WO2016026415A1 - 一种多波长激光选区快速成形系统及方法 - Google Patents

一种多波长激光选区快速成形系统及方法 Download PDF

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WO2016026415A1
WO2016026415A1 PCT/CN2015/087237 CN2015087237W WO2016026415A1 WO 2016026415 A1 WO2016026415 A1 WO 2016026415A1 CN 2015087237 W CN2015087237 W CN 2015087237W WO 2016026415 A1 WO2016026415 A1 WO 2016026415A1
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laser
powder
wavelength
laser beam
wavelength laser
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English (en)
French (fr)
Inventor
段宣明
刘洁
曹洪忠
范树迁
郑美玲
刘基权
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Chongqing Institute of Green and Intelligent Technology of CAS
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Chongqing Institute of Green and Intelligent Technology of CAS
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Priority to JP2017510577A priority Critical patent/JP6483809B2/ja
Priority to EP15833051.4A priority patent/EP3184208A4/en
Publication of WO2016026415A1 publication Critical patent/WO2016026415A1/zh
Anticipated expiration legal-status Critical
Priority to US15/437,103 priority patent/US20170157850A1/en
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    • 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
    • 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
    • B22F10/70—Recycling
    • B22F10/73—Recycling of powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B22F12/10—Auxiliary heating means
    • B22F12/13—Auxiliary heating means to preheat the 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
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    • B22F12/40—Radiation means
    • B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B22F12/40—Radiation means
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • 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
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    • B23K26/0604—Shaping the laser beam, e.g. by masks or multi-focusing by a combination of beams
    • 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
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
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    • B23K26/064—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
    • B23K26/0648—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms comprising lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/082—Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • 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
    • B23K26/70—Auxiliary operations or equipment
    • B23K26/702—Auxiliary equipment
    • B23K26/705—Beam measuring devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
    • B28B17/0063—Control arrangements
    • B28B17/0081—Process control
    • 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
    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • C—CHEMISTRY; METALLURGY
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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Definitions

  • the invention relates to a laser 3D printing technology, in particular to a multi-wavelength laser selective area rapid prototyping system and method.
  • 3D printing technology adopts computer design digital model, and through computer intelligent control, the material is accumulated layer by layer, and finally realizes solid parts with three-dimensional complex structure. It is a typical digital manufacturing, green intelligent manufacturing technology, in aerospace, The defense industry, automotive, mold, consumer electronics, biomedical and other fields have broad application prospects.
  • Laser Selective Rapid Prototyping is a high precision 3D printing technology that can be used to manufacture precision, complex and small parts.
  • rapid prototyping of laser selection mainly relies on laser selective sintering and laser selective melting.
  • the laser energy source selected is generally a 10.6 ⁇ m CO2 laser and a fiber laser or solid laser of about 1.08 ⁇ m.
  • the material in the laser scanning area appears to have a rapid heat and a rapid cooling process, resulting in a large thermal stress in the manufacturing structure, which easily causes structural deformation or even chipping.
  • F.Abe et al. used a CO2 laser with a wavelength of 10.6 ⁇ m and a Nd:YAG laser with a wavelength of 1.064 ⁇ m during the laser selective melting of the metal structure.
  • the temperature reduction rate of the CO2 laser can reduce the thermal stress inside the structure, see F.Abe et al., Journal of Materials Processing Technology, 2001, 111, 210-213.
  • Shi Yusheng et al. proposed a method for rapid prototyping by three-beam laser composite scanning metal powder.
  • the invention uses a first laser beam with a wavelength greater than 10 ⁇ m to preheat, and a second laser beam with a wavelength less than 1.1 ⁇ m for melt forming, using a third beam.
  • the subsequent heat treatment of the laser with a wavelength greater than 10 ⁇ m accelerates the rate of laser forming and reduces the thermal stress of the structure.
  • Shi Yusheng et al. a three-beam laser composite scanning metal powder melting rapid prototyping method (Public No.: CN101607311A, publication date: December 23, 2009).
  • the method is to realize three-beam laser non-co-point scanning, and the program is cumbersome, and the three lasers sequentially scan to reduce the forming efficiency, and the heat is lost in different laser scanning intervals, and the energy utilization rate is low.
  • Jan Wilkes et al. used a CO2 laser to illuminate a forming area of 20 mm ⁇ 30 mm, and used a Nd:YAG laser to scan the forming area to realize laser selective melting to produce a ceramic structure. The results show that the preheating by CO2 laser can reduce the ceramic structure manufacturing.
  • an object of the present invention is to provide a high-precision, high-efficiency, high-performance coaxial multi-wavelength laser selective area rapid prototyping system and method.
  • the laser selective beam melting is performed by using a short-wavelength laser beam, and preheating and subsequent heat treatment are performed by using a long-wavelength laser superimposed thereon. From the interaction between light and matter, the short-wavelength laser beam has a small spot size and high photon energy, which is beneficial to improve the efficiency and forming precision of the forming process.
