CN113814412A - Crack control method in selective laser melting process of high-strength aluminum alloy component - Google Patents
Crack control method in selective laser melting process of high-strength aluminum alloy component Download PDFInfo
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- CN113814412A CN113814412A CN202111101793.2A CN202111101793A CN113814412A CN 113814412 A CN113814412 A CN 113814412A CN 202111101793 A CN202111101793 A CN 202111101793A CN 113814412 A CN113814412 A CN 113814412A
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- 238000000034 method Methods 0.000 title claims abstract description 53
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 26
- 238000010309 melting process Methods 0.000 title claims abstract description 12
- 238000005245 sintering Methods 0.000 claims abstract description 31
- 239000000843 powder Substances 0.000 claims abstract description 15
- 238000002844 melting Methods 0.000 claims abstract description 11
- 230000008018 melting Effects 0.000 claims abstract description 11
- 238000010438 heat treatment Methods 0.000 claims abstract description 10
- 238000000149 argon plasma sintering Methods 0.000 claims abstract description 9
- 238000011049 filling Methods 0.000 claims abstract description 4
- 238000005457 optimization Methods 0.000 claims abstract description 4
- 239000002994 raw material Substances 0.000 claims abstract description 4
- 238000001035 drying Methods 0.000 claims abstract description 3
- 239000000463 material Substances 0.000 claims description 8
- 238000007639 printing Methods 0.000 claims description 7
- 238000002360 preparation method Methods 0.000 claims description 4
- 238000009740 moulding (composite fabrication) Methods 0.000 claims description 2
- 238000006243 chemical reaction Methods 0.000 abstract 1
- 238000010146 3D printing Methods 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 239000000956 alloy Substances 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000013386 optimize process Methods 0.000 description 2
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 238000007669 thermal treatment Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
- B22F10/364—Process control of energy beam parameters for post-heating, e.g. remelting
-
- 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
- B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
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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
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/64—Treatment of workpieces or articles after build-up by thermal means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
-
- 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
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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- 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 relates to a crack control method in the selective laser melting process of a high-strength aluminum alloy component, which comprises the following steps of S1, drying raw materials before selective laser melting and forming; s2, importing the digital-to-analog conversion format into software, layering the slices according to the minimum layer thickness of 0.01mm, keeping the original three-dimensional coordinate unchanged, and continuously importing the slice files for 2-3 times; s3, adopting a time optimization filling mode, continuously scanning to complete the sintering of the next local area after the local area is completed, adopting a checkerboard laser sintering scanning strategy, adopting a mode of preferentially sintering the part close to the air suction inlet, finishing each layer of sintering, and rotating the whole laser sintering surface by 67 degrees after the powder is spread again; s4, sintering and forming each layer of printed patterns by adopting 2-3 different process parameters, and sintering for 2-3 times layer by layer respectively; and S5, performing heat treatment on the printed and molded component. According to the invention, through the optimized forming process setting, the high-quality crack-free high-strength aluminum alloy component can be prepared.
Description
Technical Field
The invention relates to the field of selective laser melting, in particular to a crack control method in a selective laser melting process of a high-strength aluminum alloy component.
Background
With the rapid development of aerospace military equipment, higher requirements are put forward on the development of new materials and new processes. As one of important materials for metal 3D printing, aluminum alloy has been considered as a "sunward material" because of a series of excellent characteristics such as light density, good elasticity, and high specific stiffness and specific strength. The method is widely applied to the fields of war industry, aerospace, automobile manufacturing and the like, has good development prospect, and is combined with 3D printing to enable the printing paper to burst new vitality. The selective laser melting technology is a processing technology with the widest application prospect in the field of 3D printing. The technology can directly form the blank by only a selective laser melting device without using other auxiliary devices. The problems of low yield, long production period, complicated working procedures and the like of the traditional preparation process are solved.
Compared with titanium alloy, iron-based alloy and nickel-based alloy, 3D printing research and application of aluminum alloy are developed rapidly in the last decade. At present, the tensile strength of the aluminum alloy for 3D printing exceeds 540MPa, and the yield strength reaches more than 520 MPa. Along with the continuous improvement of tensile strength, the internal stress is continuously increased, and cracks are easily generated in the material in the selective laser melting forming process. When a high-strength aluminum alloy component is produced, if cracks exist in the high-strength aluminum alloy component, the fatigue performance is seriously reduced, and potential safety hazards exist when the high-strength aluminum alloy component is used. Therefore, it is very necessary to solve the problem of cracks occurring in the 3D printing process of the high-strength aluminum alloy.
Disclosure of Invention
The invention aims to provide a crack control method in a selective laser melting process of a high-strength aluminum alloy component, and the method is used for preparing a high-quality crack-free high-strength aluminum alloy component from the viewpoint of process optimization.
