CN114619049B - Process development method for forming metal material by selective laser melting - Google Patents
Process development method for forming metal material by selective laser melting Download PDFInfo
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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]
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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
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
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- 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
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- 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
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Abstract
The invention relates to a process development method for forming a metal material by selective laser melting, which comprises the following steps: measuring the values of D50 and D90 on the basis that the sphericity of metal powder to be formed is above 90%, and setting the scanning layer thickness t of the SLM process according to the values of D50 or D90; designing a two-dimensional parameter matrix related to laser power P and scanning speed v; forming a single-channel single-layer sample; observing the formed single-channel single-layer sample, and screening out a sample with good forming morphology and continuous and uniform forming property; cutting the middle part of the screened sample along the direction perpendicular to the scanning direction by utilizing linear cutting to prepare a metallographic sample, and measuring and calculating the porosity eta; observing the internal tissue of the sample with the lowest porosity, and measuring the depth d and the size r of a molten pool of the sample; calculating a critical scanning interval h' according to the size r of the molten pool; and calculating a scanning interval h according to the scanning interval h', so as to determine the scanning layer thickness t, the laser power P, the scanning speed v and the scanning interval h of four process parameters required by SLM forming.
Description
Technical Field
The invention relates to the technical field of selective laser melting additive manufacturing, in particular to a process development method for forming a metal material by selective laser melting.
Background
With the rapid development of additive manufacturing technology, selective laser melting (Selective Laser Melting, SLM) technology is based on the basic principle of discrete and stacking, and high-energy laser beams are utilized to melt and stack metal powder layer by layer into solid metal components, so that rapid and die-free forming of high-performance complex structural components can be realized. Currently, selective laser melting technology is widely applied to the fields of aerospace, automobiles, medical treatment, mold industry and the like. In the selective laser melting forming process, the technological parameters are key factors for ensuring the material forming, and mainly comprise four core technological parameters of laser power P, scanning speed v, scanning interval h and scanning layer thickness t. For the development of SLM forming process parameters of brand new materials, a large number of process experiments are designed to search, and then the screening range of the process parameters is gradually narrowed until a group of optimal process parameters are found, so that a large amount of time is required in the process of process development, and the efficiency is low.
Disclosure of Invention
The invention aims to provide a process development method for forming metal materials by selective laser melting, which can efficiently realize the development of optimal process parameters and effectively shorten the development time of brand new material process parameters.
The invention provides a process development method for forming a metal material by selective laser melting, which comprises the following steps:
s1, selecting metal powder to be formed with sphericity of more than 90%;
s2, measuring the particle size distribution of metal powder to be formed, determining the values of D50 and D90, and setting the scanning layer thickness t of the selective laser melting process according to the value of D50 or D90;
s3, designing a two-dimensional parameter matrix related to laser power P and scanning speed v;
s4, forming a single-channel single-layer sample by utilizing the designed two-dimensional parameter matrix of the scanning layer thickness t, the laser power P and the scanning speed v;
s5, screening out samples with good forming morphology and continuous and uniform forming property from the formed single-channel single-layer samples;
s6, cutting the middle part of the sample screened in the step S5 along the direction perpendicular to the scanning direction by utilizing linear cutting to prepare a metallographic sample, measuring and calculating the porosity eta of the metallographic sample, and screening out the sample with the lowest porosity eta;
s7, judging whether the minimum porosity eta meets the use requirement, if so, executing the step S8, and if not, returning to the step S3;
s8, observing the internal tissue of the sample with the lowest porosity eta screened in the step S6, and measuring the molten pool depth d of the sample with the lowest porosity eta;
s9, judging whether the molten pool depth d meets the requirement of the molten pool depth d > and scanning the layer thickness t, if so, executing the step S10, and if not, returning to the step S3;
s10, determining a bath size r of a sample with the lowest porosity eta by fitting and measuring, and calculating a critical scanning distance h' according to the measured bath size r and a scanning layer thickness t;
s11, calculating a scanning interval h according to the critical scanning interval h';
s12, forming square samples by using the scanning layer thickness t determined in the step S2, the laser power P and the scanning speed v corresponding to the sample with the lowest porosity eta screened in the step S6 and the scanning interval h calculated in the step S11, observing whether the formability of the square samples is good, if yes, finishing development, and otherwise, returning to the step S3.
