JP7355620B2 - Manufacturing method for additively manufactured objects - Google Patents
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本発明は、３Ｄプリンターによる金属粉末の積層方法に関する。特に、レーザー溶融法を利用した銅合金の金属粉末の積層造形物の製造方法、および当該方法により製造された積層造形物に関する。 The present invention relates to a method for laminating metal powder using a 3D printer. In particular, the present invention relates to a method for manufacturing a layered product made of copper alloy metal powder using a laser melting method, and a layered product manufactured by the method.
３Ｄプリンターは、３Ｄ ＣＡＤ他３次元ソフトウェアで制作された３次元データを基礎として、スライサーソフトウェア等により、積層される２次元の断面形状における設定を行い、立体（３次元のオブジェクト：製品）を造形する積層造形技術である。このうちレーザー溶融法は、一層をレーザーで溶融、固めた後、再度上層に金属粉末をかぶせ、そこにレーザーを当てて固めるという作業を繰り返すもので、金属粉末をレーザービームで溶融して積層する金属積層造形方法である。 3D printers create three-dimensional (three-dimensional objects: products) based on three-dimensional data created using 3D CAD and other three-dimensional software, and use slicer software to set the two-dimensional cross-sectional shapes that are stacked. It is an additive manufacturing technology. Among these, the laser melting method involves repeating the process of melting and solidifying one layer with a laser, then covering the top layer with metal powder, and then applying a laser beam to solidify it.The metal powder is melted with a laser beam and laminated. It is a metal additive manufacturing method.
このうち、金属粉末を積層して造形する金属積層造形技術は、他の加工法では作れない複雑な形状の造形、多様化するニーズに対応した究極の少量他品種生産の実現など、もの造りに革命を起こす潜在能力を持ち、様々な分野で期待されている。アルミニウム、コバルト、チタン、ニッケル、ステンレス鋼など、様々な金属粉末が使用されている。 Among these, metal additive manufacturing technology, which creates products by layering metal powder, is useful for manufacturing, such as creating complex shapes that cannot be created using other processing methods, and realizing the ultimate low-volume production of other products to meet diversifying needs. It has the potential to cause a revolution and is expected to be used in various fields. A variety of metal powders are used, including aluminum, cobalt, titanium, nickel, and stainless steel.
金属のうち、銅合金素材の製造・加工については、宇宙、航空、電気自動車等多くの産業から期待されている。しかし、銅合金粉末をレーザー溶融法により金属積層造形するには、素材の特性として高反射率と高熱伝導率の２点が課題として挙げられる。反射率が高いことで銅合金粉末が赤外線レーザー光のエネルギーを吸収しにくく、粉末の温度が上昇しにくくなる。また、粉末の温度が上昇して融点を超えても、熱伝導率がアルミの約２倍、ステンレスの２０倍と大きいために、すぐに冷却されて融点以下になり凝固してしまう。そのためレーザー光照射中に融点を超えて粉末が流動している時間が非常に短く、高密度な積層金属を得ることが困難である。 Among metals, the manufacturing and processing of copper alloy materials is expected to be used in many industries such as space, aviation, and electric vehicles. However, in order to perform metal additive manufacturing using a laser melting method using copper alloy powder, there are two issues to be addressed as the characteristics of the material: high reflectance and high thermal conductivity. The high reflectance makes it difficult for the copper alloy powder to absorb the energy of infrared laser light, making it difficult for the temperature of the powder to rise. Furthermore, even if the temperature of the powder rises and exceeds its melting point, because its thermal conductivity is about twice that of aluminum and 20 times that of stainless steel, it will immediately cool down to below its melting point and solidify. Therefore, the time during which the powder flows above the melting point during laser beam irradiation is very short, making it difficult to obtain a high-density laminated metal.