  • the long-wavelength laser beam has a large spot size and can guarantee short-wavelength laser.
  • the preheating and subsequent heat treatment before and after forming are completely nested, further improving the laser forming efficiency and reducing the thermal stress of the structure.
  • One of the objects of the present invention is to provide a multi-wavelength laser selective region rapid prototyping system, which is realized by the following technical solutions:
  • a multi-wavelength laser selective area rapid prototyping system comprising a laser light source, a laser transmission control component, a laser focus scanning component, a forming chamber, a powder feeding component, a powder discharging component, a gas circulation control component, a real-time monitoring component, a lifting component, and a powder recycling Components and computers,
  • the laser light source includes a first laser for supplying a laser beam of a first wavelength and a second laser for supplying a laser beam of a second wavelength, or a laser that simultaneously supplies a laser beam of a first wavelength and a laser beam of a second wavelength;
  • the laser focus scanning assembly includes a laser focusing mirror for respectively focusing a first wavelength laser beam and a second wavelength laser beam for superimposing the first wavelength laser beam and the second wavelength laser beam in the same direction a dichroic mirror that propagates a coaxially superimposed laser beam, and a two-dimensional galvanometer for scanning the laser in the forming plane;
  • the real-time monitoring component includes an imaging unit for monitoring the shape of the molten pool and a temperature monitoring unit for monitoring the temperature and temperature field distribution of the molten pool.
  • the first wavelength laser beam has a wavelength range of 200 nm to 1.1 ⁇ m
  • the second wavelength laser beam has a wavelength range of 700 nm to 10.6 ⁇ m
  • the first wavelength laser beam and the second wavelength laser beam are continuous and pulsed, respectively. Or quasi-continuous laser.
  • the laser transmission control component includes: a laser mirror for realizing deflection of the laser beam, and a laser beam expander for realizing beam expansion of the first wavelength and the second wavelength, respectively, for controlling the laser switch a laser shutter, and a laser attenuator for controlling the power of the first wavelength laser beam and the second wavelength laser beam, respectively.
  • the forming chamber includes a forming chamber door for workpiece removal, a viewing window for visual observation, a light passing window for real-time monitoring, a laser incident window for laser input, and a gas realization Circulation and atmosphere controlled gas flow ports.
  • a forming substrate is disposed in the forming chamber, and the forming substrate is connected to the lifting assembly for lifting movement of the forming substrate; the bottom of the forming chamber is further provided with a passage for recovering powder, and the passage is connected with powder recycling.
  • the imaging unit includes a CCD for image acquisition and a monitor for image presentation.
  • the temperature monitoring unit comprises an infrared camera for infrared thermal image acquisition and a data acquisition card for collecting and inputting the camera data into the computer.
  • a second object of the present invention is to provide a multi-wavelength laser selective region rapid prototyping method, which is realized by the following technical solutions:
  • the powder has a scale of 10 nm to 200 ⁇ m.
  • the powder to be formed includes metal powder, plastic powder, ceramic powder, coated sand powder, and polymer powder.
  • the system and method of the present invention which utilizes a short wavelength laser to shape a material to improve resolution and forming accuracy during forming;
  • the system and method of the present invention utilizes dual wavelength laser coaxial simultaneous scanning to improve forming efficiency during the forming process.
  • the system and method of the present invention utilizes a long-wavelength laser for preheating and subsequent heat treatment to reduce the thermal stress of the formed structure, and by selective preheating, does not cause damage to the unformed region material, and reduces the material.
  • the cost 3.
  • FIG. 1 is a schematic structural diagram of a system according to an embodiment of the present invention.
  • FIG. 2 is a second schematic structural diagram of a system according to an embodiment of the present invention.
  • FIG. 3 is a flow chart of a multi-wavelength laser selective region rapid prototyping method according to the present invention.
  • FIG. 4 is a schematic view of a laser spot formed by laser focusing in the present invention.
  • FIG. 1 is a schematic structural diagram of a system according to an embodiment of the present invention. As shown, the system includes: a first laser 1 on a first optical path and a laser transmission control component 3 thereof; and a second laser on a second optical path. 2 and its laser transmission control assembly 4; laser focus scanning assembly 5; forming substrate 6; powder feeding assembly 7; powder coating assembly 8; real-time monitoring assembly 9, lifting assembly 10; powder recovery assembly 11;
  • the first laser 1 and the second laser 2 are respectively used to provide laser beams of different wavelengths, and the lasers output by the first laser and the second laser are respectively controlled to be turned on and off by the laser transmission control components 3 and 4, and expanded, The laser power incident on the forming surface.
  • the laser focus scanning assembly 5 is configured to achieve separate focusing, superimposition, and scanning in the forming plane of the first wavelength laser beam and the second wavelength laser beam.