In an embodiment of the present invention, in step S1, a scanning electron microscope is used to observe the powder morphology of a metal powder to be formed, where the metal powder to be formed is any one of a titanium alloy powder, an aluminum alloy powder, a copper alloy powder, and an iron carbon alloy powder, or the metal powder to be formed is a superalloy powder.
In one embodiment of the present invention, in step S2, the particle size distribution of the metal powder to be formed is measured by a laser particle sizer, and the value of ten integer multiples of the D50 or D90 value is obtained by rounding when the scanned layer thickness t is set.
In one embodiment of the present invention, the laser power P set in the step S3 is in the range of 50W to 900W, and the scanning speed v is in the range of 300mm/S to 1500mm/S.
In one embodiment of the present invention, in step S4, the length of the formed single-pass single-layer sample is 4 to 8mm.
In one embodiment of the present invention, a laser confocal microscope is used to observe the formed single-channel single-layer sample in step S5.
In one embodiment of the present invention, the porosity η of the metallographic specimen is measured and calculated in step S6 using archimedes' drainage.
In one embodiment of the present invention, in step S7, the minimum porosity η satisfies the usage requirement when η < 0.5%.
In one embodiment of the present invention, the internal structure of the sample having the lowest porosity η selected in step S6 is observed in step S8 by using a metallographic microscope.
In one embodiment of the present invention, in step S10, the critical scan pitch h' =2 (r 2 -t 2 ) 1/2 。
In an embodiment of the present invention, in step S11, the scanning distance h is 0.5 to 0.8 times of h ', i.e. the scanning distance h ranges from 0.5h ' to 0.8h '.
In one embodiment of the present invention, the square sample in step S12 has a size of 10mm to 15mm.
The process development method for forming the metal material by selective laser melting can effectively reduce the experimental quantity of the SLM process parameter development process, shorten the process development time, and not only can be used for the development process of general process parameters, but also can be used for optimizing the existing process parameters. The technological parameters developed by the method can ensure the stability and consistency of the SLM forming component, and the comprehensive performance meets the use requirement.
Further objects and advantages of the present invention will become fully apparent from the following description and the accompanying drawings.
Drawings
Fig. 1 is a flow chart of a process development method for forming a metal material by selective laser melting according to the present invention.
FIG. 2 is a scanning electron microscope image of the 316L stainless steel powder used in embodiment 1.
FIG. 3 is a schematic illustration of a sample puddle fit.
Detailed Description
The following description is presented to enable one of ordinary skill in the art to make and use the invention. The preferred embodiments in the following description are by way of example only and other obvious variations will occur to those skilled in the art. The basic principles of the invention defined in the following description may be applied to other embodiments, variations, modifications, equivalents, and other technical solutions without departing from the spirit and scope of the invention.
It will be appreciated by those skilled in the art that in the present disclosure, the terms "vertical," "transverse," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," etc. refer to an orientation or positional relationship based on that shown in the drawings, which is merely for convenience of description and to simplify the description, and do not indicate or imply that the apparatus or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore the above terms should not be construed as limiting the present invention.
It will be understood that the terms "a" and "an" should be interpreted as referring to "at least one" or "one or more," i.e., in one embodiment, the number of elements may be one, while in another embodiment, the number of elements may be plural, and the term "a" should not be interpreted as limiting the number.
In the description of the present invention, it should be noted that, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically connected, electrically connected or can be communicated with each other; can be directly connected or indirectly connected through an intermediate medium, and can be communicated with the inside of two elements or the interaction relationship of the two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances.
