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CN104718047A - 用于选择性激光熔化的实心轴对称粉末床 - Google Patents

用于选择性激光熔化的实心轴对称粉末床 Download PDF

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CN104718047A
CN104718047A CN201380039764.5A CN201380039764A CN104718047A CN 104718047 A CN104718047 A CN 104718047A CN 201380039764 A CN201380039764 A CN 201380039764A CN 104718047 A CN104718047 A CN 104718047A
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powder bed
build chamber
annular powder
bending
laser instrument
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J.D.海恩斯
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Aerojet Rocketdyne of DE Inc
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Pratt and Whitney Rocketdyne Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • 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
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/30—Platforms or substrates
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    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/14—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
    • B23K26/144—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor the fluid stream containing particles, e.g. powder
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    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
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    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
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    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • 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
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/001—Turbines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys
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    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys
    • B23K2103/05—Stainless steel
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    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/10—Aluminium or alloys thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/14—Titanium or alloys thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/18—Dissimilar materials
    • B23K2103/26—Alloys of Nickel and Cobalt and Chromium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0222—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in soldering, brazing
    • B23K35/0244—Powders, particles or spheres; Preforms made therefrom
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    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/28—Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
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    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
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    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
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    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
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Abstract

一种选择性激光熔化(SLM)系统包括环形粉末床。

Description

用于选择性激光熔化的实心轴对称粉末床
相关申请的交叉引用
本公开请求享有2012年7月27日提交的美国临时专利公开序列第61/676,451号的优先权。
技术领域
本公开大体上涉及添加制造应用。
背景技术
选择性激光熔化(SLM)为添加制造过程，其使用作为数字信息源的3D CAD数据和呈大功率激光束(通常为镱纤维激光器)形式的能量来通过熔化细金属粉末而形成三维金属零件。
选择性激光熔化(SLM)机器典型地以X、Y和Z维度上大约15英寸(381mm)的直线粉末床建造室操作。可加工的材料的类型包括呈雾化粉末材料形式的不锈钢、工具钢、钴铬、钛、镍、铝和其它。
附图说明
各种特征从公开的非限制性实施例的以下详细描述将变得对本领域技术人员而言为显而易见的。附于详细描述的附图可简要描述如下：
图1为根据一个公开的非限制性实施例的示例性选择性激光熔化(SLM)系统的大体示意图；
图2为根据用于选择性激光熔化(SLM)系统的一个公开的非限制性实施例的环形粉末床的虚线侧视图；
图3为根据用于选择性激光熔化(SLM)系统的一个公开的非限制性实施例的环形粉末床的虚线侧视图；
图4为由具有图2的环形粉末床的示例性选择性激光熔化(SLM)系统制造的轴对称构件的示意性透视图；
图5为由具有图3的环形粉末床的示例性选择性激光熔化(SLM)系统制造的轴对称构件的示意性透视图；以及
图6为根据另一个公开的非限制性实施例的示例性选择性激光熔化(SLM)系统的大体示意图。
具体实施方式
图1示意性地示出了选择性激光熔化(SLM)系统20，其可具有对轴对称构件的特定适用性，如，相对显著的直径的燃气涡轮发动机外壳、燃烧器、火箭喷嘴和其它此类环形、环状、圆筒形截头圆锥形和圆锥形构件。系统20包括大体环形的粉末床22、一个或更多个激光器24、再涂器叶片26和控制器28。应当认识到的是，此外或作为备选，可提供各种构件和子系统。
大体环形的粉末床22由布置成圆形图案的多个建造室30A-30n限定。各个建造室30A-30n气密性地闭合，并且包括用于惰性气体的入口和出口，惰性气体旨在避免来自一个或更多个激光器24的激光束可穿过的熔池和窗口的不需要的反应。
各个建造室30A-30n可包括弯曲的内壁32和弯曲的外壁34。弯曲的内壁32和外壁34可相对于底座36垂直(Z轴；图2)，以便于制造大体圆筒形的构件，如，燃气涡轮发动机外壳C(图4)。作为备选，弯曲的内壁32和外壁34可相对于底座36成角(图3)，以便于制造大体圆锥形的构件，如，火箭喷嘴R(图5)。此外，各种直径的大体圆锥形的建造室22(图3)可用于形成构件的截头圆锥形区段，其随后沿Z轴组装来形成完整的构件，例如，火箭喷嘴R(图5)。
大体环形的粉末床22的底座36可降低，以使轴对称构件可在粉末原料中产生，同时在各种情况下，在轴对称构件的板层由一个或更多个激光器24产生之后，底座36降低板层厚度的量。作为备选，一个或更多个激光器24和再涂器叶片26相对于轴对称构件升高，同时底座36保持固定。仍作为备选，环形粉末床22和/或底座36围绕中心轴线Z旋转，同时一个或更多个激光器24和再涂器叶片26旋转地静止。应当理解的是，它们的各种组合可提供来便于制造。
在一个公开的非限制性实施例中，一个或更多个激光器24与多个建造室30A-30n中的各个相关联。与多个建造室30A-30n中的各个相关联的一个或更多个激光器24中的至少一个可与多个建造室30A-30n中的相关联一个部分地重叠来确保连续性。
在选择性激光熔化(SLM)系统20'的另一个公开的非限制性实施例中，一个或更多个激光器24安装于再涂器叶片26用于与其一起旋转(图6)。即，由再涂器叶片26的粉末平整以及激光束加工旋转地实现。
在操作中，根据一个公开的非限制性实施例，金属材料粉末通过在材料粉末的储存器(未示出)和环形粉末床22上面邻接中心轴线Z的再涂器叶片26的旋转来响应于控制器28分配。在一个或更多个激光器24加工各层之后，再涂器叶片26将新鲜材料粉末分配在轴对称构件上面，该轴对称构件可降低以便对应于接下来将施加的层厚度。然而，由一个或更多个激光器24加工的层可不是完全光滑的，并且在一些情况下，可大于待施加的层厚度。在这些点处，再涂器叶片26还在新材料层粉末施加期间在最后加工的层上面碾磨，以便于加工的继续。
环形粉末床22便于具有减小的残余应力的轴对称构件的有效的大轴对称建造包封。
应当理解的是，相似的附图标记表示全部若干附图中对应的或类似的元件。还应当理解的是，尽管特定构件布置在示出的实施例中公开，但其它布置将得益于此。
尽管不同的非限制性实施例具有特定示出的构件，但本发明的实施例不限于那些特别组合。有可能与来自其它非限制性实施例中的任一个的特征或构件组合使用来自非限制性实施例中的任一个的构件或特征中的一些。
说明书的上下文(尤其是以下权利要求的上下文)中的用语"一"和"一个"和"该"和类似提及的使用将解释为覆盖单数和复数两者，除非本文中另外指出，或与上下文明确抵触。结合数量使用的修饰语"大约"包括规定值，并且具有由上下文指出的意义(例如，其包括与特定数量的测量相关联的误差程度)。本文公开的所有范围包括端点，并且端点能够与彼此独立地组合。
尽管示出、描述和主张了特别步骤顺序，但应当理解的是，步骤可以以任何顺序执行、分离或组合，除非另外指出，并且仍将受益于本公开。
前述描述为示例性的，而非由内部限制来限定。本文公开了各种非限制性实施例，然而，本领域技术人员将认识的是，鉴于以上教导的各种改型和变型将落入所附权利要求的范围内。因此，将理解的是，在所附权利要求的范围内，本公开可除明确描述那样之外实践。出于该原因，应当研究所附权利要求以确定真实范围和内容。

