JP2020164890A - Lamination molding method for metal component - Google Patents
Lamination molding method for metal component Download PDFInfo
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- JP2020164890A JP2020164890A JP2019064268A JP2019064268A JP2020164890A JP 2020164890 A JP2020164890 A JP 2020164890A JP 2019064268 A JP2019064268 A JP 2019064268A JP 2019064268 A JP2019064268 A JP 2019064268A JP 2020164890 A JP2020164890 A JP 2020164890A
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- 239000002184 metal Substances 0.000 title claims abstract description 141
- 238000000034 method Methods 0.000 title claims abstract description 36
- 238000000465 moulding Methods 0.000 title abstract description 18
- 238000003475 lamination Methods 0.000 title abstract 3
- 239000000843 powder Substances 0.000 claims abstract description 64
- 238000010894 electron beam technology Methods 0.000 claims abstract description 3
- 238000010408 sweeping Methods 0.000 claims abstract description 3
- 238000010030 laminating Methods 0.000 claims description 11
- 230000001678 irradiating effect Effects 0.000 abstract description 2
- 230000000052 comparative effect Effects 0.000 description 15
- 238000004519 manufacturing process Methods 0.000 description 10
- 239000000654 additive Substances 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 229910000816 inconels 718 Inorganic materials 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 229910001240 Maraging steel Inorganic materials 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000005429 filling process Methods 0.000 description 1
- 238000009689 gas atomisation Methods 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 102200082816 rs34868397 Human genes 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 238000009692 water atomization Methods 0.000 description 1
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Abstract
Description
本発明は、オーバーハング部を有する金属部品の３Ｄ積層造形法による造形方法に関する。 The present invention relates to a modeling method of a metal part having an overhang portion by a 3D additive manufacturing method.
金属粉末を用いる積層造形法にレーザ溶融法(Selective Laser Melting, SLM)がある。ＳＬＭ法は金属粉末層の形成とその粉末にレーザ光を照射して、領域内の金属粉末の溶融・凝固させることを繰り返すことによって金属部品を形成することができる。 There is a laser melting method (Selective Laser Melting, SLM) as a layered molding method using metal powder. In the SLM method, a metal part can be formed by repeatedly forming a metal powder layer and irradiating the powder with a laser beam to melt and solidify the metal powder in the region.
ＳＬＭ法を用いてオーバーハング部を有する金属部品を積層造形すると、オーバーハング部を下から支持するのは溶融・凝固していない金属粉末層であるため、オーバーハング部を形成する溶融・凝固部が本来の位置に留まることができずオーバーハング部の平坦度が低下していた。 When a metal part having an overhang portion is laminated and molded using the SLM method, the overhang portion is supported from below by a metal powder layer that has not been melted or solidified. Therefore, the molten / solidified portion forming the overhang portion. Could not stay in its original position, and the flatness of the overhang was reduced.
そこでＳＬＭ法を用いてオーバーハング部を有する金属部品を積層造形する際、オーバーハング部を支持するサポート部材を金属部品と共に積層造形する必要がある。その後、サポート部材を手作業で除去し更にオーバーハング部の平坦度を高めるために残留サポート部材の除去加工も必要である。サポート部材の量を多く付与すると、オーバーハング部の平坦度が良くなるが、サポート部材の除去や加工に要するコストは高くなる。また、サポート部材の量が多いと造形時間が長くなり、粉末原料も多く消費されることによって造形コストは大幅に増加するという問題がある。そこで、造形品のオーバーハング部の平坦度を維持しつつ、サポート部材の量を低減し、かつ容易に除去できる方法が探索されている。 Therefore, when a metal part having an overhang portion is laminated and molded by using the SLM method, it is necessary to laminate and model a support member that supports the overhang portion together with the metal part. After that, in order to manually remove the support member and further improve the flatness of the overhang portion, it is necessary to remove the residual support member. When a large amount of the support member is applied, the flatness of the overhang portion is improved, but the cost required for removing and processing the support member is high. Further, if the amount of the support member is large, the molding time becomes long, and a large amount of powder raw material is consumed, which causes a problem that the molding cost is significantly increased. Therefore, a method is being sought that can reduce the amount of support members and easily remove them while maintaining the flatness of the overhang portion of the modeled product.
特許文献１は、除去用部材と一体形成されたサポート部材上に、金属部材を一体形成する工程と、一体形成された除去用部材、サポート部材、及び金属部材から、除去用部材を捩ることにより、除去用部材とサポート部材を除去する工程と、を備える金属部材の製造方法を開示し、サポート部材の具体的な構造として１辺が１ｍｍの正方形の断面をもち、壁の厚さが０．１５ｍｍの角柱が隙間なく集合したセル構造のものを例示している（段落００３４、図４）。 Patent Document 1 describes a step of integrally forming a metal member on a support member integrally formed with a removal member, and twisting the removal member from the integrally formed removal member, support member, and metal member. Discloses a method for manufacturing a metal member including a step of removing a removal member and a support member, and the specific structure of the support member has a square cross section with a side of 1 mm and a wall thickness of 0. An example has a cell structure in which 15 mm square pillars are assembled without gaps (paragraph 0034, FIG. 4).