  • the bottom of the forming chamber is provided with a forming substrate 6 , and a funnel-shaped powder feeding assembly 7 is arranged above for powder conveying and pretreatment; and a powder discharging assembly 8 is disposed below the corresponding powder feeding assembly.
  • the powder assembly is used to lay the powder onto the shaped substrate.
  • the real-time monitoring component 9 includes an imaging unit for monitoring the shape of the molten pool and a temperature monitoring unit for monitoring the temperature and temperature field distribution of the molten pool, the imaging unit including a CCD for image acquisition and for image presentation.
  • the monitor, temperature monitoring unit includes an infrared camera for infrared thermal image acquisition and a data acquisition card for collecting and inputting the camera data into a computer.
  • the forming substrate 6 is connected to the lifting assembly 10, and the lifting and lowering unit 10 realizes the lifting movement of the forming substrate 6.
  • the bottom of the forming chamber is also provided with a passage for recovering powder, and the passage port is connected with a powder recovery assembly 11 for recovering unformed powder.
  • the computer 12 is connected to the laser transmission control components 3 and 4, the laser focus scanning assembly 5, the forming substrate 6, the powder feeding assembly 7, the powder discharging assembly 8, the real-time monitoring component 9, the lifting assembly 10, and the powder recycling assembly 11, In the process of controlling the laser opening and closing of the forming process, laser power, focus focal length change, scanning speed, forming substrate lifting, powder feeding, powdering, molten pool image and temperature data collection, powder recovery.
  • the system includes: a laser 1 for providing a first wavelength laser beam and a second wavelength laser beam for realizing two wavelength laser beams a separate dichroic mirror, a mirror for deflecting light, a laser transmission control assembly 3 and 4 of a first wavelength laser beam and a second wavelength laser beam; a laser focus scanning assembly 5; a forming substrate 6; a powder feeding assembly 7 a powder spreading assembly 8; a real-time monitoring assembly 9; a lifting assembly 10; a powder recovery assembly 11;
  • the first wavelength laser beam and the second wavelength laser beam output by the laser are controlled to be turned on and off by the laser transmission control units 3 and 4, and the laser power of the forming surface is expanded and incident.
  • the laser focus scanning assembly 5 is configured to achieve separate focusing, superimposition, and scanning in the forming plane of the first wavelength laser beam and the second wavelength laser beam.
  • the bottom of the forming chamber is provided with a forming substrate 6 , and a funnel-shaped powder feeding assembly 7 is arranged above for powder conveying and pretreatment; and a powder discharging assembly 8 is disposed below the corresponding powder feeding assembly.
  • the powder assembly is used to lay the powder onto the shaped substrate.
  • the real-time monitoring component 9 includes an imaging unit for monitoring the shape of the molten pool and a temperature monitoring unit for monitoring the temperature and temperature field distribution of the molten pool, the imaging unit including a CCD for image acquisition and for image presentation.
  • the monitor, temperature monitoring unit includes an infrared camera for infrared thermal image acquisition and a data acquisition card for collecting and inputting the camera data into a computer.
  • the forming substrate 6 is connected to the lifting assembly 10, and the lifting and lowering unit 10 realizes the lifting movement of the forming substrate 6.
  • the bottom of the forming chamber is also provided with a passage for recovering powder, and the passage port is connected with a powder recovery assembly 11 for recovering unformed powder.
  • the computer 12 is connected to the laser transmission control components 3 and 4, the laser focus scanning assembly 5, the forming substrate 6, the powder feeding assembly 7, the powder discharging assembly 8, the real-time monitoring component 9, the lifting assembly 10, and the powder recycling assembly 11, In the process of controlling the laser opening and closing of the forming process, laser power, focus focal length change, scanning speed, forming substrate lifting, powder feeding, powdering, molten pool image and temperature data collection, powder recovery.
  • FIG. 3 is a flow chart of a multi-wavelength laser selective region rapid prototyping method according to the present invention. As shown in the figure, the method includes the following steps:
  • the powder scale is from 10 nm to 200 ⁇ m.
  • the powder to be formed includes metal powder, plastic powder, ceramic powder, coated sand powder, and polymer powder.
  • FIG. 4 is a schematic view of a laser spot formed by laser focusing of the present invention.
  • a laser spot 13 formed on a forming surface of a first wavelength laser beam having a wavelength of 200 nm to 1.1 ⁇ m
  • a laser spot 14 formed on a forming surface by a second wavelength laser beam having a wavelength of 700 nm to 10.6 ⁇ m
  • the second wavelength laser beam is coaxially illuminated into the forming surface and is focused within the forming surface.
  • the laser spot 13 of the first wavelength laser beam having a wavelength of 200 nm to 1.1 ⁇ m on the forming surface is smaller than the laser spot 14 of the second wavelength laser beam at the forming surface of the wavelength of 700 nm to 10.6 ⁇ m, and is superimposed thereon and surrounded by the laser spot 14 of the forming surface.
