CN119703086B - Intermittent scanning type laser selective melting forming method for porous metal part - Google Patents
Intermittent scanning type laser selective melting forming method for porous metal partInfo
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Abstract
The application belongs to the technical field of laser additive manufacturing, and discloses a discontinuous scanning type laser selective melting forming method of a porous metal part, which comprises the steps of slicing a three-dimensional digital-analog layer of the porous metal part to be formed according to a preset layer thickness; filling each layer of slices sequentially by using intermittent laser scanning tracks to obtain laser intermittent scanning track filling data, wherein the intermittent laser scanning tracks in the same layer of slices are parallel to each other, a preset included angle is formed between the intermittent laser scanning tracks in the odd layer of slices and the intermittent laser scanning tracks in the even layer of slices, the laser scanning tracks consist of solid line scanning tracks and interval tracks, the solid line scanning tracks and the interval tracks are alternately and linearly arranged, and laser selective area melting forming is performed based on preset layer thickness and the laser intermittent scanning track filling data to obtain the porous metal part. The application simplifies the preparation process of the porous metal part, and can prepare the metal part with higher porosity, pore uniformity and pore connectivity.
Description
Technical Field
The application belongs to the technical field of laser additive manufacturing, and particularly relates to a discontinuous scanning type laser selective melting forming method of a porous metal part.
Background
The porous metal part has the advantages of low density, large specific surface area and the like, and is generally used as a functional metal part to be widely applied to the fields of aerospace, automobile manufacturing, energy, biomedicine, construction, electronics and the like. Conventional methods for producing porous metal parts, such as sintering method, foaming method, etc., while meeting the production requirements of porous metal parts to some extent, are difficult to realize high-performance and high-efficiency production of porous metal parts. The laser selective melting technology (SELECTIVE LASER MELTING, SLM) is one of the laser additive manufacturing technologies which are very rapid in development at the present stage, has the advantages of wide material adaptability, short manufacturing period, strong performance and the like, and provides a new solution for the customization of complex porous metal parts and the integrated production requirement of structural functions. For example, in chinese patent application publication No. CN112935277B, a laser selective melting forming method of a multistage interconnection microporous metal sweating structure is disclosed, which obtains first-order micropores by simple single-mode boolean operation on an original digital model of a part, obtains second-order micropores by setting a distance between laser scanning track lines larger than a cladding line width, and obtains third-order micropores by increasing laser energy input to generate air holes at the bottom of a melting channel. Through multistage micropore design, the space interconnectivity and uniformity of the pores are enhanced, and the problems of single pore direction and anisotropism of pore structures are solved to a certain extent. However, this method still relies on pre-processing of the part model, which not only increases manufacturing costs, but also reduces production efficiency.
In summary, the existing methods for forming porous metal parts by SLM have difficulty in meeting the requirements of high-efficiency and high-performance forming of porous metal parts with controllable pore structures, mutually communicated pores and isotropy on the premise of not changing the original digital model of the metal parts.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide a discontinuous scanning type laser selective melting forming method of a porous metal part, which aims to solve the problem that the existing method for forming the porous metal part by SLM can not meet the manufacturing requirements of the porous metal part with simplified model design, reduced model data volume, adjustable pore structure, uniform pore distribution and mutual communication of pores.
In order to achieve the above object, the present application provides a discontinuous scanning type laser selective melting forming method for a porous metal part, the forming method comprising:
S1, layering and slicing a three-dimensional digital model of a porous metal part to be formed according to a preset layer thickness to obtain a multi-layer slice;
S2, filling each layer of slices sequentially by using intermittent laser scanning tracks to obtain intermittent laser scanning track filling data, wherein the intermittent laser scanning tracks in the same layer of slices are parallel to each other, and form a preset included angle with the intermittent laser scanning tracks in the even layer of slices;
and S3, performing laser selective fusion forming based on the preset layer thickness and the filling data of the intermittent laser scanning tracks, and performing laser fusion forming on the continuous scanning tracks in the forming process, and stopping laser fusion forming at the interval tracks to obtain the porous metal part.
The forming method provided by the application realizes the complete communication of the porous metal part layer by layer and channel by channel pores in the laser selective melting forming process, the porosity, the pore distribution uniformity and the pore connectivity of the metal part are greatly improved, and the anisotropism of the metal part is effectively improved. Meanwhile, the manufacturing period of the porous metal part is shortened, the production process is simplified, and the production cost of the porous metal part is greatly reduced.