一方で、電子ビームを適用した金属積層造形技術によれば造形物の生産が可能であるものの、レーザー溶融法による製造が、効率面等で有利であるために強く望まれている。この点、特定の金属粉末構成とすることで、レーザー溶融法を適用可能な銅合金粉末も開発されている。しかしながら、積層造形に期待を寄せるほとんどの銅合金の製品形状は複雑である。赤外線レーザー溶融法に関する銅合金粉末の造形方法については一部に文献（例えば特許文献１）はあるものの、銅合金粉末素材の持つ特異な材料特性のためかその実用記録はほとんど存在しない。また学会報告も極めて少なく、銅合金粉末の積層造形に対してどのような諸元が必要であるかについても過去に実用的なデータがない。特に、オーバーハング形状（例えば傾斜角度６０度以下、特に４５度以下）を有する造形では、設計通りの形状の保持すらも困難を極めている（図２参照）。現状では小さいエネルギー密度のレーザー条件で造形することが一般的手法であるが、この方法では銅粉末を十分に溶融することは難しく、必要な金属内部充填率を保てない。一方、通常の条件のままでは実用に耐えないほどの造形形状となってしまう。したがって、結果的に製品として有用な程度に提供可能な銅合金のレーザー溶融法による金属積層物は、例えばキュービクルなど、単純な形状のものに限られている（図１参照）。 On the other hand, although it is possible to produce shaped objects using metal additive manufacturing technology that uses electron beams, manufacturing using laser melting is strongly desired because it is advantageous in terms of efficiency and the like. In this regard, copper alloy powders have also been developed that can be applied with laser melting by having a specific metal powder composition. However, the shapes of most copper alloy products that are promising for additive manufacturing are complex. Although there are some documents (for example, Patent Document 1) regarding a method for shaping copper alloy powder using infrared laser melting, there are almost no records of its practical use, probably due to the unique material properties of the copper alloy powder material. Furthermore, there are very few academic conference reports, and there is no practical data in the past regarding what specifications are required for additive manufacturing of copper alloy powder. In particular, in the case of a shape having an overhang shape (for example, an inclination angle of 60 degrees or less, especially 45 degrees or less), it is extremely difficult to maintain the shape as designed (see FIG. 2). Currently, the common method is to model using a laser with a low energy density, but with this method it is difficult to sufficiently melt the copper powder and the required internal metal filling rate cannot be maintained. On the other hand, if normal conditions are used, the shape will be too large for practical use. Therefore, metal laminates of copper alloy produced by the laser melting method that can be provided as useful products are limited to those with simple shapes, such as cubicles (see FIG. 1).
そこで、本発明は、銅合金粉末を使用し、高密度・高品質な、レーザー溶融法による金属積層造形物の提供を可能とする方法を提供することを目的とする。 Therefore, an object of the present invention is to provide a method that uses copper alloy powder and makes it possible to provide a high-density, high-quality metal layered product by laser melting.
上記課題を解決するため、本発明は、金属粉末をベースプレートに敷き詰める機構と、所定の位置にレーザー光を照射する機構と、を備えた金属積層造形装置を使用し、粉末にレーザー光を照射し溶融、凝固させて積層することを繰り返す、銅または銅合金の積層造形物を製造する方法であって、
前記積層造形物は、２層目以上の少なくとも１つの層において、下層に造形部のないエリアを含む形状を備え、前記少なくとも１つの層において、第１の入熱エリアと、第２の入熱エリアを設定し、
第２の入熱エリアは下層に造形部のないエリアを含み、当該第２の入熱エリアには、第１の入熱エリアよりも高いエネルギー密度で入熱を行う行程を含むことを特徴とする製造方法からなる。
In order to solve the above problems, the present invention uses a metal additive manufacturing apparatus equipped with a mechanism for spreading metal powder on a base plate and a mechanism for irradiating a laser beam at a predetermined position, and irradiating the powder with a laser beam. A method for manufacturing a copper or copper alloy laminate product by repeating melting, solidification and lamination, the method comprising:
The laminate-produced article has a shape that includes an area without a modeling part in the lower layer in at least one of the second or higher layers, and in the at least one layer, a first heat input area and a second heat input area. Set the area,
The second heat input area includes an area in which there is no modeling part in the lower layer, and the second heat input area includes a process in which heat is input at a higher energy density than the first heat input area. It consists of a manufacturing method.