  • the laser spot 14 of the second wavelength laser beam having a wavelength of 700 nm to 10.6 ⁇ m on the forming surface enables preheating and subsequent heat treatment for the powder, and is formed in the superimposed region together with the first wavelength laser beam having a wavelength of 200 nm to 1.1 ⁇ m.
  • the surface causes the powder to melt and form.
  • the ZrO2-Al2O3 ceramic powder selected is a nearly spherical powder having a particle diameter of 30-60 ⁇ m.
  • the ceramic structure for forming is first designed, and the data is sliced, layered, and the scan path is planned.
  • the forming chamber is then evacuated.
  • the pretreatment and powder feeding of the powder were carried out by means of a powder feeding device, and the ceramic powder to be formed was laid on the forming substrate 6 by the powder spreading unit 8, and the thickness of the laid single-layer ceramic powder was 60 ⁇ m.
  • the laser beam output by the 532 nm green laser is selected as the first wavelength laser beam, and the laser power is 50-150 W.
  • the 10.6 ⁇ m laser beam outputted by the CO2 laser is selected as the second wavelength laser beam, and the laser power is 100-400 W.
  • the coated powder to be formed is simultaneously scanned by the focused first wavelength laser beam and the second wavelength laser beam at a scanning speed of about 200-400 mm/s, so that the powder melts to form a single layer structure.
  • the morphology of the molten pool and the distribution of its temperature field during the forming process are monitored by a real-time monitoring component.
  • the forming substrate 6 is lowered by 60 ⁇ m by the lifting assembly 10, the powder coating and the selective laser scanning process are repeated until the melt forming of the design structure is completed; the upper surface of the forming substrate 6 is raised by the lifting assembly 10 to the preset position before forming, and the cleaning is performed. The unmelted ceramic powder is taken out of the formed structure.
  • the present invention will be described in detail by taking the multi-wavelength laser selective region rapid shaping of titanium alloy as an example with reference to FIGS. 2 and 3.
  • the titanium alloy powder selected is a nearly spherical powder having a particle diameter of 20 to 30 ⁇ m.
  • the titanium alloy structure used for forming is designed, and the data is sliced, layered, and the scanning path is planned.