Further, in step S2, the length of the solid scanning track is 0.1mm to 5mm, and the length of the interval track is 0.05mm to 2.5mm.
Further, the ratio of the length of the interval track to the length of the solid scanning track is between 0.1 and 0.5.
Further, in step S2, the laser moving speed at the interval track is greater than the laser scanning speed at the solid line scanning track.
Further, the laser moving speed at the interval track is within the range of 1000 mm/s-6000 mm/s, and the laser scanning speed at the solid line scanning track is within the range of 300 mm/s-2000 mm/s.
In step S2, the distance between adjacent intermittent laser scanning tracks is greater than the width of the laser melt channel formed by the corresponding laser scanning tracks in the same slice, and/or the distance between adjacent intermittent laser scanning tracks is 1-5 times the width of the laser melt channel.
Further, in step S3, during layer-by-layer printing, the laser vibrating mirror motor is utilized to rotate and control laser scanning tracks in the odd-layer slices and the even-layer slices to form an included angle, and the included angle is 0 degrees < omega <180 degrees.
Further, the included angle between the laser scanning tracks between the odd layer and the even layer can be divided by 180 degrees.
Further, in step S1, the preset layer thickness is 0.02 mm-0.4 mm.
Further, in step S1, when the porosity requirements of different sections on the porous metal part to be formed are different, sectioning the porous metal part section according to the different porosities, and in the corresponding step S2, the solid line scanning track length and/or the interval track length of the intermittent laser scanning track formed in each section in different sections are different.
In general, compared with the prior art, the above technical solution conceived by the present application mainly has the following technical advantages:
1. The intermittent scanning type laser selective melting forming method of the porous metal part provided by the application does not need to carry out additional treatment on the original three-dimensional digital model of the metal part, namely the three-dimensional digital model of the porous metal part is designed according to the physical appearance, and a pore structure is not required to be designed, so that the design difficulty of the three-dimensional digital model of the porous metal part is greatly reduced, and the data volume of the three-dimensional digital model is obviously reduced. The manufacturing of the porous metal part can be realized by a discontinuous scanning type laser selective melting forming mode, the preparation process flow is simplified, and the preparation process flow meets the high-efficiency high-quality forming requirement of the porous metal part.
2. The intermittent scanning type laser selective melting forming method designs intermittent scanning type laser track lines, wherein solid scanning tracks and interval tracks are alternately arranged in a straight line, when a porous metal part is actually prepared, laser scanning melting is carried out at the solid scanning tracks, laser scanning is stopped at the interval tracks, a metal structure with holes on each layer can be obtained, the holes are completely communicated layer by layer and channel by channel in the preparation process of the porous metal part, the porosity, the uniformity of pore distribution and the connectivity of the holes are greatly improved, and the anisotropism is effectively improved.
3. The intermittent scanning type laser selective melting forming method provided by the application not only shortens the manufacturing period of the porous metal part and simplifies the production process, but also greatly reduces the production cost of the porous metal part.
4. The intermittent scanning type laser selective melting forming method provided by the application can regulate and control the porosity and pore structure of the porous metal part only by changing the lengths of the solid scanning track and the interval track in the intermittent parameters of the laser track line, and is simple and convenient to operate.
5. The intermittent scanning type laser selective melting forming method provided by the application can realize the gradient change of the porosity by regulating and controlling the lengths of the solid scanning track and the interval track in the laser intermittent scanning track line of different slice layers in different sections when the porosity requirements of different sections of the same part are different, so that the porous metal part with the gradient change of the porosity is manufactured. In a word, the intermittent scanning type laser selective melting forming method provided by the application can synchronously simplify the preparation process of the gradient porous metal part, increases the design freedom degree of the porous metal part, and provides a new solution for the integrated manufacture of the porous metal part.