非特許文献１は、オーバーハング部の角度と積層状態の関係および除去しやすさを考慮したサポートとしてＺ方向にピン形状を多数配置して造形品を固定するコーンサポート、２方向のクロスハッチの薄いブレードの上に造形品を固定するグリッドサポート、平行する複数の平板の端部で造形品を固定する平行ラインサポート等を開示している。特許文献１および非特許文献１の開示する製造方法およびサポートによればサポート部材の除去作業を容易にすることができるとともに、積層金属部品のオーバーハング部の平坦度も向上する。 Non-Patent Document 1 describes a cone support in which a large number of pin shapes are arranged in the Z direction to fix a modeled product as a support in consideration of the relationship between the angle of the overhang portion and the laminated state and the ease of removal, and a two-way cross hatch. It discloses a grid support for fixing a modeled product on a thin blade, a parallel line support for fixing a modeled product at the ends of a plurality of parallel flat plates, and the like. According to the manufacturing methods and supports disclosed in Patent Document 1 and Non-Patent Document 1, the work of removing the support member can be facilitated, and the flatness of the overhang portion of the laminated metal part is also improved.
特許文献１に開示されている金属部材の製造方法は、手作業でサポートを除去しやすくなるが、金属粉末を層状に敷き詰める際に、それまでに形成したサポート部材の最上部と金属粉末を敷き詰めるためのブレードとが干渉して金属粉末層に隙間が形成されることがあるという課題を有する。オーバーハング部を支持するサポート部材の量が多いため、サポート部材を除去した後の金属部品の表面を平滑化するための加工コストが高いという課題を有する。また、除去用部材を設ける方法は、造形時間や造形コストの増大を招くという課題を有する。非特許文献１には、平行ラインサポート部材は除去しやすくなるが、特許文献１と同様に金属粉末層に隙間が形成されることがあるという課題や、造形部の形状に歪みが発生することがあるという課題を有する。 The method for manufacturing a metal member disclosed in Patent Document 1 makes it easy to remove the support by hand, but when the metal powder is spread in layers, the uppermost portion of the support member formed so far and the metal powder are spread. There is a problem that a gap may be formed in the metal powder layer due to interference with the blade. Since the amount of the support member that supports the overhang portion is large, there is a problem that the processing cost for smoothing the surface of the metal part after removing the support member is high. Further, the method of providing the removing member has a problem that the molding time and the molding cost are increased. In Non-Patent Document 1, although the parallel line support member can be easily removed, there is a problem that a gap may be formed in the metal powder layer as in Patent Document 1, and the shape of the shaped portion is distorted. Has the problem of being.
本発明は、このような課題を解決するためになされたものであり、金属粉末を層状に敷き詰める際に金属粉末層に隙間が形成されることを防止すること、オーバーハング部を持つ部品の積層造形の際に、オーバーハング部の平坦度を維持すること、及びサポート部材の量を少なくし、容易に除去することができる金属部品の造形方法を提供することを目的とする。 The present invention has been made to solve such a problem, to prevent a gap from being formed in the metal powder layer when the metal powder is spread in layers, and to stack parts having an overhang portion. It is an object of the present invention to provide a method for forming a metal part that can be easily removed by maintaining the flatness of the overhang portion and reducing the amount of support members during modeling.
本発明の金属部品の積層造形方法は、金属粉末を所定方向に掃くことにより敷き詰めて金属粉末層を形成する敷詰工程と、前記金属粉末層の表面に区画される金属部品を形成するための第１の領域および／または前記金属部品のオーバーハング部を支持するサポート部材を形成するための第２の領域にレーザ光又は電子ビームを照射して前記第１の領域内および／または前記第２の領域内の金属粉末を溶融凝固させる照射工程、とを繰り返して前記金属部品を形成する金属部品の積層造形する方法であって、前記金属粉末層の表面における金属粉末を敷く方向に対する前記第２の領域の角度が４５°未満であることを特徴とする。 The method for laminating and molding metal parts of the present invention includes a laying step of laying metal powder in a predetermined direction to form a metal powder layer and forming a metal part partitioned on the surface of the metal powder layer. The first region and / or the second region for forming a support member for supporting the overhang portion of the metal part is irradiated with a laser beam or an electron beam to be within the first region and / or the second region. This is a method of laminating and modeling the metal parts forming the metal parts by repeating the irradiation step of melting and solidifying the metal powder in the region of the above, and the second method with respect to the direction in which the metal powder is laid on the surface of the metal powder layer. The angle of the region is less than 45 °.
