CN104404509A - Metal laser melting additive manufacturing method - Google Patents

Metal laser melting additive manufacturing method Download PDF

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Publication number
CN104404509A
CN104404509A CN201410701194.8A CN201410701194A CN104404509A CN 104404509 A CN104404509 A CN 104404509A CN 201410701194 A CN201410701194 A CN 201410701194A CN 104404509 A CN104404509 A CN 104404509A
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laser
metal
stirring
head
fsp
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CN104404509B (en
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李瑞迪
袁铁锤
邱子力
苏文俊
钟楠骞
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Central South University
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Central South University
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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
    • 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
    • B22F10/60—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
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
    • 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
    • B22F10/36—Process control of energy beam parameters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
    • 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

Abstract

The invention discloses a metal laser melting additive manufacturing method. After each layer is machined by utilizing the laser additive manufacturing method, a single-layer laser photocoagulation area is modified by utilizing a selective friction stir welding, photocoagulation cracks are eliminated and nanocrystalline is formed. Each additive-manufactured layer is subjected to laser melting and friction stir welding and multiple layers are machined by the method repeatedly, so that nanocrystalline complex metal components with high strength and ductility and no cracks are manufactured. The laser melting additive manufacturing method provided by the invention comprises a selective laser melting technique based on powder bed formation and a laser engineering near-net forming technique based on laser coaxial powder feeding, wherein the involved metal materials comprise an aluminum base, a copper base, a titanium base, an iron base, a nickel base and a cobalt base; the selective friction stir welding can eliminate cracks, balling and holes generated during laser additive manufacturing and improves the formation quality; the selective friction stir welding can crush network carbides in a laser photocoagulation structure, so that the crushed network carbides are distributed in a dispersion manner, and the structure is regulated to be the nanocrystalline.