Drawings
FIG. 1 is a schematic flow diagram of a discontinuous scanning type laser selective melting forming method for porous metal parts;
FIG. 2 is a schematic view of a conventional continuous scanning laser scanning track line and a corresponding melt channel structure provided by the present application;
FIG. 3 is a schematic view of intermittent laser scanning track lines and corresponding melt channel structures provided by the present application;
FIG. 4 is a schematic illustration of the length of the solid line trace and the interval trace of the intermittent laser scanning trace and the corresponding melt channel provided by the present application;
FIG. 5 is a schematic diagram of a conventional continuous scanning laser scanning melt channel filling effect and an intermittent laser scanning melt channel filling effect based on a 90-degree interlayer angle provided by the application;
fig. 6 is a schematic diagram showing intermittent laser scanning track line segment arrangement of a titanium alloy porous gradient metal flat plate part provided in embodiment 3 of the present application.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention. In addition, the technical features of the embodiments of the present invention described below may be combined with each other as long as they do not collide with each other.
The application provides a discontinuous scanning type laser selective melting forming method of a porous metal part, which is shown in figure 1 and comprises the following steps:
s1, guiding a three-dimensional digital model of a porous metal part into laser selective melting equipment, and slicing a three-dimensional digital model of the porous metal part to be formed into layers according to a preset layer thickness to obtain a multi-layer slice;
S2, filling each layer of slices sequentially by using intermittent laser scanning tracks to obtain intermittent laser scanning track filling data, wherein the intermittent laser scanning tracks in the same layer of slices are parallel to each other, and form a preset included angle with the intermittent laser scanning tracks in the even layer of slices;
S3, performing laser selective fusion forming based on preset layer thickness and laser intermittent scanning track filling data, and performing laser fusion forming on the solid scanning track in the forming process, and stopping laser fusion forming at the interval track to obtain the porous metal part.
In the step S1, a three-dimensional digital model of the porous metal part is firstly guided into a laser selective melting device, the three-dimensional model is subjected to layered slicing according to a preset layer thickness, and the layer-by-layer section outline of the three-dimensional model is obtained from bottom to top.
In step S2, each slice is sequentially filled with an intermittent laser scanning track, and the intermittent laser scanning track is specifically set as follows:
1) In the same slice, the intermittent laser scanning tracks are parallel to each other, and the line interval between two adjacent laser scanning tracks is larger than the width of a laser melting channel formed after laser melting along any one laser scanning track line, so that the adjacent laser melting channels are ensured not to be contacted, and an initial pore is formed. The laser melting channel refers to a melting track formed by melting a metal powder bed along a laser scanning track line, the width of the laser melting channel is related to laser processing parameters such as powder materials, preset layer thicknesses, laser power and the like, and the width value of the laser melting channel can be obtained through a large amount of basic process test historical data. The line spacing of the laser scanning tracks refers to the distance between the central axes of two adjacent laser scanning track lines in the same slice.
Specifically, the line spacing of adjacent intermittent laser scanning track lines in the same slice is selected within the range of 1-5 times of the width of the laser melting channel, for example, the line spacing of the adjacent intermittent laser scanning track lines is 1.5 times, 2 times, 2.5 times, 3 times, 3.5 times, 4 times, 4.5 times, 5 times and the like of the width of the laser melting channel, or any multiple between any two of the above multiples, so as to ensure that the adjacent laser melting channel is not contacted, and an initial pore can be generated. The line spacing of adjacent intermittent laser scanning track lines selected according to the principle is easier to calculate, and the value is more regular, so that the stability and the reliability of equipment forming are improved, and the forming quality of porous metal parts is improved. On the premise of ensuring that adjacent melt channels are not contacted, the multiple can be adjusted according to the requirement, and the larger the multiple is selected, the larger the initial pore size and the larger the corresponding porosity.
2) The projections of intermittent laser scanning tracks in the slices of the odd layers and the even layers on the X-Y horizontal plane are intersected, namely the intermittent laser scanning tracks between adjacent layers form a preset included angle. The preset included angle, namely the value of the adjacent interlayer angle, is larger than 0 degrees and smaller than 180 degrees, and because in some laser selective melting equipment, the adjustment of the adjacent interlayer angle is realized through the rotation angle of the laser galvanometer motor, and the laser galvanometer motor can drive the laser emission end to rotate within the rotation angle range so that the intermittent laser scanning track can cover the outline area of the whole porous metal part, thereby realizing uniform melting and accumulation of metal powder. If the angle between adjacent layers exceeds the range, the complexity of a software control motor can be increased, and the stability and the reliability of the laser selective melting equipment can be influenced, so that the laser scanning track line is repeated or omitted.