本発明においては、第２の領域どうしが互いに交差して交差部を形成することが好ましい。 In the present invention, it is preferable that the second regions intersect with each other to form an intersection.
本発明においては、交差部を複数個所で形成し、互いに隣接する交差部どうしの距離を２ｍｍ〜１０ｍｍとすることが好ましい。 In the present invention, it is preferable that the intersections are formed at a plurality of locations and the distance between the intersections adjacent to each other is 2 mm to 10 mm.
本発明によりオーバーハング部を持つ金属部品の積層造形の際に、オーバーハング部の平坦度を維持するとともに、サポート部材の量を少なくし、容易に除去することができる。 According to the present invention, when a metal part having an overhang portion is laminated, the flatness of the overhang portion can be maintained, the amount of the support member can be reduced, and the overhang portion can be easily removed.
以下、本発明を実施するための形態について適宜、図面を使って説明する。本発明は以下の実施形態に限定されない。 Hereinafter, embodiments for carrying out the present invention will be appropriately described with reference to the drawings. The present invention is not limited to the following embodiments.
本実施形態の金属部品の積層造形方法は、ＳＬＭ法におけるオーバーハング部を持つ金属部品の製造方法である。図１は、本実施形態に係る金属部品の積層造形方法において、サポート部材及び金属部品を示す斜視図である。図３はサポートの交差部の定義を示し、図２及び図４はＡ−Ａ’断面矢視図である。図１に示すように、積層造形するのはオーバーハング部２に２つの脚部３が接続されてコの字形状をした金属部品１である。２つの脚部３がベースプレート４の上面と接触しオーバーハング部２を支える姿勢で金属部品１は積層造形される。本実施形態では、金属部品１の積層造形において、オーバーハング部２が積層造形される間、オーバーハング部２を支えるためにサポート部材１０，２０，３０を形成する。金属部品１およびサポート部材１０，２０，３０の形成方法を説明する。金属部品及びサポート部材の積層造形方法において、図１に示すように、ステンレスのベースプレート４を準備する。ベースプレートの上面は水平面であり、XYZ座標系を導入する。X方向およびY方向が水平方向であり、Z方向は鉛直方向である。 The method for laminating metal parts of the present embodiment is a method for manufacturing a metal part having an overhang portion in the SLM method. FIG. 1 is a perspective view showing a support member and a metal part in the method for laminating metal parts according to the present embodiment. FIG. 3 shows the definition of the intersection of the supports, and FIGS. 2 and 4 are cross-sectional views taken along the line AA'. As shown in FIG. 1, what is laminated is a metal part 1 having a U-shape in which two legs 3 are connected to an overhang portion 2. The metal parts 1 are laminated in a posture in which the two legs 3 are in contact with the upper surface of the base plate 4 to support the overhangs 2. In the present embodiment, in the laminated molding of the metal part 1, the support members 10, 20, and 30 are formed to support the overhang portion 2 while the overhang portion 2 is laminated. A method of forming the metal part 1 and the support members 10, 20, and 30 will be described. As shown in FIG. 1, a stainless steel base plate 4 is prepared in a laminating molding method of metal parts and support members. The top surface of the base plate is horizontal and introduces the XYZ coordinate system. The X and Y directions are horizontal, and the Z direction is vertical.
［敷詰工程］
ベースプレート４の上に一層を形成するのに必要な金属粉末より少し多い金属粉末を供給し所定方向にリコータ（図示省略）で掃いて金属粉末を敷き詰めて金属粉末層を形成する。余剰粉末は回収される。金属粉末は、例えば、インコネル718、マルエージング鋼などからガスアトマイズ法や水アトマイズ法やプラズマ回転電極法等で形成した粉末であり、平均粒子径は10〜200μｍ程度、金属粉末層の厚さは0.01〜0.2ｍｍ程度が好ましい。リコータと呼ばれる粉末層形成機を用いることにより金属粉末を薄く、均一厚さで、かつ緻密に敷き詰めて金属粉末層を形成することができる。
[Padding process]
A little more metal powder than the metal powder required to form a layer on the base plate 4 is supplied, swept in a predetermined direction with a recorder (not shown), and the metal powder is spread to form a metal powder layer. Excess powder is recovered. The metal powder is, for example, a powder formed from Inconel 718, maraging steel, etc. by the gas atomization method, the water atomization method, the plasma rotating electrode method, etc., the average particle size is about 10 to 200 μm, and the thickness of the metal powder layer is 0.01. It is preferably about 0.2 mm. By using a powder layer forming machine called a recoater, the metal powder can be spread thinly, uniformly thickly, and densely to form a metal powder layer.
