is sintered from the bottom to the top into a print with a preset shape.
  • the selective laser melting apparatus 100 also includes a first gas input device 180, which is usually located on the top of the selective laser melting apparatus 100, and is used to pass inert gas for the 3D printing process, so the inert gas can be input through the first gas
  • the device 180 spreads to the entire printing area of the forming cylinder 150.
  • the selective laser melting device 100 further includes a second gas input device 170, which is located on the side of the selective laser melting device 100, and is used to pass other gas into the side facing the forming cylinder 150.
  • the second gas input device 170 is fed with ammonia gas.
  • the second gas input device 170 includes a plurality of gas outlets, and each gas outlet has a valve that controls its opening and closing, that is, as shown in FIG. 3, the first valve 171, the second valve 172, and the third valve 173,
  • the fourth valve 174 and the fifth valve 175 and the diffuser plate 176 have a plurality of nozzles on the diffuser plate 176.
  • the above-mentioned multiple valves control the output area of the ammonia gas according to different areas, and the nitride layer of the support member can be formed according to such divisions.
  • the first valve 171 and the fifth valve 175 are opened to introduce ammonia gas and input into the forming cylinder 150 through the corresponding nozzles on the diffuser plate 176;
  • the second valve 172 and the fourth valve 174 are opened and the ammonia gas is introduced into the forming cylinder 150 through the corresponding nozzle on the diffuser plate 176;
  • the third valve 173 is opened to introduce ammonia gas and input into the forming cylinder 150 through the corresponding nozzles on the diffuser plate 176.
  • inert gas must be introduced during the laser melting process to avoid possible material oxidation. Therefore, the present invention needs to form the main body of the printing member and the support member in an inert gas environment during the whole process, but when forming the nitride layer of the support member, it is necessary to pass in ammonia gas at the same time. Of ammonia. In this way, the inert gas in the 3D environment can be ensured as a whole.
  • the ammonia gas can only be introduced into the ammonia gas locally and in sections, which reduces the impact of the inert gas environment of the entire printing chamber by the ammonia gas.
  • the first aspect of the present invention provides an additive manufacturing method, which includes the following steps.
  • step S1 to generate a support S 2 model based on the shape of the print P 2 model, wherein at least a part of the support S 2 is in contact with at least a part of the print P 2 below, and the support S 2 A nitride layer 200 is provided on the upper surface of at least a part of the printed part P 2.
  • the support member S 2 is typically provided in the print element below the P 2 or prints lower concave portions P 2, the support member S 2 may have many or entire zigzag, the contact P 2 and the support S 2 is at least partially print,
  • the contact surface is the nitride layer 200 of the support S 2.
  • the printing piece P 2 and the supporting piece S 2 are not in contact.
  • the left side of the supporting piece S 2 does not touch the printing piece P 2 , and there is a gap g between the two.
  • step S2 the inert gas is continuously introduced into the first gas input device 180 of the selective laser melting device 100, and the first material powder is spread in the forming cylinder 150 of the selective laser melting device 100, and the first material powder is applied to the first gas input device 180.
  • material powder for laser scanning such that the material powder is first melted and the print member P is formed beneath the support 2, and in contact with the print part P 2 S 2 of P based on the print member 2 model layer by layer.
  • step S3 ammonia gas is introduced into the second gas input device 170 of the selective laser melting device 100, and the first material powder is spread in the forming cylinder 150 of the selective laser melting device 100 to treat the first material laser scanning powder, such that the material powder is melted and the first model based on the support member 2 S 2 S is formed on the nitride layer member 200 of the support surface.
  • the ammonia gas is decomposed into N and H atoms under the high temperature of the laser, and the N atoms and the metal powder form the nitride layer 200, for example, with iron or nickel to form a nitride.