  • the forming chamber is then evacuated and filled with argon as a shielding gas.
  • the pretreatment and powder feeding of the powder are realized by the powder feeding assembly, and the titanium alloy powder to be formed is laid on the forming substrate 6 by the powder discharging assembly 8, and the thickness of the single layer titanium alloy powder to be laid is 50 ⁇ m;
  • the 532 nm green laser beam output by the laser is used as the first wavelength laser beam, and the laser power is 30-50 W;
  • the 1064 nm near-infrared laser beam output from the laser is selected as the second wavelength laser beam, and the laser power is 150-200 W.
  • the coated powder to be formed is simultaneously scanned by the focused first wavelength laser beam and the second wavelength laser beam at a scanning speed of about 300-400 mm/s, so that the powder melts to form a single layer structure.
  • the morphology of the molten pool and the distribution of its temperature field during the forming process are monitored by a real-time monitoring component.
  • the forming substrate 6 is lowered by 50 ⁇ m by the lifting assembly 10, the powder coating and the selective laser scanning process are repeated until the melt forming of the design structure is completed; the upper surface of the forming substrate 6 is raised by the lifting assembly 10 to the preset position before forming, and the cleaning is performed. The unmelted metal powder is taken out of the formed structure.

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Abstract

公开了一种多波长激光选区快速成形系统，包括：激光光源、激光传输控制组件（3，4）、激光聚焦扫描组件（5）、成形腔室、送粉组件（7）、铺粉组件（8）、气体循环控制组件、实时监测组件（9）、升降组件（10）、粉末回收组件（11）和计算机（12），激光光源包括用于提供第一波长激光束的第一激光器（1）和用于提供第二波长激光束的第二激光器（2），或者同时提供第一波长激光束和第二波长激光束的激光器。该系统采用短波长激光束，有利于提高成形过程的效率和成形精度，同时叠加采用长波长激光束，保证了成形前后的预热和后续的热处理，进一步提高成形效率并减少结构的热应力。还公开了一种多波长激光选区快速成形方法。

Description

一种多波长激光选区快速成形系统及方法 技术领域
本发明涉及激光3D打印技术，具体涉及一种多波长激光选区快速成形系统与方法。
背景技术
3D打印技术采用计算机设计数字化模型，并通过计算机智能控制，将材料逐层累加成型，最终实现具有三维复杂结构的实体零部件，是一项典型的数字化制造、绿色智能制造技术，在航空航天、国防军工、汽车、模具、消费电子、生物医学等领域具有广泛的应用前景。
