CN111168067B - Pore prediction and control method based on laser directional energy deposition - Google Patents
Pore prediction and control method based on laser directional energy deposition Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- 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]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
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- 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
- B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- 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
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Abstract
The invention discloses a pore prediction and control method based on laser directional energy deposition, which comprises the following steps of establishing a computational fluid mechanics model; step two, establishing a control equation; simulating a plurality of initial multi-channel depositions according to a control equation; the laser power and the powder feeding speed of a plurality of initial multi-channel depositions are equal, the scanning speed is gradually reduced, and the inter-channel distance is gradually increased; step four, selecting the defective preliminary multi-channel deposition; step five, simulating a plurality of single-channel depositions; step six, observing the external appearance of each single-channel deposition, and setting the external appearance as a final scanning speed; and step seven, simulating the final multi-channel deposition according to a control equation, the laser power and the powder feeding rate of the primary multi-channel deposition, the maximum inter-channel distance of the primary multi-channel deposition with the defects and the final scanning rate. The invention provides a control method for obtaining deposition simulation without pore defects, and the control method has good reference significance for avoiding pore generation in specific engineering application.
Description
Technical Field
The invention belongs to the technical field of laser additive manufacturing and rapid forming, relates to a control method, and particularly relates to a pore prediction and control method based on laser directional energy deposition.
Background
With the continuous progress of scientific technology, the Additive Manufacturing technology has also been developed rapidly, and the Additive Manufacturing (AM) technology is a Manufacturing technology based on the "discrete-stacking" forming principle, which uses powder, wire rod, plate material and the like as raw materials, and stacks materials point by point layer by layer under the control of a computer system according to three-dimensional CAD model data, and can be made into more complex shapes without the need of molds or tools with specific properties and shapes, thus greatly shortening the research and development process of "design-trial-manufacture-production".
The laser directional energy deposition technology is a novel additive manufacturing technology developed based on rapid prototyping, and is mainly characterized in that a three-dimensional data model of a part is sliced and layered by using certain specific software, then metal powder synchronously sent out is melted layer by channel through a laser beam with higher energy, and a proper three-dimensional solid part is manufactured through the layer-by-layer melting and solidification process.
The laser directional energy deposition technology has many advantages, but because the laser directional energy deposition is a multi-physical-field and multi-scale process accompanied with various energy changes, the deposition morphology is difficult to predict, and defects such as cracks and pores are inevitably generated in the deposition process, the defects have great influence on the performance of finished products, and the development of the laser directional energy deposition technology is seriously restricted, so how to simulate and construct deposition without defects such as internal pores according to the defect deposition has important significance for the generation of actual laser directional energy deposition, and the research and development thereof.
Disclosure of Invention
The invention provides a pore prediction and control method based on laser directional energy deposition, which overcomes the defects of the prior art.
In order to achieve the aim, the invention provides a pore prediction and control method based on laser directional energy deposition, which comprises the following steps of establishing a computational fluid mechanics model; step two, establishing a control equation; simulating a plurality of initial multi-channel depositions according to a control equation; the input parameters of the preliminary multi-channel deposition comprise laser power, scanning speed, powder feeding speed and inter-channel distance; the laser power and the powder feeding rate of the plurality of initial multi-channel depositions are equal, the scanning speed of the plurality of initial multi-channel depositions is gradually reduced, and the distance between channels is gradually increased; selecting defective preliminary multi-channel deposition according to the external appearance and the profile of the preliminary multi-channel deposition; simulating a plurality of single-channel depositions according to a control equation, wherein the number of the single-channel depositions is equal to the number of the preliminary multi-channel depositions with defects screened in the step four, and the single-channel depositions correspond to one another one by one, and the laser power, the scanning speed and the powder feeding rate of the corresponding single-channel depositions are the same as the input parameters of the corresponding preliminary multi-channel depositions with defects; step six, observing the external appearance of each single-channel deposition, selecting single-channel depositions with stable deposition appearance, and setting the minimum scanning speed in the single-channel depositions as the final scanning speed; the stable deposition morphology means that the shape and the size of the melting channel along the scanning direction of the heat source are kept consistent and do not change correspondingly with the local position, and the contact angle between the melting channel and the metal substrate on the cross section is less than 90 degrees; and step seven, simulating the final multi-channel deposition according to a control equation, the laser power and the powder feeding rate of the primary multi-channel deposition, the maximum inter-channel distance of the primary multi-channel deposition with the defects and the final scanning speed, wherein the final multi-channel deposition is the defect-free multi-channel deposition.
In the first step, a computational fluid mechanics model is established, the size of deposition is set, grids are divided, the properties of the material are defined, and various parameters of the material are set.