  • step S2 forms the printed part P 2
  • step S3 forms the support part S 2
  • the present invention may be formed first print element and then forming a support member P 2 S 2
  • the support member may be formed first and then form a printed member S 2 P 2
  • the bottoms of the print P 2 and the support S 2 are on the same plane, and preferably the materials of the print P 2 and the support S 2 are the same, so they both follow The sequence is formed layer by layer at the same time.
  • the step of introducing ammonia gas into the additive manufacturing printing device further includes the following steps: partitioning the ammonia gas input according to the additive manufacturing printing area, and targeting the partition where the nitride layer of the support member is located.
  • a second gas is introduced into the additive manufacturing printing device.
  • the second gas includes ammonia or nitrogen, and the implementation of introducing nitrogen requires a higher laser input power. For the sake of brevity, it will not be repeated here.
  • the additional ammonia gas NH 3 will be input into the selective laser melting device 100 through diffuser nozzles, and each nozzle corresponds to a different control valve to control the ammonia gas input to the area close to the desired nitriding area, with less Affects the entire additive manufacturing printing environment.
  • the ammonia gas approaches the forming cylinder 150 of the selective laser melting device 100, and decomposes and reacts with metal materials to form nitrides and finally form nitride layers, such as iron nitride, aluminum nitride, and nickel nitride. .
  • the ammonia valve closest to the nitriding area will be opened, and only the nitriding on the main contact surface of the print P 2 and the support S 2 Floor 200 hours. Since the nitriding process is performed in the vicinity of the melting powder of the forming cylinder 150 when the ammonia decomposition temperature is high enough, the remaining powder and the printed part P 2 will not be affected to ensure the printing quality of the remaining part and the raw material powder Utilization rate.
  • the nitride layer 200 serves as the contact area between the print P 2 and the support S 2 to ensure a high contact area and a sufficiently high mechanical support force to avoid thermal deformation of the material that may occur in the process of printing the print S 2.
  • the nitride layer 200 has good thermal conductivity compared with the original metal body, which can ensure good thermal conductivity and printing quality brought by the support S 2.
  • the present invention can also control and optimize the thickness of the nitride layer 200 to ensure a good mechanical support force of the support S 2 and facilitate subsequent removal steps.
  • the density of the supporting member is less than the density of the printed member.
  • the density of the support can be controlled to be less than the density of the print by adjusting the material density, so that the support can be distinguished while ensuring the strength of the support. And avoid waste.
  • the non-nitriding layer region of the support member and the printed member are arranged at intervals.
  • the contact surface between the printed part and the support part is only the nitride layer in the vertical direction, and most of the parts where the nitride layer is not provided are kept in a non-contact state, especially a large number of side areas, which can facilitate the The support is removed from the print.
  • the additive manufacturing method further includes the step of: removing the support from the printed part by applying an external force to the nitride layer of the support.
  • the printed part P2 and the support S2 will be heat treated together to obtain a good lattice structure and high mechanical support. Due to the different thermal expansion efficiencies between different materials, cracks may occur between the nitride layer 200 and the metal material of the printed part P2 that it contacts.
  • the nitride layer 200 is fragile and has modulus properties relative to the metal material of the printed part P2. Therefore, the nitrided layer 200 as the contact layer with the printed part P2 can be easily destroyed and removed by manpower or other processing techniques, such as high-energy vibration or sandblasting.
  • the thickness of the nitride layer ranges from 10 microns to 1000 microns. Among them, the specific thickness of the nitride layer should be set according to the specific process requirements of the application scenario.
  • the additive manufacturing mechanism provided by the present invention can obtain a support that has sufficient strength and is easy to remove after the additive manufacturing is completed, ensures good 3D printing quality, and has a low cost.
  • the nitride layer provided by the present invention has a sufficiently high contact area, can avoid thermal deformation of the material, and achieves good thermal conductivity.
  • the additive manufacturing mechanism provided by the present invention and the nitrided support together also include a surface hardening step, and the printed parts have high wear resistance requirements.