［照射工程］
図２は図１のＡ−Ａ’断面矢視図である。敷詰工程でベースプレート４の上に敷き詰めた金属粉末層の表面に区画される金属部品を形成するための第１の領域１００および／または金属部品のオーバーハング部２を支持するサポート部材１０，２０，３０を形成するための第２の領域２００をレーザ照射して、選択的に溶融・凝固させた造形層を形成する。溶融・凝固させた造形層の形状は金属部品及びサポート部材の断面形状と等しい。
次に、形成された造形層及び未焼結の金属粉末上に、再び敷詰工程と照射工程を実施することにより新たな造形層及び未焼結の金属粉末を積層する。更に敷詰工程と照射工程とを繰り返して金属部品を積層造形する。
[Irradiation process]
FIG. 2 is a cross-sectional view taken along the line AA'of FIG. Support members 10, 20 that support the first region 100 and / or the overhang portion 2 of the metal part for forming the metal part partitioned on the surface of the metal powder layer spread on the base plate 4 in the filling step. The second region 200 for forming, 30 is irradiated with a laser to form a modeling layer selectively melted and solidified. The shape of the melted and solidified modeling layer is the same as the cross-sectional shape of the metal parts and support members.
Next, a new molding layer and the unsintered metal powder are laminated on the formed molding layer and the unsintered metal powder by performing the filling step and the irradiation step again. Further, the filling process and the irradiation process are repeated to laminate and shape the metal parts.
金属部品を積層造形する過程でベースプレート４の上に、金属部品１及びそれぞれが薄板状のサポート部材１０，２０，３０が一体的に形成される。第２の領域２００を直線状とし敷詰工程と照射工程とを繰り返すことで積層方向に平行な薄板状のサポート部材１０，２０，３０を形成することができる。第２の領域の形状は任意であり、直線状の他に、例えば、曲線状、折れ線状、線に比べてある程度幅のある長方形形状、又はこれらのうちの２種以上の組み合わせとすることもできる。直線状がサポート部材の量を抑制しやすいため好ましい。曲線状の場合、曲線上の全ての接線と金属粉末を敷く方向との角度を４５°未満とする。 In the process of laminating and modeling the metal parts, the metal parts 1 and the support members 10, 20 and 30 each having a thin plate shape are integrally formed on the base plate 4. By making the second region 200 linear and repeating the laying step and the irradiation step, thin plate-shaped support members 10, 20, and 30 parallel to the stacking direction can be formed. The shape of the second region is arbitrary, and in addition to the linear shape, for example, a curved shape, a polygonal line shape, a rectangular shape having a certain width compared to the line, or a combination of two or more of these may be used. it can. The linear shape is preferable because the amount of the support member can be easily suppressed. In the case of a curved line, the angle between all the tangents on the curve and the direction in which the metal powder is laid is less than 45 °.
実施形態に係る金属部品の積層造形法におけるサポート部材について図３を用いて更に説明する。図３は図２の一部拡大図である。図３に示すように金属粉末層の表面における金属粉末を敷く方向（矢印Ｘ方向）に対するサポート部材１０，２０すなわち第２の領域２００の角度を交差角θとする。サポート部材１０の交差角をθ１，サポート部材２０の交差角をθ２とする。交差角θ１，交差角θ２の何れも４５°未満である。交差角θ１と交差角θ２は異なる角度であってもよい。交差角θ１および／またはθ２が４５°以上になるとサポート部材１０，２０とリコータとが干渉し金属粉末層に隙間ができたり、干渉が著しいときはサポートが破損することもあるため寸法精度の高いサポート部材を造ることができず造形に悪影響を与える。 The support member in the additive manufacturing method for metal parts according to the embodiment will be further described with reference to FIG. FIG. 3 is a partially enlarged view of FIG. As shown in FIG. 3, the angle of the support members 10, 20, that is, the second region 200 with respect to the direction in which the metal powder is laid (arrow X direction) on the surface of the metal powder layer is defined as the intersection angle θ. The intersection angle of the support member 10 is θ 1 , and the intersection angle of the support member 20 is θ 2 . Both the intersection angle θ 1 and the intersection angle θ 2 are less than 45 °. The intersection angle θ 1 and the intersection angle θ 2 may be different angles. When the intersection angle θ 1 and / or θ 2 becomes 45 ° or more, the support members 10 and 20 interfere with each other to form a gap in the metal powder layer, and when the interference is significant, the support may be damaged. It is not possible to make a high support member, which adversely affects the molding.