In the second step, within the range of computational fluid dynamics, the flow of any object must obey the laws of conservation of momentum, conservation of mass and conservation of energy, so the establishment of the control equation comprises three aspects of establishment of an energy conservation equation, a conservation of mass equation and a conservation of momentum equation. The heat source used in the model is a Gaussian heat source, and besides, the initial condition and the boundary condition are set in terms of speed and temperature.
Further, the invention provides a pore prediction and control method based on laser directional energy deposition, which can also have the following characteristics: wherein, in step four, the preliminary multi-pass deposition has the appearance of defects on its external appearance as: and remelting regions are arranged between adjacent melting channels.
Further, the invention provides a pore prediction and control method based on laser directional energy deposition, which can also have the following characteristics: wherein, in step four, the preliminary multi-pass deposition has defects which are also represented on the external appearance as: the deposition of the melt channel along its deposition direction is not smooth. The uneven deposition means that the shape and the size of the melting channel along the scanning direction of the heat source cannot be kept consistent, but are correspondingly changed with the local position, and the contact angle between the melting channel and the metal substrate on the cross section is larger than 90 degrees.
Further, the invention provides a pore prediction and control method based on laser directional energy deposition, which can also have the following characteristics: wherein, in step four, the preliminary multi-pass deposition has the defect appearance on the cross section as follows: with unfused pores.
Further, the invention provides a pore prediction and control method based on laser directional energy deposition, which can also have the following characteristics: and in the fourth step, the longitudinal section of the lap joint of the adjacent melting channels is selected as the section of the primary multi-channel deposition.
The invention has the beneficial effects that: the invention provides a pore prediction and control method based on laser directional energy deposition, which is a prediction simulation model technology based on a laser directional energy deposition molten pool, and is a control method for obtaining deposition simulation and input parameters without pore defects through multiple times of simulation selection, wherein the simulation construction of the molten pool in a model through a control equation and the input parameters is the prior art and is not the protection content of the application.
The invention establishes a heat flow transmission model to predict the deposition morphology and the pore defects in the laser directional energy deposition process and effectively control the pore defects. Firstly, a great deal of research and analysis finds that in the process of multi-channel deposition, the occurrence of pore defects is closely related to the distance between the melt channels and the scanning speed, and pores mainly appear at the lap joint of the two melt channels, so that the pores can be eliminated by changing the distance between the melt channels and the scanning speed, and a control method capable of obtaining deposition simulation without the pore defects is provided, and the control method has good reference significance for avoiding the generation of the pores in specific engineering application.
Drawings
FIG. 1 is a deposition profile diagram of a preliminary multi-pass deposition with a laser power of 2000W, a scanning speed of 16.67mm/s, a powder feeding rate of 0.417g/s and an inter-pass distance of 1.5 mm;
FIG. 2 is a longitudinal sectional view of the preliminary multi-pass deposition at a laser power of 2000W, a scanning speed of 16.67mm/s, a powder feeding rate of 0.417g/s, and an inter-pass distance of 1.5 mm;
FIG. 3 is a deposition profile of a preliminary multi-pass deposition with a laser power of 2000W, a scanning speed of 4.2mm/s, a powder feeding rate of 0.417g/s, and an inter-pass distance of 3.75 mm;
FIG. 4 is a longitudinal sectional view of the preliminary multi-pass deposition at a laser power of 2000W, a scanning speed of 4.2mm/s, a powder feeding rate of 0.417g/s, and an inter-pass distance of 3.75 mm;
FIG. 5 is a deposition profile of a single pass deposition with a laser power of 2000W, a scan speed of 16.67mm/s, and a powder feed rate of 0.417 g/s;
FIG. 6 is a deposition profile of a single pass deposition with a laser power of 2000W, a scan speed of 4.2mm/s, and a powder feed rate of 0.417 g/s;
FIG. 7 is a deposition profile of a final multi-pass deposition with a laser power of 2000W, a scanning speed of 16.67mm/s, a powder feeding rate of 0.417g/s and an inter-pass distance of 3 mm;
FIG. 8 is a longitudinal sectional view of the final multi-pass deposition at a laser power of 2000W, a scanning speed of 16.67mm/s, a powder feeding rate of 0.417g/s, and an inter-pass distance of 3 mm.
Detailed Description
The following describes embodiments of the present invention with reference to the drawings.
The invention provides a pore prediction and control method based on laser directional energy deposition, which comprises the following steps:
step one, establishing a computational fluid mechanics model.
Establishing a computational fluid mechanics model, setting the size of deposition, dividing grids, defining the property of the material and setting various parameters of the material. The dimensions of the metal substrate of this model were 30mm x 20mm, the deposition dimensions of the single pass were 25mm, the mesh dimensions IN the deposition area were 0.2mm x 0.2mm, and the deposited metal material was IN718, the basic parameters of which are shown IN the following table.