  • the present invention has a high strength-to-weight ratio and a surface-to-mass ratio in the geometry of the additive feature unit, which can maximize the heat exchange surface while reducing the wall thickness, but can still maintain a stable Structural strength and rigidity, so as to achieve the goal of reducing the weight of parts and improving the overall heat transfer performance.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Optics & Photonics (AREA)
  • Mechanical Engineering (AREA)
  • Automation & Control Theory (AREA)
  • Powder Metallurgy (AREA)

Abstract

增材制造方法，其中，包括如下步骤：基于打印件（P 2）模型的形状产生支撑件（S 2）模型；在增材制造打印装置中持续通入惰性气体，在增材制造打印装置中的成型缸（150）中铺第一材料粉末，对第一材料粉末进行激光扫描，使得第一材料粉末融化并基于打印件（P 2）模型逐层形成打印件（P 2）以及接触于打印件（P 2）一部分的下方的支撑件（S 2）；在增材制造打印装置中通入氨气，在增材制造打印装置中的成型缸（150）中铺第一材料粉末，对第一材料粉末进行激光扫描，使得第一材料粉末融化并基于支撑件（S 2）模型形成支撑件（S 2）上表面的氮化层（200）。其提供了易于移除的支撑件，保证了打印质量，并且造价低。

Description

增材制造方法 技术领域
本发明涉及3D打印领域，尤其涉及增材制造方法。
背景技术
增材制造工艺(Additive Manufacturing)如今是世界上发展迅速的先进制造技术之一，其显示出了宽广的应用前景。选择性激光熔化(Selected Laser Melting,SLM)工艺是增材制造(Additive manufacturing)技术的一种，其通过激光选区融化的方式可快速地将与CAD模型相同的零部件制造出来。目前选择性激光熔化工艺得到了广泛的应用。和传统材料去除机制不同，增材制造是基于完全相反的材料增加制造原理(materials incremental manufacturing philosophy)，其中，选择性激光熔化利用高功率激光熔化金属粉末，并通过3D CAD输入来一层一层地建立部件/元件，这样可以成功制造出具有复杂内部沟道的元件。增材制造技术能够提供一种任意制造复杂结构元件的独特潜力，这样的复杂元件通常不能轻易由传统制程来制造。
在3D打印过程中，金属粉末利用高功率激光源融化并基于3D CAD模型逐层形成部件/元件。然而，3D打印也有其自身的局限性，例如出现残余应力。图1是执行3D打印时由于快速融化和固化过程而材料热变形的示意图，导致最后打印出来的打印件P 1和初始CAD设计相比具有变形。此外，如果打印件P 1没有固体支撑结构和足够高的导热通道，则会出现打印缺陷。具体地，附图1所示，作图示出了在3D打印装置的打印过程中，高温激光一般是垂直向下的，因此会带来从上之下垂直的热量H，因此整个样片P 1表面温度很高，激光加热方向T 1是从样片P 1中间往边缘延伸的，其中部分区域膨胀，因此整个样片P 1具有一个垂直向下的拉扯力F 1，打印片P 1则会产生如图1的左图所示的边缘部分朝下的变形。而3D打印结束以后样片P 1则有个冷却过程，冷却时样片P 1的热量T 2是趋向于收缩，因此整个样片P 1收到一个向上的应力F 2，因此又会产生如图1的右图所示的边缘部分向上的变形。