さらに、本発明は、金属粉末をベースプレートに敷き詰める機構と、所定の位置にレーザー光を照射する機構と、を備えた金属積層造形装置を使用し、粉末にレーザー光を照射し溶融、凝固させて積層することを繰り返す、銅または銅合金の積層造形物を製造する方法であって、
前記積層造形物は、ベースプレートと仰角方向の傾斜角度を有するオーバーハング部を有し、オーバーハング部の少なくとも１つの層において、第１の入熱エリアと、第２の入熱エリアを設定し、
第２の入熱エリアは下層に造形部のないエリアを含み、第１の入熱エリアのレーザー走査速度及び／又はハッチ間隔に対し、第２の入熱エリアの所定のエリアにおけるレーザー走査速度及び／又はハッチ間隔を小さくすることを特徴とする製造方法からなる。
Furthermore, the present invention uses a metal additive manufacturing apparatus equipped with a mechanism for spreading metal powder on a base plate and a mechanism for irradiating laser light onto predetermined positions, and irradiating the powder with laser light to melt and solidify it. A method for manufacturing a copper or copper alloy laminate product by repeatedly laminating layers, the method comprising:
The laminate-molded article has an overhang part having an inclination angle in the elevation direction with respect to the base plate, and a first heat input area and a second heat input area are set in at least one layer of the overhang part,
The second heat input area includes an area without a modeling part in the lower layer, and the laser scanning speed and/or hatch spacing in a predetermined area of the second heat input area is different from the laser scanning speed and/or hatch spacing of the first heat input area. and/or a manufacturing method characterized by reducing the hatch interval.
本発明で積層する造形物は、２層目以上の少なくとも１つの層において、下層に造形部のないエリアを含む形状、又はベースプレートと仰角方向の傾斜角度を有するオーバーハング部を有しており、通常条件のレーザー溶融法の入熱では実用的な成形はできない。そこで、下層に造形部のないエリアを含む一定のエリアを、通常の入熱を行う第１の入熱エリアと異なるパラメータで入熱を行う。具体的には、第２の入熱エリアには、第１の入熱エリアよりも高いエネルギー密度（Ｊ／ｍｍ３）で入熱を行う。一般的には出力を下げて小さいエネルギー密度を入熱するが、本発明では第２入熱エリアにおいて従来設定される以上の出力を提供し、レーザー走査速度及び／又はハッチ間隔が調整されエネルギー密度を非常に大きく提供する。 The shaped article to be laminated in the present invention has, in at least one of the second or higher layers, a shape including an area without a shaped part in the lower layer, or an overhang part having an inclination angle in the elevation direction with respect to the base plate, Practical molding cannot be achieved with the heat input of laser melting under normal conditions. Therefore, heat is input into a certain area including an area where there is no modeling part in the lower layer using different parameters from the first heat input area where normal heat input is performed. Specifically, heat is input into the second heat input area at a higher energy density (J/mm 3 ) than the first heat input area. Generally, the output is lowered and a small energy density is input, but in the present invention, the second heat input area provides an output higher than that conventionally set, and the laser scanning speed and/or hatch spacing are adjusted to increase the energy density. provide a very large amount of
第２入熱エリアへ入熱するエネルギー密度は、第１の入熱エリアへ入熱するエネルギー密度の２倍以上であることが好適である。さらには、３倍以上であることが好ましい。具体的な値は合金の性質や積層厚さなどにより個別に模索される必要があるが、第１の入熱エリアに対する第２の入熱エリアの出力を下げる場合であっても極力下げ比率を抑えつつ、パラメータを調整することで非常に高いエネルギー密度の入熱提供が行われる。 It is preferable that the energy density of heat input into the second heat input area is at least twice the energy density of heat input into the first heat input area. Furthermore, it is preferably 3 times or more. The specific value needs to be explored individually depending on the properties of the alloy and the laminated thickness, but even when lowering the output of the second heat input area relative to the first heat input area, the reduction ratio should be kept as much as possible. By adjusting the parameters, a very high energy density heat input can be provided.