図３において第２の領域２００，２００どうしは、交差して交差部５を形成する。金属粉末を敷く方向（矢印Ｘ方向）に対して直角方向に互いに隣接する交差部５間の距離Ｄ１は２ｍｍ〜８ｍｍであることが好ましい。サポート部材の量を抑制するには、できるだけ薄く形成することが好ましい。サポート部材の厚さはレーザ照射条件に依存し、適切な厚さ範囲は０．０２ｍｍ〜０．４ｍｍである。０．０２ｍｍ未満ではサポート強度が弱いため、オーバーハング部を支えなくなり、０．４ｍｍを超えるとサポート強度が強すぎるために造形後の除去が困難となる。このような構造とすることによりサポート部材１０，２０，３０に高い剛性を付与し、オーバーハング部２を支持することができる。また、オーバーハング部を支えるサポート部材の量が大幅に減少する。サポート部材20を容易に除去することができる。 In FIG. 3, the second regions 200, 200 intersect to form an intersection 5. The distance D 1 between the intersections 5 adjacent to each other in the direction perpendicular to the direction in which the metal powder is laid (arrow X direction) is preferably 2 mm to 8 mm. In order to suppress the amount of the support member, it is preferable to form it as thin as possible. The thickness of the support member depends on the laser irradiation conditions, and the appropriate thickness range is 0.02 mm to 0.4 mm. If it is less than 0.02 mm, the support strength is weak, so that the overhang portion cannot be supported, and if it exceeds 0.4 mm, the support strength is too strong, and it becomes difficult to remove it after molding. With such a structure, high rigidity can be imparted to the support members 10, 20 and 30, and the overhang portion 2 can be supported. In addition, the amount of support members that support the overhang portion is significantly reduced. The support member 20 can be easily removed.
サポート部材の別形態を図４に示す。図４は図２とは別の図１のＡ−Ａ’断面矢視図である。サポートの交差部５は金属部品のオーバーハング部２の端部に位置している。金属粉末を敷く方向（矢印Ｘ方向）に対して直角方向に互いに隣接する交差部５間の距離Ｄ２は２ｍｍ〜８ｍｍであることが好ましい。このような場合でも、サポート部材の量は大幅に減少ができ、容易に除去することができる。 Another form of the support member is shown in FIG. FIG. 4 is a cross-sectional view taken along the line AA'of FIG. 1, which is different from FIG. The crossing portion 5 of the support is located at the end of the overhang portion 2 of the metal part. The distance D 2 between the intersections 5 adjacent to each other in the direction perpendicular to the direction in which the metal powder is laid (arrow X direction) is preferably 2 mm to 8 mm. Even in such a case, the amount of the support member can be significantly reduced and can be easily removed.
（実施例１）
本実施例で積層造形した金属部品の斜視図と寸法を図５に示す。金属部品の形状は図１のコの字形状をした金属部品と同形状であり、サポート部材の構造は図２で説明したものと同様とした。積層造形機はEOS社製M290である。積層造形用ベースプレートはS45C製でサイズは250mm×250mm×35mmである。
(Example 1)
FIG. 5 shows a perspective view and dimensions of the metal parts laminated and molded in this embodiment. The shape of the metal part was the same as that of the U-shaped metal part of FIG. 1, and the structure of the support member was the same as that described in FIG. The laminating machine is M290 manufactured by EOS. The base plate for laminated modeling is made of S45C and the size is 250 mm x 250 mm x 35 mm.
ベースプレート４上に、リコータ（図示省略）を用いてインコネル718の金属粉末（平均粒子径40μｍ）を図３の矢印Ｘ方向に掃くことにより０．０４ｍｍの厚さで緻密に敷き詰めて金属粉末層を形成した（敷詰工程）。 A metal powder layer of Inconel 718 (average particle diameter 40 μm) was densely spread on the base plate 4 with a thickness of 0.04 mm by sweeping in the direction of arrow X in FIG. 3 using a recorder (not shown). Formed (padding process).
そして、金属粉末層の表面に区画される金属部品１を形成するための第１の領域１００および金属部品のオーバーハング部２を支持するサポート部材１０，２０，３０を形成するための第２の領域２００をレーザ照射して、選択的に溶融・凝固させた造形層を形成した。第２の領域の交差角度θ１，θ２は何れも１０°とした（照射工程）。 Then, the first region 100 for forming the metal component 1 partitioned on the surface of the metal powder layer and the second support members 10, 20, 30 for supporting the overhang portion 2 of the metal component are formed. The region 200 was irradiated with a laser to form a modeling layer that was selectively melted and solidified. The intersection angles θ 1 and θ 2 of the second region were both set to 10 ° (irradiation step).
敷詰工程と照射工程を繰り返すことにより図５の金属部品を積層造形した。第２の領域２００は直線状であり、形成されるサポート部材は積層方向に平行で厚さ０．１ｍｍの薄板状とした。交差部５，５間の距離Ｄ１は２ｍｍとした。 By repeating the laying step and the irradiation step, the metal parts of FIG. 5 were laminated and molded. The second region 200 is linear, and the support member to be formed is a thin plate having a thickness of 0.1 mm parallel to the stacking direction. The distance D 1 between the intersections 5 and 5 was set to 2 mm.