In a more preferred embodiment, the included angle between the laser scanning tracks between the odd and even layers can be divided by 180 °, for example, 30 °, 45 °,60 °, 90 °, etc. In the laser selective melting process, residual stress can be generated in the metal part due to rapid heating and cooling, and the angle between adjacent layers is selected to be an angle value capable of being divided by 180 degrees, so that the rotation angle of the motor can be controlled more easily, the laser scanning track lines are distributed more uniformly among different layers, the accumulation of the residual stress is reduced, and the forming quality of the porous metal part is improved.
3) As shown in fig. 2, the conventional continuous laser scanning track a and the corresponding melt channel B are all a straight line segment. As shown in FIG. 3, the intermittent laser scanning track a provided by the application is formed by alternating a solid scanning track a1 and an interval track a2 between two adjacent sections of solid scanning tracks, the lengths of the solid scanning track a1 and the interval track a2 are adjustable, laser only scans molten metal powder in the solid scanning track a1 and stops scanning melting work in the interval track a2, so that the interval track a2 finally forms an interconnection channel of an initial pore, and the corresponding melting channel b is also intermittent and comprises a solid melting channel b1 and an interval melting channel b2.
Specifically, as shown in fig. 4, the solid line scanning track length m refers to the line segment length of the single-segment laser action track line, and the interval track length n refers to the line segment length of the single-segment no-laser action track line. Specifically, the length m of the solid line scanning track a1 is 0.1 mm-5 mm, the length n of the interval track a2 is 0.05 mm-2.5 mm, and the ratio of the length n of the interval track a2 to the length m of the solid line scanning track a1 is between 0.1 and 0.5. When the ratio of n/m is less than 0.10, the laser interval track length is too short to form stable interconnection channels, and when the ratio of n/m is greater than 0.50, the laser interval track length n is greater than the solid line scanning track length m, and at this time, the solid line fusing track b1 is insufficient to maintain stable formation of the porous metal part.
In step S2, the laser speeds at the solid line scanning track and the interval track are set so that the laser moving speed at the interval track is greater than the laser scanning speed at the solid line scanning track, so as to reduce the time of no laser action in the interval track, thereby improving the production efficiency and further reducing the cost.
Specifically, the scanning speed at the solid line scanning track refers to the actual scanning speed when the laser scans the solid line scanning track, and the laser moving speed at the interval track refers to the speed when the laser moves from the end of the last solid line scanning track to the beginning of the next solid line scanning track through the interval track. More specifically, the laser movement speed at the interval track is set to be in the range of 1000mm/s to 6000mm/s, such as 1000mm/s, 2000mm/s, 3000mm/s, 4000mm/s, 5000mm/s, 6000mm/s, or any one speed value between any two speed values, and the laser scanning speed at the solid line scanning track is set to be in the range of 300mm/s to 2000mm/s, such as 300mm/s, 500mm/s, 700mm/s, 900mm/s, 1000mm/s, 1300mm/s, 1500mm/s, 1800mm/s, 2000mm/s, or any one speed value between any two speed values.
In the step S3, the thickness of the laser selective melting single-layer powder bed is set to be a preset layer thickness, and the preset layer thickness is set to be 0.02mm-0.4mm, such as 0.02mm, 0.05mm, 0.08mm, 0.1mm, 0.13mm, 0.15mm, 0.18mm, 0.2mm, 0.23mm, 0.25mm, 0.28mm, 0.3mm, 0.35mm, 0.4mm and the like, or any value between any two values. If the thickness of the single-layer powder bed is less than 0.02mm, the molding efficiency is too low, and if the thickness of the single-layer powder bed is more than 0.40mm, the molding accuracy is too low.
When the laser selective melting process is adopted for actual layer-by-layer manufacturing, the selected metal powder materials comprise common metal additive manufacturing materials such as nickel-based superalloy, titanium alloy, aluminum alloy, cobalt-based alloy, tungsten-based alloy and the like, and in the preparation process, the laser scanning tracks in the odd-numbered layer slices and the even-numbered layer slices are controlled to form an included angle by utilizing the rotation of a laser galvanometer motor, and the included angle is 0 degree < omega <180 degrees.