Description

A kind of metal laser melting increasing material manufacture method
Technical field
The invention belongs to and increase material and manufacture field, be specifically related to successively laser fusion and increase material manufacture and constituency agitating friction compounding technology, the manufacture of flawless, nanocrystalline, high-toughness metal component can be realized.
Background technology
Laser fusion increases material manufacturing technology, and printing also known as laser fusion 3D, is development in recent years a kind of advanced manufacturing technology faster.It is by high energy laser beam successively deposite metal powder that the laser fusion of metal parts increases material manufacturing technology, and then realizes the manufacture of metal parts complicated arbitrarily, but still there is following technical bottleneck:
The first, because laser gain material manufacturing processed has the feature such as fast hot rapid cooling, high-gradient Re-Li-stream multi-scenarios method, cause there is higher thermal stresses in laser gain material finished parts, form crackle.When tensile stress is greater than the tensile strength of cladding layer, easily produce stress concentration at the place such as pore, At A Flat Inclusion Tip, thus form crackle.Crackle is the defect of a kind of extensive existence in laser gain material manufacture and even field of laser processing.Produce for crackle, Chinese scholars have studied stress field and the crackle mechanism of production of laser melting process from theoretical modeling, experimental observation, fabric analysis isogonism, proposes the method for minimizing crackle: the preheating of (1) powder bed; (2) interpolation alloying element, netted foil carry out toughness reinforcing and plasticising; (3) ultrasonic vibration.Above method decreases stress concentration and tearing tendency to a certain extent, serves active effect for advancing the development of laser processing.But because laser molten pool process of setting is extremely complicated, above-mentioned resistance cracking method still exists certain limitation: first, and above method is difficult to eliminate tiny crack completely, particularly for Ni-based, the contour crack-sensitivity material of cobalt-based; Secondly, above method is difficult to have general applicability.
The second, the brittle ceramic phase in iron-based, Ni-based and cobalt base alloy laser gain material manufacture tissue is (as M 7c 3, M 23c 6) easily with continuous net-shaped structure distribution around matrix grain, greatly reduce the obdurability that laser gain material manufactures.Although the existence of ceramic phase can put forward hardness and the wear resistance of laser gain material finished parts greatly, but metal grain is isolated from each other and comes by the ceramic phase of these network-like distributions, largely reducing intercrystalline bonding force, laser gain material finished parts overall performance is caused to show as fragility, when laser gain material finished parts are on active service under external load function, stress is difficult to transmit, and then crack initiation and workpiece can be caused to lose efficacy.But, not yet there is the removing method of this carbide network of literature research.Although thermal treatment can reduce carbide content and segregation to a certain extent, be difficult to the continuous net-shaped distribution changing thick-layer carbide completely, on the other hand, thermal treatment cannot eliminate micro-crack.
3rd, laser gain material manufactures forming process and also easily produces nodularization and hole, greatly affect the mechanical property that laser gain material manufactures forming effect and drip molding, remain the major defect of laser gain material finished parts, become the bottleneck problem that forming laser increases material manufacturing technology, affect laser gain material and manufacture toward the application of high-performance metal part.
The above analysis, the tiny crack existing for common laser gain material finished parts, ceramic phase net distribution, nodularization, pore problem are provided with obstacle on this technology way forward.Although Chinese scholars was carried out studying for the problems referred to above and achieved positive progress, synchronously realized the elimination of laser gain material finished parts crackle, ceramic phase Dispersed precipitate, organized the method for nanometer so far not yet by complete grasp.
Mixing yoghurt (Friction Stir Processing, FSP) be a kind of novel by surface plastic deformation to improve the method for tissue, by the stirring-head of movement and workpiece severe friction, workpiece surface temperature is raised rapidly, metal plastifies, mixing needle stirs skin-material makes it produce plastic flow and mixing, and the shaft shoulder also applies forging effect the transmission of materials of being stirred distortion by mixing needle on rear side of stirring-head simultaneously.Because the material in FSP processing district creates severe plastic deformation, mixing, fragmentation and beat exposure, thus the grain refining of metallic substance microtexture can be realized, nanometer, crackle eliminate.This working method and laser fusion increase the combination of material manufacturing technology does not also have relevant report at present.
Summary of the invention
The object of the invention is: for metallurgical imperfections such as above laser gain material manufacturing processed crackle, carbide network distribution, nodularization, holes, consider the advantage of constituency FSP technology in tissue modification, the present invention is by the course of processing of the every one deck in laser gain material manufacture, introduce the modification of FSP constituency, every one deck laser photocoagulation tissue is made to experience gross distortion, realization organizes nanometer, crackle to eliminate, thus prepares the tough flawless complicated metallic element of nanocrystalline height.
The complicated metal parts of the strong flawless of nanocrystalline high-ductility provided by the invention increases material manufacture method, comprises the steps:
(1) metal laser melting increasing material manufactures individual layer processing: according to required metal parts shape, adopts 3D sculpting software to design the three-dimensional CAD model of part, the data message of file is transported to laser gain material manufacturing equipment; According to current slice layer information, increase material manufacturing technology by laser gain material and scanning fusing is carried out to slicing layer region, pass into protection of inert gas molten bath simultaneously.
(2) agitating friction individual layer processing: after laser scanning, adopt the flat shaft shoulder stirring-head of high speed rotating immediately, constituency mixing yoghurt is carried out to the region of laser fusion, by regulation and control FSP rotating speed and gait of march, FSP viscous deformation layer thickness is made to be greater than the individual layer thickness of laser gain material manufacture, thus all crackles in laser individual layer district are made up, carbide network dispersion, organizes nanometer.After mixing yoghurt, change stirring-head into milling cutter, a small amount of overlap that FSP is formed is excised, makes machined layer smooth.
(3) worktable declines a slice thickness distance, repeats (1), (2), until whole part forming is complete; Formation of parts is taken out from metal substrate, aftertreatment is carried out to formation of parts, the tough flawless metal parts of the nanocrystalline height of required complicated shape can be obtained.
In the present invention, laser fusion increases material manufactured materials and comprises: aluminium base, copper base, titanium base, iron-based, Ni-based, cobalt-based pure metal and alloy.
Laser power is adopted to be more than or equal to the semiconductor pumped YAG laser of 100W, optical fiber laser or CO 2laser apparatus carries out scanning fusing to monolayer slices region.Wherein, the method that metal laser increases material manufacture comprises following two kinds: (a) precinct laser fusion (Selective Laser Melting, SLM), powder feeding mechanism tiles the metal-powder that one deck is about 0.05 ~ 0.15mm thickness, particle diameter is 10-100 μm on metallic substrates, the concrete kind of metal-powder by metal parts material determine; (b) laser near-net-shape (Laser Engineering Net Shaping, LENS), by coaxial powder feeding device, by laser, metal-powder, protection gas simultaneously by being input on base material, this method is different from SLM, and SLM is by paving powder, forms powder bed; And the powder of LENS is sent into by powder feeder.Powder sending quantity 10 ~ the 150g/min of LENS, thickness 0.1 ~ 1mm.