The invention realizes the purpose through the following technical scheme: a crack control method in a selective laser melting process of a high-strength aluminum alloy component comprises the following steps:
s1, material preparation: before selective laser melting and forming, drying the raw materials to reduce the moisture content in the powder;
s2, model processing: converting a digital-to-analog mode into an STL format in UG NX software, then importing the digital-to-analog mode into Magics software, performing subsequent file repair, placement, support and slice data processing, layering slice thicknesses according to the minimum layer thickness of 0.01mm, and continuously importing 2-3 times of slice files while keeping original three-dimensional coordinates unchanged when importing parameter editing software;
s3, setting a laser scanning strategy: adopting a time optimization filling mode, continuously scanning to complete the sintering of the next local area after the local area is completed, adopting a scanning strategy of checkered laser sintering, adopting a mode of preferentially sintering the part close to the air suction inlet, finishing each layer of sintering, and paving the powder again to ensure that the rotation angle of the whole laser sintering surface is 67 degrees;
s4, setting process parameters: sintering and forming each layer of printing pattern by adopting 2-3 different process parameters, and sintering for 2-3 times layer by layer respectively;
s5, heat treatment: and carrying out heat treatment on the printed and formed member.
Further, the powder in the S1 is heated to 60-80 ℃ in a vacuum environment, and the temperature is kept for 6-12 hours.
Further, the S4 sets 3 different process parameters for each layer, and when sintering a certain layer of the printed pattern,
a) firstly, adopting A-type process parameters, wherein the laser power is 100-;
b) sintering the layer by B-type process parameters, wherein the laser power is 350-;
c) sintering with C-type process parameters, with a laser power of 100-300W and a scanning speed of 2000-4000 mm/s.
Further, the heat treatment temperature of S5 is 300-360 ℃, the temperature is kept for 3-9 hours, and air cooling is carried out.
Compared with the prior art, the crack control method in the selective laser melting process of the high-strength aluminum alloy component has the beneficial effects that: through the optimized forming process setting, the high-quality crack-free high-strength aluminum alloy component can be prepared. Each layer is sintered by 3 types of process parameters, and although the forming efficiency is reduced, an optimized process scheme of selective laser melting forming without cracks of the high-strength aluminum alloy component is provided for aerospace key parts.
Drawings
FIG. 1 is a flow chart of a sintering process using 3 different process parameters for each layer of printed pattern.
Detailed Description
A crack control method in a selective laser melting process of a high-strength aluminum alloy component comprises the following steps:
s1, material preparation: before the selective laser melting and forming, the raw materials are dried to reduce the moisture content in the powder, the powder is heated to 60-80 ℃ in a vacuum environment, and the temperature is kept for 6-12 hours. The impurity proportion of O element and H element is increased when the moisture content in the powder is too high, and the risk of generating internal cracks of the high-strength aluminum alloy material is aggravated when the moisture content in the powder is too high.
S2, model processing: and converting the digital analogy into an STL format in UG NX software, and then importing the digital analogy into Magics software for subsequent data processing such as file repair, placement, support, slicing and the like. It is worth noting that the slice thickness is layered according to the minimum layer thickness of 0.01mm, when the parameter editing software is imported, the original three-dimensional coordinate is kept unchanged, and the slice file is continuously imported for 2-3 times, so that when the subsequent laser selective melting forming is carried out, the printing pattern of each layer can be sintered and formed by 2-3 different process parameters.
S3, setting a laser scanning strategy: in order to improve the printing forming efficiency and reduce the laser beam idle running path during the printing forming of the component, a time-optimized filling mode is adopted, a next local area is sintered after the local area is continuously scanned, and a checkerboard laser sintering scanning strategy is adopted, so that the internal stress can be effectively reduced, and the generation of cracks can be favorably controlled. During laser sintering, the sputtered metal steam condensate can fall on a flat metal powder bed along the wind direction, and the mode of preferentially sintering the part close to the air suction opening is adopted, so that the phenomenon of poor fusion inside the part caused by remelting the metal condensate can be avoided. After each layer is sintered, the rotation angle of the whole laser sintering surface is 67 degrees after the powder is spread again, the complete overlapping of the upper sintering layer and the lower sintering layer is avoided as far as possible, the anisotropy is reduced, and the generation of cracks is controlled to a certain extent.
S4, setting process parameters: in the model processing stage, the slicing file is imported into parameter editing software, the original three-dimensional coordinates are kept unchanged, and the slicing file is continuously imported for 2-3 times, so that each layer of printed patterns can be sintered and formed by adopting 2-3 different process parameters and sintered for 2-3 times layer by layer.
Taking 3 different process parameters for each layer as an example, when sintering a certain layer of the printed pattern,
a) firstly, adopting A-type process parameters which are characterized by high laser scanning speed and low energy density, and aiming at slightly sintering and fixing the layer of powder at the original position with the laser power of 100-;
b) and sintering the layer by B-type process parameters, wherein the process parameters are characterized by high laser power and high energy density, and the purpose is to sinter the layer into an internally compact entity, wherein the laser power is 350-. Because the powder is fixed at the original position by the A-type process parameters, a plurality of molten pools can not be aggregated when the B-type process parameters are sintered;
c) and C-type process parameter sintering is carried out, wherein the process parameters are characterized by high laser scanning speed and low energy density, the layer is subjected to rapid thermal treatment to release the internal stress of the material, the effect of reducing the generation of cracks is achieved, the laser power is 100-300W, and the scanning speed is 2000-4000 mm/s. The process parameter sintering can avoid the generation of internal cracks caused by the rapid temperature drop after the B-type parameter sintering.