In other preferred embodiments, in step S1, when the porosity requirements of different sections on the porous metal part to be formed are different, the porous metal part sections are sectioned according to the different porosities, and in the corresponding step S2, the solid line scanning track length and/or the interval track length forming the intermittent laser scanning track in each section are different.
The specific implementation method of the different porosities comprises the following steps:
① Setting the same solid line scanning track length and interval track length for all slice layers, and adjusting the solid line scanning track length and interval track length can realize the integral regulation of the internal pore characteristics of the porous metal part;
② According to the actual pore demand, the slice layers of the three-dimensional model of the porous metal part are segmented, different solid line scanning track lengths and interval track lengths are set for slice layers of different segments, or different solid line scanning track lengths and same interval track lengths are set for slice layers of different segments, or the same solid line scanning track lengths and different interval track lengths are set for slice layers of different segments, so that gradient setting of pore characteristics of the porous metal part is realized through combination of solid line scanning tracks and interval tracks of various lengths.
The intermittent scanning type laser selective melt forming method of the porous metal part provided above is described below by way of a number of examples.
Example 1
In this embodiment, a GH4169 nickel-based superalloy porous test block is taken as an example, the size of the test block is 10mm×10mm×10mm, and the specific steps of the forming method of the GH4169 nickel-based superalloy porous test block are as follows:
(1) Introducing a three-dimensional digital model (hereinafter referred to as three-dimensional model) of the nickel-based superalloy porous test block into a laser selective melting device, and slicing the three-dimensional digital model layer by layer according to a preset layer thickness of 0.05mm to obtain a layer-by-layer section profile of the three-dimensional model from bottom to top, wherein the layer-by-layer section profile is square and has a size of 10mm multiplied by 10mm. The three-dimensional digital model of the nickel-based superalloy porous test block only comprises the outline dimension of the solid test block, and the internal pore structure of the solid test block is not designed.
(2) Filling the sections of the multi-layer slices layer by adopting intermittent laser scanning track lines, wherein the related parameters of the intermittent laser scanning track are set as follows:
① In the same layer section, intermittent laser scanning track lines are arranged in parallel, the laser track width of GH4169 nickel-based superalloy under the condition of 300W of laser power is confirmed to be 100 mu m according to a basic process test, and correspondingly, the distance between adjacent laser scanning track lines is set to be 1.5 times of the track width, namely, the distance between adjacent laser scanning track lines is 150 mu m, so that the adjacent laser track lines are ensured not to be contacted, and an initial pore is formed.
② The intermittent laser scanning track line is formed by alternately arranging solid scanning tracks and interval tracks, specifically, the length m of the solid scanning track is=1.00 mm, the length n of the interval track is=0.20 mm, the ratio of the length of the interval track to the length of the solid track is 0.2, the laser scanning speed of the solid scanning track section is set to 1000mm/s, and the moving speed of the laser skipping interval track section is set to 3000mm/s;
③ The included angle of the intermittent laser scanning track lines between two adjacent layers (namely the angle between the adjacent layers) is selected to be 90 degrees.
And (3) filling all slice section outlines layer by layer from bottom to top by adopting the intermittent laser scanning track line set in the step (2) so as to generate a laser intermittent scanning filling file which can be identified by the laser selective melting equipment. Specifically, after combining each layer of laser scanning filling file, complete laser intermittent scanning filling data containing laser scanning filling information of all slice layers is obtained.
(3) And (3) loading the dried GH4169 nickel-based superalloy metal powder into a laser selective area melting device, and completing laser selective area melting forming of the superalloy porous test block layer by layer and channel by channel according to the preset layer thickness of 0.05mm in the step (1) and the complete laser intermittent scanning filling file obtained in the step (2), wherein in the forming process, the laser molten metal powder in a solid line scanning track in an intermittent laser scanning track forms compact pore walls, and the laser forms interconnection channels between initial pores in interval tracks. The nickel-based superalloy porous test block with uniform pore distribution and interconnected pores is prepared according to a layer-by-layer intermittent scanning type laser selective melting forming method, the internal pore structure is shown in the right graph in fig. 5, and compared with the internal pore structure of a metal plate which is prepared according to a continuous laser scanning track and is shown in the left graph in fig. 5 and prepared by adopting a laser selective melting process under the same condition, the metal internal porosity in the embodiment is obviously higher, the pore distribution uniformity is better, and the pore connectivity is stronger.