第２の入熱エリアの設定面積は、造形に十分な成形を行うべく、合金の性質や積層厚さなどにより具体的に模索され、その算出はＴＲ／ｔａｎθ（ｍｍ）にて行われ（Ｔ＝厚さ、Ｒ＝造形形状に由来する個別値（１≦Ｒ）、θ＝ベースプレートと仰角方向の傾斜角度）、溶融箇所の既積層の垂直距離に依存する。この構成が上記した入熱構成に反映されると、非常に高精度かつ高品質な造形物として製造可能である。当該構成は、下層に造形部ない部分が存在しない層においても、第１の入熱エリアと、第２の入熱エリアを設定し、当該第２の入熱エリアには、第１の入熱エリアよりも高いエネルギー密度で入熱を行う行程を内包する。 The set area of the second heat input area is specifically explored based on the properties of the alloy and the laminated thickness, etc., in order to perform sufficient forming for modeling, and its calculation is performed using TR/tanθ (mm) (T = thickness, R = individual value derived from the shaped shape (1≦R), θ = angle of inclination in the elevation direction relative to the base plate), and depends on the vertical distance of the already laminated layers at the melting point. When this configuration is reflected in the heat input configuration described above, it is possible to manufacture a molded article with extremely high precision and high quality. In this configuration, a first heat input area and a second heat input area are set even in a layer where there is no part without a modeling part in the lower layer, and the second heat input area has a first heat input area. It includes the process of inputting heat with a higher energy density than the area.
また、本発明は、上記方法にて製造された、ベースプレートとの仰角方向の傾斜角度が６０度以下のオーバーハング部分を有する積層造形物からなる。さらに、当該オーバーハング部の造形物の内部充填率が９９．５％ 以上であることからなる Further, the present invention includes a laminate-molded article manufactured by the above-mentioned method and having an overhang portion having an inclination angle of 60 degrees or less in the elevation direction with respect to the base plate. Furthermore, the internal filling rate of the modeled object in the overhang part is 99.5% or more.
本発明では、例えば波長１０６４ｎｍの赤外線ファイバーレーザー光（Ｎｄ：ＹＡＧレーザー）を熱源としたレーザー溶融法で、銅合金粉末を造形ステージに敷き詰める機構とその所定の位置に赤外線レーザー光を照射する機構と粉末を溶融、凝固させて積層することを繰り返す機構の金属積層造形装置を使用する。装置構成は本発明を実行可能である限り特に限定されない。例えば２系統のレーザー照射機構を有しており、各々のレーザー出力が最大で７００Ｗの出力の装置を使用できる。銅合金粉末を造形ステージに敷き詰める機構において、厚さは限定されないが、リコータ機構に関しては精密かつ均質に銅合金粉末を溶融させるため０．０２～０．１ｍｍの厚さで均一に敷き詰め可能な機構を有したリコータ機構が、好ましい。 The present invention uses a laser melting method using an infrared fiber laser beam (Nd: YAG laser) with a wavelength of 1064 nm as a heat source, for example, to spread copper alloy powder onto a modeling stage, and to irradiate infrared laser beams at predetermined positions. A metal additive manufacturing device is used that repeatedly melts, solidifies, and laminates powder. The device configuration is not particularly limited as long as the present invention can be carried out. For example, it is possible to use a device that has two systems of laser irradiation mechanisms, each with a maximum laser output of 700W. In the mechanism for spreading copper alloy powder on the modeling stage, the thickness is not limited, but the recoater mechanism is a mechanism that can evenly spread the copper alloy powder to a thickness of 0.02 to 0.1 mm in order to melt the copper alloy powder precisely and homogeneously. A recoater mechanism having the following is preferred.
上記積層造形に使用する銅合金粉末の成分は、例えばＣｒ１．０～１．５％質量、Ｚｒ０．２０～０．２５％質量、残部がＣｕ及び不可避的不純物からなる銅合金粉末を採用可能である。銅合金粉末はＣｒを含むことにより造形中の熱伝導率を下げる効果があり、銅合金粉末の造形を容易にする効果がある。更に凝固時にＣｒ相が析出して機械的強度と電気伝導性、熱伝導性に優れる銅合金造形物が期待できる。またＺｒは微量の添加によりＣｕ合金の中間温度脆性を改善し、熱伝導率を下げる酸素（Ｏ）等の不純物と化合物を形成して不純物の影響を抑える効果が期待できる。また造形作業の生産性と作業性を考慮して、粉末は例えば１５μｍ～４５μｍの粒径のものを使用することが望ましい。 As for the components of the copper alloy powder used in the above-mentioned additive manufacturing, for example, a copper alloy powder consisting of 1.0 to 1.5% Cr by mass, 0.20 to 0.25% Zr by mass, and the balance being Cu and unavoidable impurities can be adopted. be. By containing Cr, the copper alloy powder has the effect of lowering the thermal conductivity during shaping, and has the effect of facilitating the shaping of the copper alloy powder. Furthermore, a Cr phase is precipitated during solidification, and a copper alloy shaped article with excellent mechanical strength, electrical conductivity, and thermal conductivity can be expected. Further, when added in a small amount, Zr can be expected to have the effect of improving the intermediate temperature brittleness of the Cu alloy, forming a compound with impurities such as oxygen (O), which lowers the thermal conductivity, and suppressing the influence of impurities. Further, in consideration of the productivity and workability of the molding operation, it is desirable to use a powder having a particle size of, for example, 15 μm to 45 μm.