As shown in fig. 1, the process development method for forming a metal material by selective laser melting of the invention comprises the following steps:
s1, selecting metal powder to be formed with sphericity of more than 90%;
s2, measuring the particle size distribution of metal powder to be formed, determining the values of D50 and D90, and setting the scanning layer thickness t of the selective laser melting process according to the value of D50 or D90;
s3, designing a two-dimensional parameter matrix related to laser power P and scanning speed v;
s4, forming a single-channel single-layer sample by utilizing the designed two-dimensional parameter matrix of the scanning layer thickness t, the laser power P and the scanning speed v;
s5, screening out samples with good forming morphology and continuous and uniform forming property from the formed single-channel single-layer samples;
s6, cutting the middle part of the sample screened in the step S5 along the direction perpendicular to the scanning direction by utilizing linear cutting to prepare a metallographic sample, measuring and calculating the porosity eta of the metallographic sample, and screening out the sample with the lowest porosity eta;
s7, judging whether the minimum porosity eta meets the use requirement, if so, executing the step S8, and if not, returning to the step S3;
s8, observing the internal tissue of the sample with the lowest porosity eta screened in the step S6, and measuring the molten pool depth d of the sample with the lowest porosity eta;
s9, judging whether the molten pool depth d meets the requirement of the molten pool depth d > and scanning the layer thickness t, if so, executing the step S10, and if not, returning to the step S3;
s10, determining a bath size r of a sample with the lowest porosity eta by fitting and measuring, and calculating a critical scanning distance h' according to the measured bath size r and a scanning layer thickness t;
s11, calculating a scanning interval h according to the critical scanning interval h';
s12, forming square samples by using the scanning layer thickness t determined in the step S2, the laser power P and the scanning speed v corresponding to the sample with the lowest porosity eta screened in the step S6 and the scanning interval h calculated in the step S11, observing whether the formability of the square samples is good, if yes, finishing development, and otherwise, returning to the step S3.
It will be appreciated that in order to meet the requirements of SLM technology, metal powder to be formed with a sphericity of more than 90% needs to be screened out in step S1.
Specifically, in step S1, the powder morphology of the metal powder to be formed is observed by using a scanning electron microscope, where the metal powder to be formed is any one of titanium alloy powder, aluminum alloy powder, copper alloy powder, and iron-carbon alloy powder, or the metal powder to be formed is high-temperature alloy powder, or the metal powder to be formed is a brand-new metal powder material suitable for an SLM forming process, which is not limited in the present invention.
Specifically, in step S2, the particle size distribution of the metal powder to be formed is measured by a laser particle sizer, and when the scanning layer thickness t is set, the value of the integer multiple of the value of D50 or D90 is obtained by rounding.
It is worth mentioning that the laser frequency P in the two-dimensional parameter matrix in step S3 should be determined according to the maximum rated laser power value of the laser used in the SLM device. If the maximum rated laser power value of the laser is 500W, the set value of the laser power P is in the range of 50W-450W; if the maximum rated laser power value of the laser is 1000W, the laser power P is set to be in the range of 100W-900W. That is, the laser power P set in step S3 is in the range of 50W to 900W.
In addition, it is also worth mentioning that the scanning speed v in step S3 is different according to the selection of the laser power P, and the high scanning speed is selected when the laser power is high, and the low scanning speed is selected when the laser power is low, wherein the scanning speed v is set in the range of 300mm/S to 1500mm/S.
Further, in step S4, the length of the single-pass single-layer sample to be formed is 4 to 8mm. And the step S4 also comprises the step of numbering the formed single-channel single-layer samples according to natural numbers, so that the single-channel single-layer samples with corresponding numbers can be conveniently screened out in the subsequent step, and the subsequent test record is convenient.
Specifically, in step S5, the formed single-channel single-layer sample is observed by using a laser confocal microscope.
It will be appreciated that the sample with the lowest porosity is selected in step S6, the lowest porosity representing the best forming quality. It should be understood that the porosity η corresponds to different values for different metallic materials.
It is worth mentioning that in step S6, the porosity η of the metallographic specimen is measured and calculated by archimedes' drainage.
Specifically, in step S7, when the minimum porosity η satisfies η < 0.5%, the use requirement is satisfied.
Specifically, in step S8, the internal structure of the sample with the lowest porosity η screened in step S6 is observed by a metallographic microscope, that is, the molten pool morphology of the sample with the lowest porosity η is observed, and the molten pool width w and the molten pool depth d are measured.
It will be appreciated that in step S9 it is necessary to ensure that the bath depth d is greater than the scanned layer thickness t in order to meet the requirements of the SLM forming process.
Specifically, in step S10, a curve-fitting bath morphology is employed, as shown in fig. 3, and a bath size r is measured by the fitted bath, and a critical scan pitch h' =2 (r 2 -t 2 ) 1/2 。
That is, step S10 determines the bath size r by fitting and measuring, and calculates the critical scan interval h'.