Example 2
Taking an AlSi10Mg aluminum alloy porous metal flat plate as an example, the dimensions of the AlSi10Mg aluminum alloy porous metal flat plate are 100mm×80mm×10mm, and the specific steps of the forming method of the AlSi10Mg aluminum alloy porous metal flat plate are as follows:
(1) The three-dimensional digital model (the size is 100mm multiplied by 80mm multiplied by 10mm, hereinafter referred to as three-dimensional model) of the AlSi10Mg aluminum alloy porous metal flat plate metal part is led into a laser selective area melting device, the three-dimensional digital model is subjected to layered slicing according to the preset layer thickness of 0.02mm, the layer-by-layer section profile of the three-dimensional model is obtained from bottom to top, the layer-by-layer section profile is rectangular, the size is 80mm multiplied by 10mm, and the three-dimensional digital model of the aluminum alloy porous metal flat plate is designed according to the external size of a solid flat plate without additional design of pore structures.
(2) Filling the sections of the multi-layer slices layer by adopting a preset intermittent laser scanning track line, wherein the related parameters of the intermittent laser scanning track are set as follows:
① In the same layer section, intermittent laser scanning track lines are arranged in parallel, the width of an AlSi10Mg aluminum alloy laser melting channel under the condition of 400W of laser power is confirmed to be 150 mu m according to a basic process test, and correspondingly, the distance between adjacent intermittent laser scanning track lines is set to be 2.0 times of the width of the melting channel, namely, the distance between adjacent intermittent laser scanning track lines is 300 mu m, so that the adjacent melting channels are ensured not to be contacted, and an initial pore is formed;
② The intermittent laser scanning track line is formed by alternately arranging solid scanning tracks and interval tracks, specifically, the length m=2.00 mm of the solid scanning track, the length n=0.50 mm of the interval track, the ratio of the length of the interval track to the length of the solid track is 0.25, the laser scanning speed of the solid scanning track section is set to 1400mm/s, and the moving speed of the laser skipping interval track section is set to 4000mm/s;
③ The included angle of the intermittent laser scanning track lines between two adjacent layers (namely the angle between the adjacent layers) is selected to be 60 degrees.
And (3) filling all slice section outlines layer by layer from bottom to top by adopting the intermittent laser scanning track line set in the step (2) so as to generate a laser intermittent scanning filling file which can be identified by the laser selective melting equipment. Specifically, after combining each layer of laser scanning filling file, complete laser intermittent scanning filling data containing laser scanning filling information of all slice layers is obtained.
(3) And (3) loading the dried AlSi10Mg aluminum alloy metal powder into a laser selective melting device, and completing laser selective melting forming of the aluminum alloy porous metal flat plate layer by layer and layer by layer according to the preset layer thickness of 0.02mm in the step (1) and the complete laser intermittent scanning filling file generated in the step (2), wherein in the forming process, laser melting metal powder in a solid line scanning track in an intermittent laser scanning track forms compact pore walls, and an interconnection channel between initial pores is formed by closing laser in an interval track. The nickel-based superalloy porous test block with uniform pore distribution and mutually communicated pores is prepared according to a layer-by-layer intermittent scanning type laser selective melting forming method.
Example 3
In this embodiment, a Ti6Al4V titanium alloy porous gradient metal flat plate part is taken as an example, and the dimensions of the titanium alloy porous gradient metal flat plate part are 150mm×70mm×10mm, and the titanium alloy porous gradient metal flat plate part is required to have a porosity set of porosity values at intervals of 50mm along the height direction (the total height is 150 mm), three porous flat plate areas with different porosities are arranged in total, and the three porosity values are increased progressively. The method comprises the following specific steps:
(1) Introducing a three-dimensional digital model (with the size of 150mm multiplied by 70mm multiplied by 10 mm) of the Ti6Al4V titanium alloy porous gradient metal flat plate part into laser selective area melting equipment, and slicing the three-dimensional digital model in a layering way according to the preset layer thickness of 0.04mm so as to obtain the layer-by-layer cross section profile of the three-dimensional model from bottom to top, wherein the layer-by-layer cross section profile is rectangular (with the size of 70mm multiplied by 10 mm). According to the porosity requirement of the titanium alloy porous gradient metal flat plate, the slice layer of the porous gradient flat plate is equally divided into three sections according to the height range of 0-150mm from bottom to top, namely the layer number range corresponding to 1-3750, as shown in fig. 6:
the first section is with the height range of 0-50mm and the layer number range of 1-1250 layers;
the second section, the height range is 50-100mm, and the layer number range is 1251-2500;
The third section is 100-150mm, the layer number range is 2501-3750;
the original model of the three-dimensional digital model of the Ti6Al4V titanium alloy porous gradient metal flat plate is designed by the shape information of a solid flat plate, and a pore structure is not additionally designed in the original model.