TABLE-IN 718 Property parameters
And step two, establishing a control equation.
Within the scope of computational fluid dynamics, the flow of any one object must obey the laws of conservation of momentum, conservation of mass, and conservation of energy, so the establishment of the governing equation includes the establishment of the energy conservation equation, the conservation of mass equation, and the conservation of momentum equation.
Conservation of mass equation:
conservation of momentum equation:
energy conservation equation:
phase equation:
where p is the density of the material,
is the velocity vector, t is time, p is pressure, μ is dynamic viscosity,
in order to be a momentum source term,
is the Marangoni force, and is,
in order to be a surface tension force,
in order to be a buoyancy force,
damping force in the mushy zone, T is temperature, CpIs specific heat capacity, k is thermal conductivity, STIs an energy source term, QhIs surface heat, QlDue to heat convectionFlow, thermal radiation and energy lost to evaporation.
The heat source used for this model was a gaussian heat source:
wherein f is a distribution factor, eta is an absorption rate, P is laser power, r is a laser radius, (x)o，yo) Is the laser beam center coordinate.
The setting of the initial conditions and the boundary conditions includes both the temperature field and the velocity field.
In order to reasonably solve the temperature control equation, initial conditions are set according to the characteristics of the formation in the heat transfer process, wherein the set initial temperature is 298K, and the temperature boundary conditions are as follows:
T(x，y，z，0)＝T0(x，y，z) (6)
the speed boundary condition is set to 0 at each boundary.
Step three, simulating a plurality of initial multi-channel depositions according to the control equation and the input parameters established in the step two; the input parameters of the preliminary multi-channel deposition comprise laser power, scanning speed, powder feeding speed and inter-channel distance; the laser power and the powder feeding rate of the plurality of initial multi-channel depositions are equal, the scanning speed of the plurality of initial multi-channel depositions is gradually reduced, and the distance between channels is gradually increased.
This example simulates two preliminary multi-pass depositions, each having the input parameters shown in the table below.
TABLE II input parameters for preliminary multipass deposition
The prediction simulation of the deposition morphology and the position of the pore is shown in figures 1 and 2 when the laser power is 2000W, the scanning speed is 16.67mm/s, the powder feeding rate is 0.417g/s, and the inter-lane distance is 1.5mm, the deposition morphology under the parameters is shown in figure 1, the remelting area between each deposition lane is larger, the obvious poor lapping phenomenon occurs at the fifth lane, and the longitudinal section of the lapping part of the fourth lane and the fifth lane is observed, so that the obvious unfused pore can be seen as shown in figure 2.
The prediction simulation of the deposition morphology and the position of the pore is shown in figures 3 and 4 when the laser power is 2000W, the scanning speed is 4.2mm/s, the powder feeding rate is 0.417g/s, and the inter-channel distance is 3.75mm, the deposition morphology is shown in figure 3 under the parameters, the unstable deposition of the melting channel along the deposition direction can be observed, the shape and the size of the melting channel along the scanning direction of the heat source can not be consistent, but are correspondingly changed with the local position, specifically, a large bulge can appear in the initial stage of the deposition channel, then the bulge gradually reduces along the deposition direction, and finally the bulge tends to be stable. The two lanes have more reflow areas and, due to the larger contact angle of the lanes, it is speculated that void defects may occur at the lap of the lanes. The presence of porosity defects can be observed along a longitudinal section taken at the junction of two melt channels, as shown in fig. 4.
And step four, selecting the defective primary multi-channel deposition according to the external appearance and the profile of the primary multi-channel deposition.
As can be seen from the accompanying fig. 1-4 and the above analysis, both preliminary multipass depositions have defects, including their appearance as: a remelting area is arranged between adjacent melting channels, and the melting channels are not stably deposited along the deposition direction of the melting channels, wherein the instability means that the shapes and the sizes of the melting channels along the scanning direction of a heat source cannot be kept consistent, but the instability is correspondingly changed with the local positions, and the contact angle between the melting channels on the cross section and the metal substrate is larger than 90 degrees; and in its cross-section: with unfused pores.
And step five, simulating a plurality of single-channel depositions according to a control equation, wherein the number of the single-channel depositions is equal to the number of the preliminary multi-channel depositions with the defects screened out in the step four, and the single-channel depositions correspond to each other one by one, and the corresponding laser power, scanning speed and powder feeding rate of the single-channel depositions are the same as the input parameters of the corresponding preliminary multi-channel depositions with the defects.