激光选区快速成形技术是一种高精度的3D打印技术，可以用于精密、复杂和小型零件的制造。目前，激光选区快速成形主要依赖激光选区烧结和激光选区熔化两种技术来实现。其所选择的激光能量源一般为10.6μm的CO2激光和1.08μm左右的光纤激光或固体激光。在快速成形制造过程中，激光扫描区域内材料出现快热和快冷过程，导致制造结构内存在较大的热应力，容易造成结构变形甚至碎裂。通过在成形腔内加入加热和保温措施能够提高成形激光能量的利用率，并减小结构内部的热应力，但是容易对成形区域外的粉末造成破坏，使得材料无法重复利用，增加结构成形成本。为了在不对成形区域外的材料造成破坏的同时减少结构内部的热应力，F.Abe等在激光选区熔化制造金属结构过程中利用波长为10.6μm的CO2激光和波长为1.064μm的Nd:YAG激光，通过调节两束激光在成形面内的距离证明Nd:YAG激光成形过后，利用CO2激光的加热减少其温度的降低速率可以降低结构内部的热应力，参见F.Abe等，Journal ofMaterials Processing Technology，2001，111，210-213。史玉升等提出了利用三束激光复合扫描金属粉末熔化快速成形的方法，该发明利用第一束波长大于10μm的激光预热，利用第二束波长小于1.1μm的激光进行熔化成形，利用第三束波长大于10μm的激光进行后续的热处理，加快了激光成形的速率，并降低了结构热应力，参见史玉升等，一种三束激光复合扫描金属粉末熔化快速成形方法(公开号：CN101607311A，公开日期：2009年12月23日)。但是该方法要实现三束激光先后非共点扫描，程序繁琐，而且三束激光先后扫描会降低成形效率，不同激光扫描间隔内热量存在散失，能量利用率低。JanWilkes等利用CO2激光照射面积为20mm×30mm的成形区域，利用Nd：YAG激光在成形区域内扫描实现激光选区熔化制造了陶瓷结构，结果表明通过CO2激光的预热能够很好的减少陶瓷结构制造过程中的热应力，参见JanWilkes等，Rapid Prototyping Journal，2013，19，51-57。该方法需要大的CO2激光光斑保持长时间照射成形区域，需要激光功率较高，激光的能量利用低，而且会造成照射区域的材料的浪费。因此，迫切需要发展新的技术，在减少成形结构热应力的同时，提高 成形效率和成形精度、并且减少对未成形区域材料的破坏。
发明内容
有鉴于此，本发明的目的在于提供一种高精度、高效率、高性能的共轴多波长激光选区快速成形系统与方法。利用短波长的激光束进行激光选区熔化成形，利用与之共轴叠加的长波长激光器进行预热和后续的热处理。从光与物质相互作用来看，短波长激光束的聚焦光斑尺寸小、光子能量高，有利于提高成形过程的效率和成形精度，长波长激光束的聚焦光斑尺寸大，能够保证将短波长激光完全嵌套在内实现成形前后的预热和后续的热处理，进一步提高激光成形效率并减少结构的热应力。
本发明的目的之一在于提出一种多波长激光选区快速成形系统，且通过下述的技术方案实现：
一种多波长激光选区快速成形系统，包括激光光源、激光传输控制组件、激光聚焦扫描组件、成形腔室、送粉组件、铺粉组件、气体循环控制组件、实时监测组件、升降组件、粉末回收组件和计算机，
所述的激光光源包括用于提供第一波长激光束的第一激光器和用于提供第二波长激光束的第二激光器，或者同时提供第一波长激光束和第二波长激光束的激光器；
所述的激光聚焦扫描组件包括分别用于实现对第一波长激光束和第二波长激光束聚焦的激光聚焦镜，用于将第一波长激光束和第二波长激光束叠加为沿着同一方向传播的共轴叠加激光束的二向色镜，以及用于实现激光在成形平面扫描的二维振镜；
所述的实时监测组件包括用于监测成形熔池形貌的成像单元和用于监测熔池温度及温度场分布的温度监测单元。
进一步的，所述第一波长激光束的波长范围为200nm-1.1μm，第二波长激光束的波长范围为700nm-10.6μm；且第一波长激光束和第二波长激光束分别为连续、脉冲或准连续激光。
进一步的，所述的激光传输控制组件包括：用于实现激光束偏折的激光反射镜，用于分别实现第一波长和第二波长激光束扩束的激光扩束镜，用于控制激光开关的激光光闸，和用于分别控制第一波长激光束和第二波长激光束功率的激光衰减器。
进一步的，所述的成形腔室包括用于工件取出的成形腔室门，用于目视观察的观察窗口，用于实时监测的通光窗口，用于激光输入的激光入射窗口，以及实现气体循环和气氛控制的气体流通口。
进一步的，所述成形腔室内设置成形基板，所述成形基板与升降组件连接，用于成形基板的升降运动；所述成形腔室底部还设置有用于回收粉末的通道，通道口连接有粉末回收组件。
进一步的，所述的成像单元包括用于图像采集的CCD以及用于图像呈现的监视器。
进一步的，所述的温度监测单元包括用于红外热图像采集的红外热像仪以及对热像仪数据进行采集并输入计算机的数据采集卡。
本发明的目的之二在于提出一种多波长激光选区快速成形方法，且通过下述的技术方案实现：
1)利用计算机作图软件建立几何模型，并对数据进行切片、分层，规划扫描路径；
2)对成形腔室进行抽真空，根据需要充入保护气体；
3)利用送粉装置实现粉末的预处理和送粉，利用铺粉装置在成形基板上铺覆待成形粉末；
4)利用聚焦的第一波长激光束和第二波长激光束同时扫描铺覆的待成形粉末，使得粉末熔化形成单层结构；
5)将成形基板降低一层，重复粉末铺覆和选择性激光扫描过程，完成设计几何模型结构的熔化成形；
6)清理未熔化的金属粉末，取出已成形结构。
进一步的，所述的粉末尺度为10nm-200μm。
进一步的，所述的待成形粉末包括金属粉末、塑料粉末、陶瓷粉末、覆膜砂粉末、聚合物粉末。
本发明的有益技术效果是：
1、本发明的系统和方法，利用短波长激光对材料进行成形，提高了成形过程中的分辨率和成形精度；
2、本发明的系统和方法，利用双波长激光共轴同时扫描，提高了成形过程中的成形效率。
3、本发明的系统和方法，利用长波长激光进行预热和后续的热处理，减小了成形结构的热应力，并且通过选择性的预热，不对未成形区域材料造成破坏，减小了材料的耗费。
本发明的其它优点、目标和特征在某种程度上将在随后的说明书中进行阐述，并且在某种程度上，基于对下文的考察研究对本领域技术人员而言将是显而易见的，或者可以从本发明的实践中得到教导。
附图说明
为了使本发明的目的、技术方案和优点更加清楚，下面将结合附图对本发明作进一步的 详细描述，其中：
图1为本发明的实施方式系统结构示意图之一；
图2为本发明的实施方式系统结构示意图之二；