Specifically, as shown in FIG. 3, the bath width w is related to the bath size r as: the beginning of the bath dimension r (point B in fig. 3) is the midpoint of the bath width w (AC segment distance in fig. 3).
Further, in step S11, a scanning pitch h is calculated according to the critical scanning pitch h 'calculated in step S10, where the scanning pitch h is 0.5 to 0.8 times of h', i.e. the scanning pitch h ranges from 0.5h 'to 0.8h'.
It should be noted that the square sample in step S12 has a size of 10mm to 15mm, that is, the square sample of 10mm×10mm can be molded in step S12 to observe the moldability, and the square sample of 15mm×15mm can be used to observe the moldability, and the present invention is not limited to the size of the molded square sample.
The invention will now be described in detail with reference to the drawings and specific examples.
Example 1
Step one, selecting 316L stainless steel powder material as a case for illustration, wherein a Scanning Electron Microscope (SEM) chart of 316L stainless steel powder is shown in FIG. 2, and the sphericity is more than 90%;
step two, measuring the particle size distribution of 316L stainless steel powder by using a laser particle sizer, wherein d50=45.9 μm and d90=67.3 μm, and setting a scanning layer thickness t=50 μm according to D50;
step three, setting a two-dimensional parameter matrix about the laser power P and the scanning speed v, as shown in the following table 1:
TABLE 1 two-dimensional parameter matrix of laser power P and scanning speed v
Step four, forming a single-channel single-layer sample by utilizing the scanning layer thickness t=50μm designed in the step two and the two-dimensional parameter matrix in the step three;
observing all formed single-channel single-layer samples by using a laser confocal microscope, wherein the formed shape is good, and the serial and uniform sample numbers of the formed shapes comprise (1), (8), (9), (10), (15), (16), (17), (18), (22), (23) and (24);
step six, preparing a metallographic sample by using the sample screened in the step five by using linear cutting, measuring and calculating the porosity of the metallographic sample by using an Archimedes drainage method, wherein the porosity of the sample with the number (17) is the lowest and less than 0.5%;
step seven, judging that the lowest porosity is less than 0.5%, meeting the use requirement, and executing step eight;
step eight, observing the molten pool morphology of the sample with the number of (17) by using a metallographic microscope, and actually measuring the molten pool width w=155 μm (the AC distance in fig. 3), the molten pool depth d=135 μm (the BG distance in fig. 3) and the molten pool size r=88 μm (the BI distance in fig. 3);
step nine, based on the molten pool depth d measured in the step eight, the depth d of the molten pool is satisfied, the thickness t of the scanned layer is larger than the depth d of the molten pool, and the step ten is executed;
step ten, adopting curve fitting to form a molten pool shape, wherein the molten pool shape mainly refers to the shape of a molten pool in a longitudinal section, as shown in fig. 3, measuring the size r of the molten pool by a metallographic microscope, and calculating a critical scanning distance h' =2 (r 2 -t 2 ) 1/2 =145 μm (O in fig. 3) 1 O 2 Or GH distance);
step eleven, calculating a scanning interval h=0.75h '=110 μm according to the critical scanning interval h';
step twelve, according to the scan layer thickness t=50μm determined in the step two, the laser power P=350w corresponding to the sample with the number (17) screened in the step six, the scan speed v=900 mm/s, and the scan interval h=110μm calculated in the step eleven, square samples with the thickness of 10mm×10mm are formed, the formability is good, and the SLM process parameter is developed.
In summary, the invention provides a process development method capable of rapidly developing the SLM process parameters, and the process development method for forming the metal material by selective laser melting can effectively reduce the experimental quantity of the SLM process parameter development process, shorten the process development time, not only be used for the development process of general process parameters, but also be used for optimizing the existing process parameters. The technological parameters developed by the method can ensure the stability and consistency of the SLM forming component, and the comprehensive performance meets the use requirement.
The technical features of the above embodiments may be arbitrarily combined, and all possible combinations of the technical features in the above embodiments are not described for brevity of description, however, as long as there is no contradiction between the combinations of the technical features, they should be considered as the scope of the description.