S5, heat treatment: and carrying out heat treatment on the printed and formed component at the temperature of 300-360 ℃, preserving heat for 3-9 hours, and cooling by air.
According to the invention, through the optimized forming process setting, the high-quality crack-free high-strength aluminum alloy component can be prepared. Each layer is sintered by 3 types of process parameters, and although the forming efficiency is reduced, an optimized process scheme of selective laser melting forming without cracks of the high-strength aluminum alloy component is provided for aerospace key parts.
While there have been shown and described what are at present considered the fundamental principles and essential features of the invention and its advantages, it will be apparent to those skilled in the art that the invention is not limited to the details of the foregoing exemplary embodiments, but is capable of other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.
Claims (4)
1. A crack control method in a selective laser melting process of a high-strength aluminum alloy component is characterized by comprising the following steps:
s1, material preparation: before selective laser melting and forming, drying the raw materials to reduce the moisture content in the powder;
s2, model processing: converting a digital-to-analog mode into an STL format in UG NX software, then importing the digital-to-analog mode into Magics software, performing subsequent file repair, placement, support and slice data processing, layering slice thicknesses according to the minimum layer thickness of 0.01mm, and continuously importing 2-3 times of slice files while keeping original three-dimensional coordinates unchanged when importing parameter editing software;
s3, setting a laser scanning strategy: adopting a time optimization filling mode, continuously scanning to complete the sintering of the next local area after the local area is completed, adopting a scanning strategy of checkered laser sintering, adopting a mode of preferentially sintering the part close to the air suction inlet, finishing each layer of sintering, and paving the powder again to ensure that the rotation angle of the whole laser sintering surface is 67 degrees;
s4, setting process parameters: sintering and forming each layer of printing pattern by adopting 2-3 different process parameters, and sintering for 2-3 times layer by layer respectively;
s5, heat treatment: and carrying out heat treatment on the printed and formed member.
2. The method for controlling the cracks in the selective laser melting process of the high-strength aluminum alloy component according to claim 1, wherein the method comprises the following steps: and heating the powder in the S1 to 60-80 ℃ in a vacuum environment, and preserving heat for 6-12 hours.
3. The method for controlling the cracks in the selective laser melting process of the high-strength aluminum alloy component according to claim 1, wherein the method comprises the following steps: the S4 sets 3 different process parameters for each layer, and when sintering a certain layer of printing pattern,
a) firstly, adopting A-type process parameters, wherein the laser power is 100-;
b) sintering the layer by B-type process parameters, wherein the laser power is 350-;
c) sintering with C-type process parameters, with a laser power of 100-300W and a scanning speed of 2000-4000 mm/s.
4. The method for controlling the cracks in the selective laser melting process of the high-strength aluminum alloy component according to claim 1, wherein the method comprises the following steps: the heat treatment temperature of S5 is 300-.
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| US20200254547A1 (en) * | 2019-02-07 | 2020-08-13 | General Electric Company | Manufactured article and method |
| CN112008079A (en) * | 2020-08-30 | 2020-12-01 | 中南大学 | Method for improving mechanical property of 3D printing nickel-based superalloy through in-situ heat treatment |
| CN112453426A (en) * | 2020-12-10 | 2021-03-09 | 安徽工程大学 | 3D printing enhancement process for titanium alloy for aviation |
| CN112475316A (en) * | 2020-11-05 | 2021-03-12 | 上海云铸三维科技有限公司 | Composite reinforced laser melting scanning method |
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2021
- 2021-09-18 CN CN202111101793.2A patent/CN113814412A/en active Pending
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN109202080A (en) * | 2018-10-17 | 2019-01-15 | 浙江海洋大学 | A kind of method of selective laser fusing preparation TiAl alloy structural member |
| US20200254547A1 (en) * | 2019-02-07 | 2020-08-13 | General Electric Company | Manufactured article and method |
| CN110405209A (en) * | 2019-08-28 | 2019-11-05 | 上海工程技术大学 | The method in situ for reducing precinct laser fusion preparation titanium composite material residual stress |
| CN111360257A (en) * | 2020-03-27 | 2020-07-03 | 中国商用飞机有限责任公司 | Method for improving formability of 3D printing high-strength aluminum alloy powder |
| CN112008079A (en) * | 2020-08-30 | 2020-12-01 | 中南大学 | Method for improving mechanical property of 3D printing nickel-based superalloy through in-situ heat treatment |
| CN112475316A (en) * | 2020-11-05 | 2021-03-12 | 上海云铸三维科技有限公司 | Composite reinforced laser melting scanning method |
| CN112453426A (en) * | 2020-12-10 | 2021-03-09 | 安徽工程大学 | 3D printing enhancement process for titanium alloy for aviation |
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