图3为本发明的一种多波长激光选区快速成形方法的流程图；
图4为本发明中激光聚焦形成的激光光斑示意图；
图中：1-第一激光器；2-第二激光器；3-激光传输控制组件；4-激光传输控制组件；5-激光聚焦扫描组件；6-成形基板；7-送粉组件；8-铺粉组件；9-实时监测组件；10-升降组件；11-粉末回收组件；12-计算机。
具体实施方式
以下是本发明优选实施例的详细描述，应当理解，优选实施例仅为了说明本发明，而不是为了限制本发明的保护范围。
图1为本发明的实施方式系统结构示意图之一，如图所示，该系统包括：位于第一光路上的第一激光器1及其激光传输控制组件3；位于第二光路上的第二激光器2和及其激光传输控制组件4；激光聚焦扫描组件5；成形基板6；送粉组件7；铺粉组件8；实时监测组件9；升降组件10；粉末回收组件11；计算机12。
第一激光器1和第二激光器2，分别用于提供不同波长的激光束，且第一激光器和第二激光器所输出的激光各通过激光传输控制组件3和4控制其开启和关闭，扩束、入射成形面的激光功率。
所述的激光聚焦扫描组件5用于实现第一波长激光束和第二波长激光束的分别聚焦，叠加，和在成形面内扫描。
所述的成形腔室底部设置有成形基板6，上方设置有漏斗状的送粉组件7，用于将实现粉末输送和预处理；送粉组件对应的下方设置有铺粉组件8，所述铺粉组件用于将粉末铺覆到成形基板上。
所述的实时监测组件9包括用于监测成形熔池形貌的成像单元和用于监测熔池温度及温度场分布的温度监测单元，成像单元包括用于图像采集的CCD以及用于图像呈现的监视器，温度监测单元包括用于红外热图像采集的红外热像仪以及对热像仪数据进行采集并输入计算机的数据采集卡。
所述的成形基板6与升降组件10连接，通过升降组件10实现成形基板6升降运动。
所述的成形腔室底部还设置有用于回收粉末的通道，通道口连接有粉末回收组件11，用于回收未成形的粉末。
所述的计算机12与激光传输控制组件3和4、激光聚焦扫描组件5、成形基板6、送粉组件7、铺粉组件8；实时监测组件9、升降组件10、粉末回收组件11相连，用于控制成形过程的激光开启与关闭，激光功率，聚焦焦距改变，扫描速度、成形基板升降、送粉、铺粉、熔池图像及温度数据采集，粉末回收。
图2为为本发明的实施方式系统结构示意图之二，如图所示，该系统包括：用于提供第一波长激光束和第二波长激光束的激光器1，用于实现两个波长激光束分离的二向色镜，用于光线偏折的反射镜，第一波长激光束和第二波长激光束的激光传输控制组件3和4；激光聚焦扫描组件5；成形基板6；送粉组件7；铺粉组件8；实时监测组件9；升降组件10；粉末回收组件11；计算机12。
激光器输出的第一波长激光束和第二波长激光束各通过激光传输控制组件3和4控制其开启和关闭，扩束、入射成形面的激光功率。
所述的激光聚焦扫描组件5用于实现第一波长激光束和第二波长激光束的分别聚焦，叠加，和在成形面内扫描。
所述的成形腔室底部设置有成形基板6，上方设置有漏斗状的送粉组件7，用于将实现粉末输送和预处理；送粉组件对应的下方设置有铺粉组件8，所述铺粉组件用于将粉末铺覆到成形基板上。
所述的实时监测组件9包括用于监测成形熔池形貌的成像单元和用于监测熔池温度及温度场分布的温度监测单元，成像单元包括用于图像采集的CCD以及用于图像呈现的监视器，温度监测单元包括用于红外热图像采集的红外热像仪以及对热像仪数据进行采集并输入计算机的数据采集卡。
所述的成形基板6与升降组件10连接，通过升降组件10实现成形基板6升降运动。
所述的成形腔室底部还设置有用于回收粉末的通道，通道口连接有粉末回收组件11，用于回收未成形的粉末。
所述的计算机12与激光传输控制组件3和4、激光聚焦扫描组件5、成形基板6、送粉组件7、铺粉组件8；实时监测组件9、升降组件10、粉末回收组件11相连，用于控制成形过程的激光开启与关闭，激光功率，聚焦焦距改变，扫描速度、成形基板升降、送粉、铺粉、熔池图像及温度数据采集，粉末回收。
图3为本发明的一种多波长激光选区快速成形方法的流程图，如图所示，该方法包括以下步骤：
1)利用计算机作图软件建立几何模型，并对数据进行切片、分层，规划扫描路径；
2)对成形腔室进行抽真空，根据需要充入保护气体；
3)利用送粉装置实现粉末的预处理和送粉，利用铺粉装置在成形基板上铺覆待成形粉末；
4)利用聚焦的第一波长激光束和第二波长激光束同时扫描铺覆的待成形粉末，使得粉末熔化形成单层结构；
5)将成形基板降低一层，重复粉末铺覆和选择性激光扫描过程，完成设计几何模型结构的熔化成形；
6)清理未熔化的金属粉末，取出已成形结构。
所述的粉末尺度为10nm-200μm。
所述的待成形粉末包括金属粉末、塑料粉末、陶瓷粉末、覆膜砂粉末、聚合物粉末。
图4为本发明激光聚焦形成的激光光斑示意图。波长为200nm-1.1μm的第一波长激光束在成形面上形成的激光光斑13，波长为700nm-10.6μm的第二波长激光束在成形面上形成的激光光斑14，第一波长激光束和第二波长激光束共轴照射到成形面内，并且在成形面内聚焦。波长为200nm-1.1μm的第一波长激光束在成形面的激光光斑13小于波长700nm-10.6μm的第二波长激光束在成形面的激光光斑14，与其产生叠加并且被其环绕。波长700nm-10.6μm的第二波长激光束在成形面的激光光斑14能够实现对于粉末的预热和后续的热处理，并且在叠加区域共同与波长为200nm-1.1μm的第一波长激光束在成形面引起粉末熔化成形。
实施例1
以下结合图1和图3，以ZrO2-Al2O3陶瓷的多波长激光选区快速成形为例对本发明进行详细的说明。选用的ZrO2-Al2O3陶瓷粉末为粒径在30-60μm的近球形的粉末。