为了解决在3D打印中上述热胀冷缩带来的材料变形，现有技术通常会在 打印基台和打印件之间的支撑件，其功能是锚具机构(anchor structure)，其具有足够强大的机械支撑力来对抗残余应力，从而避免材料变形。此外，支撑件也会充当固体支撑，并作为在突出机构(overhang structure)下面的热传导通道，以避免局部过热可能导致的打印缺陷。基于3D打印设备的操作手册，打印件具有小于45度的倾斜角度和突出尺寸大于1mm的情况下就需要在打印过程中设置支撑件，并且在打印执行完毕以后移除打印件。
然而，执行打印完毕以后支撑件的移除步骤会导致额外工作和花费，也会影响打印件表面质量，其会导致降低表面流体特性，也会显著减少疲劳寿命，因此往往在移除支撑件后需要在打印件接壤支撑件的部分执行额外表面抛光。如图2所示，为了成功将支撑件S 1移除，通常在打印件P 1和支撑件S 1之间的连接部分会被设计为锯齿形或者格子状，以减少打印件P 1和支撑件S 1之间的接触面积。然而，锯齿形的支撑件S 1有时并不能提供足够高的机械支撑力来克服热变形力或者残余应力，甚至在锯齿部分会出现打印件P 1的破损和变形。此外，锯齿形的支撑件S 1也会显著减少热传导能力，因此影响整个3D打印能力。
发明内容
本发明提供了增材制造方法，其中，包括如下步骤：基于打印件模型的形状产生支撑件模型，其中，所述支撑件的至少一部分接触于所述打印件至少一部分的下方，所述支撑件接触于所述打印件至少一部分的上表面具有一个氮化层；在增材制造打印装置中持续通入惰性气体，在所述增材制造打印装置中的成型缸中铺第一材料粉末，对所述第一材料粉末进行激光扫描，使得所述第一材料粉末融化并基于所述打印件模型逐层形成所述打印件以及接触于所述打印件一部分的下方的支撑件；在增材制造打印装置中通入氨气，在所述增材制造打印装置中的成型缸中铺第一材料粉末，对所述第一材料粉末进行激光扫描，使得所述第一材料粉末融化并基于所述支撑件模型形成所述支撑件上表面的氮化层。
进一步地，所述在增材制造打印装置中通入氨气的步骤还包括如下步骤：按照所述增材制造打印区域对氨气输入进行分区，仅针对所述支撑件的氮化层位于的分区在增材制造打印装置中通入第二气体。
进一步地，所述支撑件的密度小于所述打印件的密度。
进一步地，所述支撑件的非氮化层区域和所述打印件间隔设置。
进一步地，述增材制造方法还包括如下步骤：通过对支撑件的氮化层施加外力来从所述打印件上去除所述支撑件。
进一步地，所述去除步骤采用高能量震动制程或者喷砂打磨制程。
进一步地，所述第一气体为氮气或者氨气。
进一步地，所述氮化层的厚度取值范围为10微米到1000微米。
本发明提供的增材制造机制能够获得足够强度并且在增材制造完毕以后易于移除的支撑件，保证了良好的3D打印质量，并且造价低。本发明提供的氮化层具有足够高的接触区域，能够避免材料热变形，并且达到了良好的热传导性能。此外，本发明提供的增材制造机制和氮化支撑一起还包括表面硬化步骤，打印件具有高耐磨性要求。
附图说明
图1是执行3D打印时由于快速融化和固化过程而材料热变形的示意图；
图2是打印件和支撑件的连接示意图；
图3是根据本发明一个具体实施例的选择性激光熔化设备的示意图；
图4是根据本发明一个具体实施例的打印件和支撑件的结构示意图。
具体实施方式
以下结合附图，对本发明的具体实施方式进行说明。