なお、本発明の上記行程は、レーザー溶融法を利用した銅合金の金属粉末の積層造形物の製造方法としてだけではなく、３Ｄデータを基にしてスライサー等により設定する、２次元の断面形状における設定方法としても把握される。 Note that the above process of the present invention is not only used as a method for manufacturing a copper alloy metal powder layered product using a laser melting method, but also as a method for manufacturing a two-dimensional cross-sectional shape that is set using a slicer or the like based on 3D data. It can also be understood as a setting method.
上記積層造形は造形中の銅合金粉末の溶融・凝固金属の酸化と造形物の欠陥発生を防止する観点から、酸素濃度を０．０１～０．１％の範囲に保持する密室スペースで造形を行うことが望ましい。 In order to prevent the oxidation of the molten and solidified metal of the copper alloy powder and the occurrence of defects in the modeled object, the additive manufacturing process described above is performed in a closed space where the oxygen concentration is maintained within the range of 0.01 to 0.1%. It is desirable to do so.
上記に加えてベースプレートにオーステナイト系ステンレス鋼ベースプレートを使用することが好適である。共材の銅系ベースプレートを使用した場合、造形開始後の銅合金の粉末溶融形態は粉末の温度が上昇して融点を超えても、熱伝導率が高いために、すぐに冷却されて融点以下になり凝固してしまう。そのためレーザー照射中に融点を超えて粉末が流動している時間が非常に短く、高密度な積層金属を得ることが困難になる。オーステナイト系ステンレス鋼ベースプレートは銅系のプレートに比較して熱伝導率が約２０倍小さいため、造形開始後の銅合金の粉末の急冷・凝固を緩和し、銅合金粉末を十分に溶融し、凝固を規則正しく繰り返させる効果で、造形物全体の品質が向上し、上記構成と合わせ、オーバーハング部を含め内部充填率を９９．５０％以上、さらには９９．８０％近傍まで達成可能となる。 In addition to the above, it is preferred to use an austenitic stainless steel base plate for the base plate. When using a co-material copper base plate, even if the temperature of the powder rises and exceeds the melting point after the start of modeling, the powder quickly cools down to below the melting point due to its high thermal conductivity. and solidify. Therefore, the time during which the powder flows above its melting point during laser irradiation is extremely short, making it difficult to obtain a high-density laminated metal. The austenitic stainless steel base plate has approximately 20 times lower thermal conductivity than copper-based plates, so it eases the rapid cooling and solidification of copper alloy powder after the start of modeling, and allows the copper alloy powder to sufficiently melt and solidify. The effect of regularly repeating this improves the quality of the entire modeled object, and in combination with the above configuration, it becomes possible to achieve an internal filling rate of 99.50% or more, even close to 99.80%, including the overhang portion.
また、一般的に銅合金鋼を熱加工する方法として組成のもつ熱的特性に対処するため、加工前の母相の予熱、加工中の母相温度を制御する必要があるが、ベースプレートにオーステナイト系ステンレス鋼ベースプレートを使用することで、積層造形中の過度な熱拡散を防止し、本銅合金粉末の造形においては予熱及び積層造形中の母相の温度制御等は特に必要とせずに安定した積層造形物の構築を可能にする。 In addition, in order to deal with the thermal characteristics of the composition in general when heat working copper alloy steel, it is necessary to preheat the parent phase before processing and control the parent phase temperature during processing. By using a stainless steel base plate, excessive heat diffusion during additive manufacturing is prevented, and the modeling of this copper alloy powder is stable without the need for preheating or temperature control of the matrix during additive manufacturing. Enables the construction of additively manufactured objects.