首先设计用于成形的陶瓷结构，并对数据进行切片、分层，规划扫描路径。然后对成形腔室进行抽真空。利用送粉装置实现粉末的预处理和送粉，利用铺粉组件8在成形基板6上铺覆待成形陶瓷粉末，铺覆的单层陶瓷粉末的厚度为60μm。选择532nm的绿光激光器输出的激光束为第一波长激光束，激光功率为50-150W；选择选择CO2激光器输出的10.6μm的激光束为第二波长激光束，激光功率为100-400W。利用聚焦的第一波长激光束和第二波长激光束同时扫描铺覆的待成形粉末，扫描速度约为200-400mm/s，使得粉末熔化形成单层结构。通过实时监测组件监测成形过程中熔池的形貌及其温度场的分布。
通过升降组件10将成形基板6降低60μm，重复粉末铺覆和选择性激光扫描过程，直至完成设计结构的熔化成形；利用升降组件10将成形基板6上表面提高至进行成形前预设位置，清理未熔化的陶瓷粉末，取出已成形结构。
实施例2
以下结合图2和图3，以钛合金的多波长激光选区快速成形为例对本发明进行详细的说明。选用的钛合金粉末为粒径在20-30μm的近球形的粉末。
首先设计用于成形的钛合金结构，并对数据进行切片、分层，规划扫描路径。然后对成形腔室进行抽真空，充入氩气作为保护气体。利用送粉组件实现粉末的预处理和送粉，利用铺粉组件8在成形基板6上铺覆待成形钛合金粉末，铺覆的单层钛合金粉末的厚度为50μm；如图2所示选择激光器输出的532nm的绿光激光束作为第一波长激光束，激光功率为30-50W；选择激光器输出的1064nm的近红外激光束作为第二波长激光束，激光功率为150-200W。利用聚焦的第一波长激光束和第二波长激光束同时扫描铺覆的待成形粉末，扫描速度约为300-400mm/s，使得粉末熔化形成单层结构。通过实时监测组件监测成形过程中熔池的形貌及其温度场的分布。
通过升降组件10将成形基板6降低50μm，重复粉末铺覆和选择性激光扫描过程，直至完成设计结构的熔化成形；利用升降组件10将成形基板6上表面提高至进行成形前预设位置，清理未熔化的金属粉末，取出已成形结构。
最后说明的是，以上优选实施例仅用以说明本发明的技术方案而非限制，尽管通过上述优选实施例已经对本发明进行了详细的描述，但本领域技术人员应当理解，可以在形式上和细节上对其做出各种各样的改变，而不偏离本发明权利要求书所限定的范围。

Claims (10)

  1. 一种多波长激光选区快速成形系统，包括激光光源、激光传输控制组件、激光聚焦扫描组件、成形腔室、送粉组件、铺粉组件、气体循环控制组件、实时监测组件、升降组件、粉末回收组件和计算机，其特征在于：
    所述的激光光源包括用于提供第一波长激光束的第一激光器和用于提供第二波长激光束的第二激光器，或者同时提供第一波长激光束和第二波长激光束的激光器；
    所述的激光聚焦扫描组件包括分别用于实现对第一波长激光束和第二波长激光束聚焦的激光聚焦镜，用于将第一波长激光束和第二波长激光束叠加为沿着同一方向传播的共轴叠加激光束的二向色镜，以及用于实现激光在成形平面扫描的二维振镜；
    所述的实时监测组件包括用于监测成形熔池形貌的成像单元和用于监测熔池温度及温度场分布的温度监测单元。
  2. 根据权利要求1所述的一种多波长激光选区快速成形系统，其特征在于：所述第一波长激光束的波长范围为200nm-1.1μm，第二波长激光束的波长范围为700nm-10.6μm；且第一波长激光束和第二波长激光束分别为连续、脉冲或准连续激光。
  3. 根据权利要求1所述的一种多波长激光选区快速成形系统，其特征在于，所述的激光传输控制组件包括：用于实现激光束偏折的激光反射镜，用于分别实现第一波长和第二波长激光束扩束的激光扩束镜，用于控制激光开关的激光光闸，和用于分别控制第一波长激光束和第二波长激光束功率的激光衰减器。
  4. 根据权利要求1所述的一种多波长激光选区快速成形系统，其特征在于，所述的成形腔室包括用于工件取出的成形腔室门，用于目视观察的观察窗口，用于实时监测的通光窗口，用于激光输入的激光入射窗口，以及实现气体循环和气氛控制的气体流通口。
  5. 根据权利要求4所述的一种多波长激光选区快速成形系统，其特征在于：所述成形腔室内设置成形基板，所述成形基板与升降组件连接，用于成形基板的升降运动；所述成形腔室底部还设置有用于回收粉末的通道，通道口连接有粉末回收组件。
  6. 根据权利要求1所述的一种多波长激光选区快速成形系统，其特征在于，所述的成像单元包括用于图像采集的CCD以及用于图像呈现的监视器。
  7. 根据权利要求1所述的一种多波长激光选区快速成形系统，其特征在于，所述的温度监测单元包括用于红外热图像采集的红外热像仪以及对热像仪数据进行采集并输入计算机的数据采集卡。
  8. 一种多波长激光选区快速成形方法，其特征在于：包括以下步骤：
    1)利用计算机作图软件建立几何模型，并对数据进行切片、分层，规划扫描路径；
    2)对成形腔室进行抽真空，根据需要充入保护气体；
    3)利用送粉装置实现粉末的预处理和送粉，利用铺粉装置在成形基板上铺覆待成形粉末；
    4)利用聚焦的第一波长激光束和第二波长激光束同时扫描铺覆的待成形粉末，使得粉末熔化形成单层结构；
    5)将成形基板降低一层，重复粉末铺覆和选择性激光扫描过程，完成设计几何模型结构的熔化成形；
    6)清理未熔化的金属粉末，取出已成形结构。
  9. 根据权利要求8所述的一种多波长激光选区快速成形方法，其特征在于，所述的粉末尺度为10nm-200μm。
  10. 根据权利要求8所述的一种多波长激光选区快速成形方法，其特征在于，所述的待成形粉末包括金属粉末、塑料粉末、陶瓷粉末、覆膜砂粉末、聚合物粉末。
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