Claims (20)

1. 一种选择性激光熔化(SLM)系统，其包括：环形粉末床。
2. 根据权利要求1所述的系统，其特征在于，所述环形粉末床为圆筒形的。
3. 根据权利要求1所述的系统，其特征在于，所述环形粉末床为截头圆锥形的。
4. 根据权利要求1所述的系统，其特征在于，所述环形粉末床由布置成圆形图案的多个建造室限定。
5. 根据权利要求1所述的系统，其特征在于，所述多个建造室中的各个包括弯曲的内壁和弯曲的外壁。
6. 根据权利要求5所述的系统，其特征在于，所述弯曲的内壁和所述弯曲的外壁垂直于底座。
7. 根据权利要求5所述的系统，其特征在于，所述弯曲的内壁和所述弯曲的外壁相对于底座成角。
8. 根据权利要求1所述的系统，其特征在于，所述系统还包括多个激光器。
9. 根据权利要求8所述的系统，其特征在于，所述环形粉末床由多个建造室限定，所述多个建造室中的各个与所述多个激光器中的至少一个相关联。
10. 根据权利要求1所述的系统，其特征在于，所述系统还包括能够围绕轴线旋转的再涂器叶片，所述环形粉末床围绕所述轴线限定。
11. 根据权利要求10所述的系统，其特征在于，所述系统还包括安装于所述再涂器叶片的至少一个激光器。
12. 一种选择性激光熔化(SLM)系统，其包括：
布置成圆形图案的多个建造室。
13. 根据权利要求12所述的系统，其特征在于，所述多个建造室中的各个包括弯曲的内壁和弯曲的外壁。
14. 根据权利要求13所述的系统，其特征在于，所述弯曲的内壁和所述弯曲的外壁垂直于底座。
15. 根据权利要求13所述的系统，其特征在于，所述弯曲的内壁和所述弯曲的外壁相对于底座成角。
16. 一种添加制造方法，其包括：
在环形粉末床内制造轴对称构件。
17. 根据权利要求16所述的方法，其特征在于，所述方法还包括将多个建造室布置成圆形图案来限定所述环形粉末床。
18. 根据权利要求17所述的方法，其特征在于，使至少一个激光器与所述多个建造室中的各个相关联。
19. 根据权利要求16所述的方法，其特征在于，所述方法还包括使再涂器叶片围绕轴线旋转，所述环形粉末床围绕所述轴线限定。
20. 根据权利要求16所述的方法，其特征在于，将至少一个激光器安装于所述再涂器叶片。
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