In the processing of step (2) agitating friction individual layer, stirring-head shaft shoulder diameter 1 ~ 10mm, rotating speed 300 ~ 1500rpm, gait of march 100 ~ 1000mm/min, FSP volume under pressure 0.01 ~ 0.03mm.
The stirring-head material selection principle of mixing yoghurt is that hardness and hot strength are greater than material to be processed.If laser gain material manufactured materials is soft metal and the alloy such as aluminium, copper base, stirring-head adopts the materials such as tool steel; If laser gain material manufactured materials is the high hardness materials such as titanium, iron, nickel, cobalt, stirring-head adopts WC-Co hard alloy or cube BN material.
Laser gain material manufacture increases material manufacture method in conjunction with constituency agitating friction and has the following advantages:
(1) constituency agitating friction laser gain material manufacture can be produced crackle, nodularization, hole eliminate, improve forming quality;
(2) carbide network in laser photocoagulation tissue can be broken for Dispersed precipitate by constituency agitating friction, and tissue is adjusted to nanocrystalline;
(3) this nanocrystalline, carbide dispersion distribution, flawless metallic element have higher-strength, toughness, hardness and fatigue property.
Accompanying drawing explanation
Fig. 1 is the schematic diagram that the every one deck of the present invention manufactures;
Fig. 2 is the schematic diagram that the every one deck manufacture of the present invention has stirring-head movement locus.
Below in conjunction with the drawings and specific embodiments, the invention will be further described.
Embodiment
embodiment 1:
(1) for the shaping of high-performance 316L Stainless Steel Alloy part, 3D sculpting software is adopted to design the three-dimensional CAD model of part, then save as stl file after being treated to by Slice Software, the data message of stl file is transported to laser gain material and manufactures Quick-forming equipment; Adopt SLM to process current slice layer, powder feeding mechanism tiles the 316L powder of stainless steel that one deck is about 0.05mm thickness, particle diameter is 10 μm on metallic substrates, fibre laser power 200W; In Fig. 1,1 is laser beam; 2 represent laser beam walking path; 3 is multi-layer body.
(2) SLM is to after current slice layer completion of processing, selects cube BN material as stirring-head 4, carries out mixing yoghurt line by line to laser fusion region.Wherein rotate shaft shoulder diameter 2mm, rotating speed 500rpm, gait of march 500mm/min, FSP volume under pressure 0.01mm, FSP deformation layer thickness 0.2mm, makes FSP deformation layer thickness be greater than laser thickness in monolayer.After mixing yoghurt, change stirring-head 4 into milling cutter, a small amount of overlap that FSP rear surface is formed is excised, makes machined layer smooth; In Fig. 2,4 is stirring-head; 5 represent stirring-head walking path.
(3) worktable declines a slice thickness 0.05mm, repeats (1), (2), until whole part forming is complete; Formation of parts is taken out from Linear cut metal substrate, the nanocrystalline height of required complicated shape tough flawless 316L stainless steel metal part can be obtained.
embodiment 2:
(1) for the shaping of high-performance cobalt-based Co-27Cr-5Mo-0.5Ti alloy part, 3D sculpting software is adopted to design the three-dimensional CAD model of part, then save as stl file after being treated to by Slice Software, the data message of stl file is transported to laser gain material and manufactures Quick-forming equipment; Adopting LENS to process current slice layer, making the YAG laser of 500W, 50g/min Co-based alloy powder, Ar gas simultaneously by being input on base material, thickness 0.15mm;
(2) LENS is to after current slice layer completion of processing, selects cube BN material as stirring-head 4, carries out mixing yoghurt line by line to LENS region.Wherein rotate shaft shoulder diameter 2mm, rotating speed 500rpm, gait of march 500mm/min, FSP volume under pressure 0.01mm, FSP deformation layer thickness 0.3mm, ensure that FSP deformation layer thickness is greater than laser thickness in monolayer; After mixing yoghurt, change stirring-head into milling cutter, a small amount of overlap that FSP is formed is excised, makes machined layer smooth;
(3) laser head promotes a slice thickness 0.15mm, repeats (1), (2), until whole part forming is complete; Formation of parts is taken out from Linear cut metal substrate, the nanocrystalline height of required complicated shape tough flawless cobalt base alloy part can be obtained.
embodiment 3:
(1) for the shaping of high-performance Al-Si alloy part, 3D sculpting software is adopted to design the three-dimensional CAD model of part, then save as stl file after being treated to by Slice Software, the data message of stl file is transported to laser gain material and manufactures Quick-forming equipment; Adopt SLM technology to process current slice layer, powder feeding mechanism tiles the Al-Si powdered alloy that one deck is about 0.05mm thickness, particle diameter is 20 μm on metallic substrates, fibre laser power 150W;
(2) SLM is to after current slice layer completion of processing, selects tool steel as stirring-head 4, carries out mixing yoghurt line by line to laser fusion region.Wherein rotate shaft shoulder diameter 1mm, rotating speed 1000rpm, gait of march 800mm/min, FSP volume under pressure 0.01mm, FSP deformation layer thickness 0.2mm, ensure that FSP deformation layer thickness is greater than laser thickness in monolayer; After mixing yoghurt, change stirring-head into milling cutter, a small amount of overlap that FSP rear surface is formed is excised, makes machined layer smooth;
(3) worktable declines a slice thickness 0.05mm, repeats (1), (2), until whole part forming is complete, can obtain the nanocrystalline height of required complicated shape tough flawless Al-Si part.
embodiment 4:
(1) for the shaping of high performance Ti 6Al4V alloy part, 3D sculpting software is adopted to design the three-dimensional CAD model of part, then save as stl file after being treated to by Slice Software, the data message of stl file is transported to laser gain material and manufactures Quick-forming equipment; Adopt SLM technology to process current slice layer, powder feeding mechanism tiles the Ti6Al4V powdered alloy that one deck is about 0.05mm thickness, particle diameter is 20 μm on metallic substrates, fibre laser power 200W;
(2) SLM is to after current slice layer completion of processing, selects tool steel as stirring-head 4, carries out mixing yoghurt line by line to laser fusion region.Wherein rotate shaft shoulder diameter 1mm, rotating speed 1000rpm, gait of march 500mm/min, FSP volume under pressure 0.01mm, FSP deformation layer thickness 0.2mm, ensure that FSP deformation layer thickness is greater than laser thickness in monolayer; After mixing yoghurt, change stirring-head into milling cutter, a small amount of overlap that FSP rear surface is formed is excised, makes machined layer smooth;
(3) worktable declines a slice thickness 0.05mm, repeats (1), (2), until whole part forming is complete, can obtain the nanocrystalline height of required complicated shape tough flawless Ti6Al4V part.
embodiment 5:
(1) for the shaping of the Ni-based GH4169 alloy part of high-performance, 3D sculpting software is adopted to design the three-dimensional CAD model of part, then save as stl file after being treated to by Slice Software, the data message of stl file is transported to laser gain material and manufactures Quick-forming equipment; Adopting LENS to process current slice layer, making the YAG laser of 500W, 50g/min GH4169 powdered alloy, Ar gas simultaneously by being input on base material, thickness 0.15mm;
(2) LENS is to after current slice layer completion of processing, selects cube BN material as stirring-head 4, carries out mixing yoghurt line by line to LENS region.Wherein rotate shaft shoulder diameter 2mm, rotating speed 600rpm, gait of march 600mm/min, FSP volume under pressure 0.01mm, FSP deformation layer thickness 0.25mm, ensure that FSP deformation layer thickness is greater than laser thickness in monolayer; After mixing yoghurt, change stirring-head into milling cutter, a small amount of overlap that FSP is formed is excised, makes machined layer smooth;
(3) laser head promotes a slice thickness 0.15mm, repeats (1), (2), until whole part forming is complete, can obtain the Ni-based GH4169 alloy part of the tough flawless of the nanocrystalline height of required complicated shape.