The foregoing examples only represent preferred embodiments of the present invention, which are described in more detail and are not to be construed as limiting the scope of the invention. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the invention, which are all within the scope of the invention. Accordingly, the scope of protection of the present invention is to be determined by the appended claims.
Claims (9)
1. A process development method for forming a metal material by selective laser melting is characterized by comprising the following steps:
s1, selecting metal powder to be formed with sphericity of more than 90%;
s2, measuring the particle size distribution of metal powder to be formed, determining the values of D50 and D90, and setting the scanning layer thickness t of the selective laser melting process according to the value of D50 or D90;
s3, designing a two-dimensional parameter matrix related to laser power P and scanning speed v;
s4, forming a single-channel single-layer sample by utilizing the designed two-dimensional parameter matrix of the scanning layer thickness t, the laser power P and the scanning speed v;
s5, screening out samples with good forming morphology and continuous and uniform forming property from the formed single-channel single-layer samples;
s6, cutting the middle part of the sample screened in the step S5 along the direction perpendicular to the scanning direction by utilizing linear cutting to prepare a metallographic sample, measuring and calculating the porosity eta of the metallographic sample, and screening out the sample with the lowest porosity eta;
s7, judging whether the minimum porosity eta meets the use requirement, if so, executing the step S8, and if not, returning to the step S3;
s8, observing the internal tissue of the sample with the lowest porosity eta screened in the step S6, and measuring the molten pool depth d of the sample with the lowest porosity eta;
s9, judging whether the molten pool depth d meets the requirement of the molten pool depth d > and scanning the layer thickness t, if so, executing the step S10, and if not, returning to the step S3;
s10, determining a bath size r of a sample with the lowest porosity eta by fitting and measuring, wherein the bath size r is a section of size measured on a fitted bath by a metallographic microscope, the starting point of the bath size r is the midpoint of the bath width, the end point is the intersection point of a straight line which is downwards parallel to the bath width and has a distance of a scanning layer thickness t from the bath width on a circumscribing circle corresponding to the fitted bath, and the critical scanning distance h' =2 (r) are calculated according to the measured bath size r and the scanning layer thickness t 2 -t 2 ) 1/2 ；
S11, calculating a scanning interval h according to a critical scanning interval h ', wherein the range of the scanning interval h is 0.5h ' to 0.8h ';
s12, forming square samples by using the scanning layer thickness t determined in the step S2, the laser power P and the scanning speed v corresponding to the sample with the lowest porosity eta screened in the step S6 and the scanning interval h calculated in the step S11, observing whether the formability of the square samples is good, if yes, finishing development, and otherwise, returning to the step S3.
2. The process development method for forming a metal material by selective laser melting according to claim 1, wherein in step S1, a scanning electron microscope is used to observe the powder morphology of a metal powder to be formed, wherein the metal powder to be formed is any one of titanium alloy powder, aluminum alloy powder, copper alloy powder, iron carbon alloy powder, or the metal powder to be formed is a high-temperature alloy powder.
3. The process development method for forming a metal material by selective laser melting according to claim 1, wherein in step S2, the particle size distribution of the metal powder to be formed is measured by a laser particle sizer, and the integer multiple of the value of D50 or D90 is obtained by rounding when the scanning layer thickness t is set.
4. The process development method for selective laser melting forming of a metal material according to claim 1, wherein the laser power P set in step S3 ranges from 50W to 900W, and the scanning speed v ranges from 300mm/S to 1500mm/S.
5. The process development method for forming a metal material by selective laser melting according to claim 1, wherein in step S4, the length of the formed single-pass single-layer sample is 4 to 8mm.
6. The process development method for selective laser melting forming of a metallic material according to claim 1, wherein in step S5, the formed single-pass single-layer sample is observed by a laser confocal microscope.
7. The process development method for selective laser melting forming of a metallic material according to claim 1, wherein the porosity η of the metallographic specimen is measured and calculated by archimedes' drainage in step S6.
8. The process development method for selective laser melting forming of a metal material according to claim 1, wherein in step S7, the use requirement is satisfied when the minimum porosity η satisfies η < 0.5%.
9. The process development method for forming a metal material by selective laser melting according to claim 1, wherein the internal structure of the sample having the lowest porosity η selected in step S6 is observed in step S8 by a metallographic microscope.
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