(2) Filling the sections of the multi-layer slices layer by adopting intermittent laser scanning track lines, wherein the related parameters of the intermittent laser scanning track are set as follows:
① In the same layer section, intermittent laser scanning track lines are arranged in parallel, the width of a Ti6Al4V titanium alloy laser melting channel under the condition of 280W of laser power adopted is confirmed to be 110 mu m according to a basic process test, and correspondingly, the distance between adjacent intermittent laser scanning track lines is set to be 2.5 times of the width of the melting channel, namely, the distance between the intermittent laser scanning track lines is 275 mu m, so that the adjacent melting channels are ensured not to be contacted, and an initial pore is formed;
② The intermittent laser scanning track line is formed by alternately arranging solid scanning tracks and interval tracks, and specifically, the laser only works on the solid scanning track section and does not work on the interval track inner section, so that the interval track section does not have a melting channel, and an interconnection channel of an initial pore is formed.
③ The adjacent interlayer angle is selected to be 60 °.
④ Because the porosity of the titanium alloy porous gradient slab is required to be distributed in an equidistant gradient manner along the length direction, the solid line scanning track length and the interval track length are arranged in a gradient manner within the three-section slicing layering range of the porous gradient slab, and the specific arrangement mode is as follows in combination with the description of fig. 6:
The first section is 0-50mm, the layer number range is 1-1250 layers, the length m1=2.00 mm of the solid scanning track is set, the length n1=0.30 mm of the interval track is set, and the ratio of the length of the interval track to the length of the solid scanning track is 0.15 under the value parameter;
the second section is 50-100mm, the layer number range is 1251-2500 layers, the length m2=2.00 mm of the solid scanning track is set, the length n2=0.40 mm of the interval track is set, and the ratio of the length of the interval track to the length of the solid scanning track is 0.20 under the value parameter;
The third section is 100-150mm, the layer number range is 2501-3750 layers, the length m3=2.00 mm of the solid scanning track is set, the length n3=0.50 mm of the interval track is set, and the ratio of the length of the interval track to the length of the solid scanning track is 0.25 under the value parameter;
The solid scanning track length and the interval track length gradient in the layering range of the three sections of slices meet the requirement of stable forming of the Ti6Al4V titanium alloy porous gradient flat plate metal part, the ratio of the interval track length to the solid scanning track length of the three sections of porous flat plate areas is 0.15, 0.20 and 0.25 from bottom to top, and the porosity gradient is increased.
And after filling all the corresponding slice section outlines according to the intermittent laser scanning track lines, merging laser scanning filling files generated layer by layer to obtain a complete laser intermittent scanning filling file containing all slice layer laser scanning filling file information.
(3) And (3) loading the dried Ti6Al4V titanium alloy metal powder into a laser selective melting device, and completing laser selective melting forming of the Ti6Al4V titanium alloy gradient porous metal flat plate metal part layer by layer from bottom to top according to the preset layer thickness of 0.04mm in the step (1) and the complete laser intermittent scanning filling file obtained in the step (2), wherein in the forming process, in a laser intermittent scanning track, the laser melting metal powder forms compact pore walls in a solid line scanning track, and laser is closed in an interval track, so that interconnected channels among initial pores are formed. After the metal part is subjected to layer-by-layer intermittent scanning type laser selective melting forming, the Ti6Al4V titanium alloy gradient porous metal flat metal part with uniformly distributed pore gradients and mutually communicated pores is obtained.
The above description is only of the preferred embodiments of the present invention and is not intended to limit the present invention, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
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