Claims (4)

1. a metal laser melting increasing material manufacture method, is characterized in that comprising the steps:
(1) metal laser melting increasing material manufactures individual layer processing: according to required metal parts shape, adopts 3D sculpting software to design the three-dimensional CAD model of part, the data message of file is transported to laser gain material manufacturing equipment; According to current slice layer information, increase material manufacture method by laser gain material and scanning fusing is carried out to slicing layer region, pass into protection of inert gas molten bath simultaneously;
(2) agitating friction individual layer processing: after laser scanning, adopt the flat shaft shoulder stirring-head of high speed rotating immediately, constituency mixing yoghurt is carried out to the region of laser fusion, by regulation and control FSP rotating speed and gait of march, FSP viscous deformation layer thickness is made to be greater than the individual layer thickness of laser gain material manufacture, thus all crackles in laser individual layer district are made up, carbide network dispersion, organizes nanometer; After mixing yoghurt, change stirring-head into milling cutter, a small amount of overlap that FSP is formed is excised, makes machined layer smooth;
(3) worktable declines a slice thickness distance, repeats (1), (2), until whole part forming is complete; Formation of parts is taken out from metal substrate, aftertreatment is carried out to formation of parts, obtain the required tough flawless metal parts of the nanocrystalline height of complicated shape.
2. metal laser melting increasing material manufacture method as claimed in claim 1, is characterized in that: described laser fusion increases material manufactured materials and comprises aluminium base, copper base, titanium base, iron-based, Ni-based, cobalt-based pure metal and alloy.
3. metal laser melting increasing material manufacture method as claimed in claim 1, it is characterized in that: the stirring-head material selection principle of mixing yoghurt is that hardness and hot strength are greater than material to be processed, if laser gain material manufactured materials is aluminium, copper base soft metal and alloy, stirring-head adopts tool steel material; If laser gain material manufactured materials is titanium, iron, nickel, cobalt high hardness material, stirring-head adopts WC-Co hard alloy or cube BN material.
4. metal laser melting increasing material manufacture method as claimed in claim 1, it is characterized in that: in the processing of step (2) agitating friction individual layer, stirring-head shaft shoulder diameter is 1 ~ 10mm, and rotating speed is 300 ~ 1500rpm, gait of march is 100 ~ 1000mm/min, FSP is volume under pressure 0.01 ~ 0.03mm.
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