本发明提供的增材制造机制能够获得足够强度并且在增材制造完毕以后易于移除的支撑件，并且不会对打印件和支撑件接触的表面造成影响，又能够改善所述支撑件由于残余应力带来的材料变形，移除支撑件以后的打印件仍然具有很高的表面质量。
优选地，本发明提供的增材制造机制是在选择性激光设备中执行的。图3是选择性激光熔化设备的示意图。如图3所示，选择性激光熔化设备100包括一个激光源110、一个镜面扫描器120、一个棱镜130、一个送粉缸140、一成型缸150和一个回收缸160。其中，激光源110设置于选择性激光融化设备100上方，充当金属粉末的加热源，即融化金属粉末来进行3D打印。
其中，送粉缸140下部有一个能够上下移动的第一活塞(未示出)，在送粉缸140的第一活塞上面的腔体空间放置了备用的金属粉末，并随着第一活 塞的上下移动从送粉缸140将金属粉末送入成型缸150。在成型缸150中设置有一个3D打印件放置台154，放置台154上方夹持有一个3D打印件，放置台154下方固定有一个第二活塞152,其中，第二活塞152和放置台154垂直设置。在3D打印过程中，第二活塞152自上而下移动，以在成型缸220中形成打印空间。激光扫描的激光源110应设置于选择性激光融化设备的成型缸150的上方，镜面扫描器120通过调整一个棱镜130的角度调整激光的位置，通过棱镜130的调节来决定激光融化哪个区域的金属粉末。送粉缸140还包括一个滚轮(未示出)，金属粉末堆设于第一活塞的上表面，第一活塞垂直地自下而上移动传递金属粉末至送粉缸140上部。滚轮可在金属粉末上滚动，以将金属粉末送至成型缸150中。从而持续对金属粉末执行激光扫描，将金属粉末分解为粉末基体，继续对所述粉末基体进行激光扫描直至使所述粉末基体自下而上地烧结为预设形状的打印件。
选择性激光熔化设备100还包括第一气体输入装置180，其通常位于选择性激光熔化设备100的顶部，其用于通入用于3D打印制程的惰性气体，因此惰性气体可以通过第一气体输入装置180扩散到整个成型缸150的打印区域。
此外，选择性激光熔化设备100还包括第二气体输入装置170，其位于所述选择性激光熔化设备100的侧面，用于面对所述成型缸150的侧面通入其他气体。在本实施例中，第二气体输入装置170通入的为氨气。其中，所述第二气体输入装置170包括多个出气口，每个出气口都具有一个控制其开关的阀门，即如图3所示第一阀门171、第二阀门172、第三阀门173、第四阀门174和第五阀门175以及扩散板176，扩散板176上具有多个喷嘴。上述多个阀门根据不同的区域控制了氨气的输出区域，按照这样的分区可以形成支撑件的氮化层。例如，当想要在成型缸150的边缘区域形成氮化层时，则打开第一阀门171和第五阀门175通入氨气并通过扩散板176上对应的喷嘴输入至成型缸150中；当想要在成型缸150的中间区域形成氮化层时，则打开第二阀门172和第四阀门174通入氨气并通过扩散板176上对应的喷嘴输入至成型缸150中；当想要在成型缸150的中间区域形成氮化层时，则打开第三阀门173通入氨气并通过扩散板176上对应的喷嘴输入至成型缸150中。
通常在激光融化过程中必须通入惰性气体，以避免可能的材料氧化。因此，本发明在整个过程中都需要在惰性气体环境中形成打印件和支撑件的主体，但是在形成支撑件的氮化层时则需要同时通入氨气，此时同时存在惰性 气体和局部的氨气。这样可以整体上保证3D环境的惰性气体，氨气只能局部和分区通入氨气，减少通入氨气对于整个打印腔体惰性气体环境的影响。
本发明第一方面提供了增材制造方法，其中，包括如下步骤。