Based on the two initial multi-channel depositions with defects, the same input parameters (laser power, scanning speed and powder feeding rate) are respectively taken to simulate the deposition appearances of the two corresponding single-channel depositions, data support is provided for the generation of pores in the multi-channel depositions by researching the variation trend of the deposition appearances in the laser directional energy deposition process, and the specific input parameters of the single-channel depositions are shown in the following table:
TABLE THREE SINGLE-PASS DEPOSITION BASE PARAMETERS
And sixthly, observing the external appearance of each single-channel deposition, selecting the single-channel deposition with the stable deposition appearance, and setting the minimum scanning speed in the single-channel depositions as the final scanning speed. The stable deposition morphology means that the shape and the size of the melting channel along the scanning direction of the heat source are kept consistent and do not change correspondingly with the local position, and the contact angle between the melting channel and the metal substrate on the cross section is smaller than 90 degrees.
The deposition profiles for the two single pass depositions are shown in figures 5 and 6. As shown in fig. 5, when the scanning speed is higher, the melt channel has smaller width and height, and the whole deposition profile is more stable. As shown in fig. 6, when the scanning speed is reduced, the deposition process becomes unstable, a large protrusion appears at the beginning of deposition, and then gradually stabilizes along the scanning direction, the height and width of the melt channel become large, and the melt channel and the substrate form an included angle larger than 90 °.
Only one of the two single pass depositions has a smooth deposition profile and therefore the minimum scan speed is the scan speed of that deposition, i.e. the final scan speed is 16.67 mm/s.
And step seven, simulating the final multi-channel deposition according to a control equation, the laser power and the powder feeding rate of the primary multi-channel deposition, the maximum inter-channel distance of the primary multi-channel deposition with the defects and the final scanning speed, wherein the final multi-channel deposition is the defect-free multi-channel deposition.
The final multi-pass deposition input is shown in the following table.
TABLE IV input parameters for final deposition of multiple passes
The predicted simulation of the deposition profile and the position of the pores at a laser power of 2000W, a scanning speed of 16.67mm/s, a powder feeding rate of 0.417g/s and an inter-track distance of 3mm is shown in FIGS. 7 and 8. The deposition profile under the parameters is shown in FIG. 7, and it can be seen that the deposition process of the melting channel is relatively stable, the shapes and the sizes of all the melting channels are similar, and the remelting parts among all the deposition channels are relatively small. The longitudinal section of the film is shown in FIG. 8, and no void was observed in the longitudinal section. It can be seen that the input parameters obtained by the above method can well control the generation of pores in multi-pass deposition during the laser directional energy deposition process.
Claims (4)
1. A pore prediction and control method based on laser directional energy deposition is characterized in that:
step one, establishing a computational fluid mechanics model;
step two, establishing a control equation;
simulating a plurality of initial multi-channel depositions according to a control equation;
the input parameters of the preliminary multi-channel deposition comprise laser power, scanning speed, powder feeding speed and inter-channel distance;
the laser power and the powder feeding rate of the plurality of initial multi-channel depositions are equal, the scanning speed of the plurality of initial multi-channel depositions is gradually reduced, and the distance between channels is gradually increased;
selecting defective preliminary multi-channel deposition according to the external appearance and the profile of the preliminary multi-channel deposition; the preliminary multi-pass deposition has the appearance of defects on its external appearance: a remelting area is arranged between the adjacent melting channels;
simulating a plurality of single-channel depositions according to a control equation, wherein the number of the single-channel depositions is equal to the number of the preliminary multi-channel depositions with defects screened in the step four, and the single-channel depositions correspond to one another one by one, and the laser power, the scanning speed and the powder feeding rate of the corresponding single-channel depositions are the same as the input parameters of the corresponding preliminary multi-channel depositions with defects;
step six, observing the external appearance of each single-channel deposition, selecting single-channel depositions with stable deposition appearance, and setting the minimum scanning speed in the single-channel depositions as the final scanning speed;
and step seven, simulating the final multi-channel deposition according to a control equation, the laser power and the powder feeding rate of the primary multi-channel deposition, the maximum inter-channel distance of the primary multi-channel deposition with the defect and the final scanning speed, wherein the final multi-channel deposition is the defect-free multi-channel deposition.
2. The method of claim 1, wherein the pore prediction and control method comprises:
wherein, in step four, the preliminary multi-pass deposition has defects which are also represented on the external appearance as: the deposition of the melt channel along its deposition direction is not smooth.
3. The method of claim 1, wherein the pore prediction and control method comprises:
wherein, in step four, the preliminary multi-pass deposition has the defect appearance on the cross section as follows: with unfused pores.
4. The method of claim 1, wherein the pore prediction and control method comprises:
and in the fourth step, the longitudinal section of the lap joint of the adjacent melting channels is selected as the section of the primary multi-channel deposition.
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