［敷き詰め性］
積層造形の途中の段階で、レーザ照射後の金属粉末層に生じる隙間の有無から敷き詰め性を評価した。本実施例におけるレーザ照射後の金属粉末層の写真を図６（１）に示す。隙間は認められなかった。隙間の数は金属粉末層の表面であって第１の領域の全てと第２の領域の全てを含む領域を目視にて確認した。隙間数０〜１箇所を○、隙間数２〜４箇所を△、隙間数５箇所以上を×として表１に示す。
[Filling]
In the middle of the laminated molding, the spreadability was evaluated from the presence or absence of gaps generated in the metal powder layer after laser irradiation. A photograph of the metal powder layer after laser irradiation in this example is shown in FIG. 6 (1). No gap was found. The number of gaps was visually confirmed on the surface of the metal powder layer, which included all of the first region and all of the second region. Table 1 shows 0 to 1 gaps as ◯, 2 to 4 gaps as Δ, and 5 or more gaps as x.
［平坦度］
オーバーハング部のサポート支持面の平坦度を評価した。積層造形した金属部品をベースプレートから取り外し、未焼結金属粉末を取り除き、サポート部材を除去した。平坦度は窪みの有無で評価した。窪みの有無は光学式非接触測定機（VR３２００、キーエンス）で深さ分布を色で評価して確認した。本実施例では窪みは認められなかった。窪みの深さが０〜０．２ｍｍ範囲を○、深さが０．２ｍｍ超〜0.5mm範囲を△として表１に示す。オーバーハング部に評価△の窪みがあっても実用上の問題は無い。
[Flatness]
The flatness of the support support surface of the overhang was evaluated. The laminated metal parts were removed from the base plate, the unsintered metal powder was removed, and the support member was removed. Flatness was evaluated by the presence or absence of dents. The presence or absence of dents was confirmed by evaluating the depth distribution by color with an optical non-contact measuring machine (VR3200, KEYENCE). No dent was observed in this example. Table 1 shows the depth of the depression in the range of 0 to 0.2 mm as ◯ and the depth of more than 0.2 mm to 0.5 mm as Δ. There is no practical problem even if there is a dent of evaluation △ in the overhang part.
（実施例２）
第２の領域の交差角度θ１，θ２を何れも２０°としたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間、窪みの何れも認められなかった。
(Example 2)
Metal parts were laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 in the second region were both set to 20 °, and the spreadability and flatness were evaluated. No gaps or dents were found.
（実施例３）
第２の領域の交差角度θ１，θ２を何れも３０°としたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間、窪みの何れも認められなかった。
(Example 3)
Metal parts were laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 in the second region were both set to 30 °, and the spreadability and flatness were evaluated. No gaps or dents were found.
（比較例１）
第２の領域の交差角度θ１，θ２を何れも４５°としたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間数は２箇所であった。本比較例におけるレーザ照射後の金属粉末層の写真を図６（２）に示す。一部のサポートに沿って隙間が認められる。リコータを用いて金属粉末を敷き詰める際に、リコータとサポートとの接触があり、振動によって隙間ができたものと考えられる。窪みは認められなかった。
(Comparative Example 1)
Metal parts were laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 in the second region were both set to 45 °, and the spreadability and flatness were evaluated. The number of gaps was two. A photograph of the metal powder layer after laser irradiation in this comparative example is shown in FIG. 6 (2). There is a gap along some of the supports. It is probable that when the metal powder was spread using the recorder, there was contact between the recorder and the support, and a gap was created due to vibration. No dents were found.
（比較例２）
第２の領域の交差角度θ１，θ２を何れも６０°としたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間数は１９箇所であった。本比較例におけるレーザ照射後の金属粉末層の写真を図６（３）に示す。多くのサポートに沿って隙間が認められる。比較例１と同様の原因で隙間ができたと考えられる。窪みは認められたが実用上の問題はなかった。オーバーハング部のサポート支持面の模式図を図７（ａ）に示す。サポート部材の痕跡１１，２１，３１に囲まれる領域に窪み５０が生じていることがある。窪みの一例の写真を図７（ｂ）に示す。サポート部材の痕跡１１の間の黒ずんで見える箇所が窪み５０である。深さ0.5ｍｍを超える窪みが生じるとサポート部材のオーバーハング部支持機能が不十分と判断される。
(Comparative Example 2)
Metal parts were laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 in the second region were both set to 60 °, and the spreadability and flatness were evaluated. The number of gaps was 19. A photograph of the metal powder layer after laser irradiation in this comparative example is shown in FIG. 6 (3). There are gaps along many supports. It is considered that a gap was formed due to the same cause as in Comparative Example 1. A dent was observed, but there was no practical problem. A schematic view of the support support surface of the overhang portion is shown in FIG. 7 (a). A depression 50 may be formed in the area surrounded by the traces of the support member 11, 21, 31. A photograph of an example of the depression is shown in FIG. 7 (b). The darkened portion between the traces 11 of the support member is the recess 50. If a dent having a depth of more than 0.5 mm is generated, it is judged that the overhang portion supporting function of the support member is insufficient.