首先执行步骤S1，基于打印件P 2模型的形状产生支撑件S 2模型，其中，所述支撑件S 2的至少一部分接触于所述打印件P 2至少一部分的下方，所述支撑件S 2接触于所述打印件P 2至少一部分的上表面具有一个氮化层200。其中，支撑件S 2通常设置在打印件P 2的下方或者打印件P 2的凹部下方，支撑件S 2可以具有很多或者整个呈锯齿状，打印件P 2和支撑件S 2至少部分接触，接触面是支撑件S 2的氮化层200。在没有氮化层200的部分，打印件P 2和支撑件S 2并不接触，例如支撑件S 2的左侧并不接触于打印件P 2，两者具有间隙g。
然后执行步骤S2和S2。
在步骤S2中，在选择性激光熔化设备100的第一气体输入装置180中持续通入惰性气体，在选择性激光熔化设备100中的成型缸150中铺第一材料粉末，对所述第一材料粉末进行激光扫描，使得所述第一材料粉末融化并基于所述打印件P 2模型逐层形成所述打印件P 2以及接触于所述打印件P 2一部分的下方的支撑件S 2。
在步骤S3中，在选择性激光熔化设备100的第二气体输入装置170中通入氨气，在选择性激光熔化设备100中的成型缸150中铺第一材料粉末，对所述第一材料粉末进行激光扫描，使得所述第一材料粉末融化并基于所述支撑件S 2模型形成所述支撑件S 2上表面的氮化层200。此时，氨气在激光的高温下分解为N和H原子，N原子和金属粉末形成了氮化层200，例如和铁或镍形成氮化物。
需要说明的是，步骤S2形成打印件P 2，步骤S3形成支撑件S 2，两者并无特定顺序。本发明可以先形成打印件P 2再形成支撑件S 2，也可以先形成支撑件S 2再形成打印件P 2，还可以同时形成打印件P 2和支撑件S 2。例如，如图4所示，打印件P 2和支撑件S 2的底部在一个平面上，并且在优选地打印件P 2和支撑件S 2的材料相同，所以两者同时按照从下朝上的顺序同时逐层形成。
优选地，所述在增材制造打印装置中通入氨气的步骤还包括如下步骤：按照所述增材制造打印区域对氨气输入进行分区，针对所述支撑件的氮化层位于的分区在增材制造打印装置中通入第二气体。其中，所述第二气体包括氨气或氮气，并且，通入氮气的实施方式需要更高的激光输入功率，为简明 起见，此处不再赘述。
具体地，额外的氨气NH 3会通过扩散流喷嘴输入到选择性激光熔化设备100中，每个喷嘴都对应了不同的控制阀门，以控制氨气输入到接近期望氮化区域，以更少地影响到整个增材制造打印环境。在打印过程中，氨气接近于选择性激光熔化设备100的成型缸150，并分解并和金属材料反应从而形成氮化物最终形成氮化层，例如氮化铁、氮化铝和氮化镍等。为了减少氨气在选择性激光熔化设备100中打印气体环境的影响，最接近氮化区域的氨气阀门会打开，并且仅仅是在打印件P 2和支撑件S 2的主要接触表面的氮化层200时。由于氮化过程在具有足够高的氨气分解温度时才会在成型缸150融化粉末的附近区域执行，剩余粉末和打印件P 2并不会被影响，以保证剩余部分的打印质量以及原料粉末的利用率。
氮化层200作为打印件P 2和支撑件S 2的接触区域会保证高接触区域和足够高的机械支撑力，以避免打印打印件S 2的过程中可能出现的材料热变形。此外，氮化层200相比较于原始金属主体来说具有良好的热传导性，这可以保证由支撑件S 2带来的良好热传导力和打印质量。
其中，本发明还可以控制和优化氮化层200的厚度来保证支撑件S 2的良好机械支撑力，并有利于后续移除步骤。
进一步地，所述支撑件的密度小于所述打印件的密度。其中，虽然打印件和支撑件都是用打印件的金属粉末制造的，但是可以通过调节材料密度来控制所述支撑件的密度小于所述打印件的密度，在保证支撑件强度的同时加以区分并避免浪费。
进一步地，所述支撑件的非氮化层区域和所述打印件间隔设置。所述打印件和支撑件的接触面仅仅为垂直方向上的氮化层，而大部分并没有设置氮化层的部分两者都保持不接触的状态，特别是大量侧面区域，这样可以方便将支撑件从所述打印件中去除。
进一步地，所述增材制造方法还包括如下步骤：通过对支撑件的氮化层施加外力来从所述打印件上去除所述支撑件。在利用选择性激光熔化设备100执行3D打印后，打印件P2会和支撑件S2一起执行热处理，以获得良好的晶格结构和高机械支撑力。由于不同材料之间的不同热膨胀效率，裂纹会在氮化层200及其接触的打印件P2金属材料之间发生。此外，氮化层200易碎，并具有相对于打印件P2金属材料的模量特性(modulus properties)。因此，氮 化层200作为和打印件P2的接触层能够轻易用人力或者利用其他处理技术破坏和去除，例如高能量震动或者喷砂打磨法。
所述氮化层的厚度取值范围为10微米到1000微米。其中，氮化层的具体厚度应当按照应用场景的具体工艺要求来设定。
本发明提供的增材制造机制能够获得足够强度并且在增材制造完毕以后易于移除的支撑件，保证了良好的3D打印质量，并且造价低。本发明提供的氮化层具有足够高的接触区域，能够避免材料热变形，并且达到了良好的热传导力。此外，本发明提供的增材制造机制和氮化支撑一起还包括表面硬化步骤，打印件具有高耐磨性要求。本发明和传统设计与制造方法相比，所述的增材特征单元几何具有高的强重比和表面积对质量比，能在最大化换热表面的同时减少壁厚，但可以依旧保持稳定的结构强度与刚性，从而达到减少零部件重量又提高整体换热性能的目标。
尽管本发明的内容已经通过上述优选实施例作了详细介绍，但应当认识到上述的描述不应被认为是对本发明的限制。在本领域技术人员阅读了上述内容后，对于本发明的多种修改和替代都将是显而易见的。因此，本发明的保护范围应由所附的权利要求来限定。此外，不应将权利要求中的任何附图标记视为限制所涉及的权利要求；“包括”一词不排除其它权利要求或说明书中未列出的装置或步骤；“第一”、“第二”等词语仅用来表示名称，而并不表示任何特定的顺序。

Claims (8)

  1. 增材制造方法，其中，包括如下步骤：
    基于打印件模型的形状产生支撑件模型，其中，所述支撑件的至少一部分接触于所述打印件至少一部分的下方，所述支撑件接触于所述打印件至少一部分的上表面具有一个氮化层；
    在增材制造打印装置中持续通入惰性气体，在所述增材制造打印装置中的成型缸中铺第一材料粉末，对所述第一材料粉末进行激光扫描，使得所述第一材料粉末融化并基于所述打印件模型逐层形成所述打印件以及接触于所述打印件一部分的下方的支撑件；
    在增材制造打印装置中通入氨气，在所述增材制造打印装置中的成型缸中铺第一材料粉末，对所述第一材料粉末进行激光扫描，使得所述第一材料粉末融化并基于所述支撑件模型形成所述支撑件上表面的氮化层。
  2. 根据权利要求1所述的增材制造方法，其特征在于，所述在增材制造打印装置中通入氨气的步骤还包括如下步骤：
    按照所述增材制造打印区域对氨气输入进行分区，针对所述支撑件的氮化层位于的分区在增材制造打印装置中通入第二气体。
  3. 根据权利要求1所述的增材制造方法，其特征在于，所述支撑件的密度小于所述打印件的密度。
  4. 根据权利要求1所述的增材制造方法，其特征在于，所述支撑件的非氮化层区域和所述打印件间隔设置。
  5. 根据权利要求4所述的增材制造方法，其特征在于，所述增材制造方法还包括如下步骤：
    通过对支撑件的氮化层施加外力来从所述打印件上去除所述支撑件。
  6. 根据权利要求5所述的增材制造方法，其特征在于，所述去除步骤采用高能量震动制程或者喷砂打磨制程。
  7. 根据权利要求1所述的增材制造方法，其特征在于，所述第二气体为氮气或者氨气。
  8. 根据权利要求1所述的增材制造方法，其特征在于，所述氮化层的厚度取值范围为10微米到1000微米。
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