（実施例4）
交差部５，５間の距離Ｄ１を３ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間、窪みの何れも認められなかった。
(Example 4)
The distance D 1 of the between intersections 5,5 except that the 3mm similarly layered manufacturing metal parts in Example 1 to evaluate the spread of the flatness. No gaps or dents were found.
（実施例5）
第２の領域の交差角度θ１，θ２を何れも２０°としたこと及び交差部５，５間の距離Ｄ１を３ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間、窪みの何れも認められなかった。
(Example 5)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 20 ° and the distance D 1 between the intersections 5 and 5 is 3 mm. Then, the spreadability and flatness were evaluated. No gaps or dents were found.
（実施例6）
第２の領域の交差角度θ１，θ２を何れも３０°としたこと及び交差部５，５間の距離Ｄ１を３ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間、窪みの何れも認められなかった。
(Example 6)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 30 ° and the distance D 1 between the intersections 5 and 5 is 3 mm. Then, the spreadability and flatness were evaluated. No gaps or dents were found.
（比較例3）
第２の領域の交差角度θ１，θ２を何れも４５°としたこと及び交差部５，５間の距離Ｄ１を３ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間数は３箇所であった。一部のサポートに沿って隙間が認められた。窪みは認められなかった。
(Comparative example 3)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 45 ° and the distance D 1 between the intersections 5 and 5 is 3 mm. Then, the spreadability and flatness were evaluated. The number of gaps was three. A gap was found along some of the supports. No dents were found.
（比較例4）
第２の領域の交差角度θ１，θ２を何れも６０°としたこと及び交差部５，５間の距離Ｄ１を３ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間数は１０箇所であった。多くのサポートに沿って隙間が認められた。窪みは認められた。
(Comparative example 4)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 60 ° and the distance D 1 between the intersections 5 and 5 is 3 mm. Then, the spreadability and flatness were evaluated. The number of gaps was 10. Gap was found along many supports. A dent was observed.
（実施例7）
交差部５，５間の距離Ｄ１を５ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間、窪みの何れも認められなかった。
(Example 7)
The distance D 1 of the between intersections 5,5 except that the 5mm similarly layered manufacturing metal parts in Example 1 to evaluate the spread of the flatness. No gaps or dents were found.
（実施例8）
第２の領域の交差角度θ１，θ２を何れも２０°としたこと及び交差部５，５間の距離Ｄ１を５ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間、窪みの何れも認められなかった。
(Example 8)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 20 ° and the distance D 1 between the intersections 5 and 5 is 5 mm. Then, the spreadability and flatness were evaluated. No gaps or dents were found.
（実施例9）
第２の領域の交差角度θ１，θ２を何れも３０°としたこと及び交差部５，５間の距離Ｄ１を５ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間、窪みの何れも認められなかった。
(Example 9)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 30 ° and the distance D 1 between the intersections 5 and 5 is 5 mm. Then, the spreadability and flatness were evaluated. No gaps or dents were found.
（比較例5）
第２の領域の交差角度θ１，θ２を何れも４５°としたこと及び交差部５，５間の距離Ｄ１を５ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間数は４箇所であった。一部のサポートに沿って隙間が認められた。窪みは認められなかった。
(Comparative example 5)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 45 ° and the distance D 1 between the intersections 5 and 5 is 5 mm. Then, the spreadability and flatness were evaluated. The number of gaps was four. A gap was found along some of the supports. No dents were found.
（比較例6）
第２の領域の交差角度θ１，θ２を何れも６０°としたこと及び交差部５，５間の距離Ｄ１を５ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間数は１３箇所であった。多くのサポートに沿って隙間が認められた。窪みは認められた。
(Comparative example 6)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 60 ° and the distance D 1 between the intersections 5 and 5 is 5 mm. Then, the spreadability and flatness were evaluated. The number of gaps was 13. Gap was found along many supports. A dent was observed.
（実施例10）
交差部５，５間の距離Ｄ１を８ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間、窪みの何れも認められなかった。
(Example 10)
The distance D 1 of the between intersections 5,5 except that the 8mm Similarly the metal parts and the laminate molding as in Example 1 to evaluate spread resistance and flatness. No gaps or dents were found.
（実施例11）
第２の領域の交差角度θ１，θ２を何れも２０°としたこと及び交差部５，５間の距離Ｄ１を８ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間、窪みの何れも認められなかった。
(Example 11)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 20 ° and the distance D 1 between the intersections 5 and 5 is 8 mm. Then, the spreadability and flatness were evaluated. No gaps or dents were found.
（実施例12）
第２の領域の交差角度θ１，θ２を何れも３０°としたこと及び交差部５，５間の距離Ｄ１を８ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間、窪みの何れも認められなかった。
(Example 12)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 30 ° and the distance D 1 between the intersections 5 and 5 is 8 mm. Then, the spreadability and flatness were evaluated. No gaps or dents were found.
（比較例7）
第２の領域の交差角度θ１，θ２を何れも４５°としたこと及び交差部５，５間の距離Ｄ１を８ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間数は４箇所であった。一部のサポートに沿って隙間が認められた。窪みは認められなかった。
(Comparative example 7)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 45 ° and the distance D 1 between the intersections 5 and 5 is 8 mm. Then, the spreadability and flatness were evaluated. The number of gaps was four. A gap was found along some of the supports. No dents were found.
（比較例8）
第２の領域の交差角度θ１，θ２を何れも６０°としたこと及び交差部５，５間の距離Ｄ１を８ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間数は１５箇所であった。多くのサポートに沿って隙間が認められた。窪みは認められた。
(Comparative example 8)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 60 ° and the distance D 1 between the intersections 5 and 5 is 8 mm. Then, the spreadability and flatness were evaluated. The number of gaps was 15. Gap was found along many supports. A dent was observed.
（実施例13）
交差部５，５間の距離Ｄ１を１０ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間は認められなかった。窪みは認められた。
(Example 13)
The distance D 1 of the between intersections 5,5 except that the 10mm similarly layered manufacturing metal parts in Example 1 to evaluate the spread of the flatness. No gap was found. A dent was observed.
（実施例14）
第２の領域の交差角度θ１，θ２を何れも２０°としたこと及び交差部５，５間の距離Ｄ１を１０ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間は認められなかった。窪みは認められた。
(Example 14)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 20 ° and the distance D 1 between the intersections 5 and 5 is 10 mm. Then, the spreadability and flatness were evaluated. No gap was found. A dent was observed.
（実施例15）
第２の領域の交差角度θ１，θ２を何れも３０°としたこと及び交差部５，５間の距離Ｄ１を１０ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間は認められなかった。窪みは認められた。
(Example 15)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 30 ° and the distance D 1 between the intersections 5 and 5 is 10 mm. Then, the spreadability and flatness were evaluated. No gap was found. A dent was observed.
（比較例9）
第２の領域の交差角度θ１，θ２を何れも４５°としたこと及び交差部５，５間の距離Ｄ１を１０ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間数は３箇所であった。一部のサポートに沿って隙間が認められた。窪みも認められた。
(Comparative example 9)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 45 ° and the distance D 1 between the intersections 5 and 5 is 10 mm. Then, the spreadability and flatness were evaluated. The number of gaps was three. A gap was found along some of the supports. A dent was also observed.
（比較例10）
第２の領域の交差角度θ１，θ２を何れも６０°としたこと及び交差部５，５間の距離Ｄ１を１０ｍｍとしたことを除いて実施例１と同様に金属部品を積層造形し、敷き詰め性と平坦度を評価した。隙間数は１１箇所であった。多くのサポートに沿って隙間が認められた。窪みも認められた。
(Comparative example 10)
Metal parts are laminated and molded in the same manner as in Example 1 except that the intersection angles θ 1 and θ 2 of the second region are both 60 ° and the distance D 1 between the intersections 5 and 5 is 10 mm. Then, the spreadability and flatness were evaluated. The number of gaps was 11. Gap was found along many supports. A dent was also observed.
１ 金属部品
２ オーバーハング部
３ 脚部
４ ベースプレート
５ 交差部
１０，２０，３０ サポート部材
１００ 第１の領域
２００ 第２の領域
1 Metal parts 2 Overhangs 3 Legs 4 Base plates 5 Crossings 10, 20, 30 Support members 100 First area 200 Second area
Claims (3)
前記金属粉末層の表面における金属粉末を敷く方向に対する前記第２の領域の角度が４５°未満であることを特徴とする金属部品の積層造形方法。 A filling step of forming a metal powder layer by sweeping a metal powder in a predetermined direction, and a first region and / or of the metal part for forming a metal part partitioned on the surface of the metal powder layer. Irradiation of a second region for forming a support member for supporting the overhang portion with a laser beam or an electron beam to melt and solidify the metal powder in the first region and / or in the second region. It is a method of laminating metal parts that forms the metal parts by repeating the process.
A method for laminating metal parts, wherein the angle of the second region with respect to the direction in which the metal powder is laid on the surface of the metal powder layer is less than 45 °.
The method for laminating metal parts according to claim 2, wherein the intersections are formed at a plurality of locations, and the distance between the intersections adjacent to each other is 2 mm to 10 mm.
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