以下、図面を参照して説明する。
図１は、銅合金粉末における単純形状（キュービクル）造形物の積層方向に平行な断面とその内部充填状況を示す図（写真）である。ベースプレートと仰角方向の傾斜角度を有するオーバーハング部が存在しない造形物については、レーザー溶融法によっても造形可能なものが存在している。
This will be explained below with reference to the drawings.
FIG. 1 is a diagram (photograph) showing a cross section parallel to the stacking direction of a simple shaped (cubicle) shaped object made of copper alloy powder and its internal filling state. As for objects that do not have an overhang portion that has an inclination angle in the elevation direction with respect to the base plate, there are objects that can also be formed by laser melting.
これに対し、図２はオーバーハングを有する形状の造形結果を示す図である。設定される造形物１は、キュービクル状の底部６から上に向けて６０度、５０度、４５度、４０度のオーバーハング部２～５を有している。図２上部には造形物の斜視、図下部には正面及び側面が示される。サポート７は造形物を支え、製造後に切り離される。当該オーバーハング部２～５においては、各層において下層に造形部がない部分を有し、かつその面積は角度が下がるごとに増大する。 On the other hand, FIG. 2 is a diagram showing the modeling result of a shape having an overhang. The modeled object 1 to be set has overhang parts 2 to 5 of 60 degrees, 50 degrees, 45 degrees, and 40 degrees upward from the cubicle-shaped bottom 6. The upper part of FIG. 2 shows a perspective view of the model, and the lower part of the figure shows the front and side views. The support 7 supports the modeled object and is separated after manufacturing. In each of the overhang parts 2 to 5, there is a part in which there is no shaped part in the lower layer, and the area thereof increases as the angle decreases.
図３従来の造形手法を用いた銅合金粉末において、図２に示す造形物の造形結果を示す図である。上部には側面、下部には底面である。明らかに、オーバーハング部２～５の下面において形状が崩れる。特に、５０度以下の面において顕著である。さらに、４５度以下になると、側面からでも一見して形状の崩れが見て取れる状態となる。当該造形は、図２の設定造形とは明確に異なり、精密さの要求に耐えない。 FIG. 3 is a diagram showing the results of modeling the object shown in FIG. 2 using copper alloy powder using a conventional modeling method. The upper part is the side surface, and the lower part is the bottom surface. Obviously, the shapes of the overhang parts 2 to 5 are distorted on the lower surfaces. This is particularly noticeable on surfaces of 50 degrees or less. Furthermore, if the angle is 45 degrees or less, the shape will be deformed, which can be seen at a glance even from the side. This shape is clearly different from the set shape shown in FIG. 2 and does not meet the requirements for precision.
図４は、本発明の方法を示す概念図である。オーバーハング部を有するＮ－１～Ｎ＋１層において、通常のエネルギー密度にて入熱を行う第１の入熱エリア８、より高いエネルギー密度にて入熱を行う第２の入熱エリア９が設けられる。これら入熱エリアにおいて、レーザー機器１０が２系統の出力原を有していれば、より効率的に製造が可能となる。第２の入熱エリア９は、設計としては、端部１１から境界位置１２までの距離をＸとしたとき、オーバーハング形状のベースプレートとのなす角をθ、積層厚さを０．０３ｍｍとすれば、Ｘ＝０．０３Ｒ／ｔａｎθ（ｍｍ）（Ｒ：Reference：溶融箇所の既積層の垂直距離に依存し、造形物形状によって適宜変更される値）として表され、下層に既積層がない部分の距離に対し、下層に既積層がある部分の距離が数倍以上はおろか、数十倍～数百倍となり得る、非常に大きい面積を採る。第２の入熱エリア９には、第１の入熱エリア８よりも高いエネルギー密度で入熱を行う。 FIG. 4 is a conceptual diagram showing the method of the present invention. In the N-1 to N+1 layers having an overhang part, a first heat input area 8 that inputs heat at a normal energy density and a second heat input area 9 that inputs heat at a higher energy density are provided. It will be done. In these heat input areas, if the laser device 10 has two systems of output sources, more efficient manufacturing becomes possible. The second heat input area 9 is designed so that when the distance from the end 11 to the boundary position 12 is X, the angle formed with the overhang-shaped base plate is θ, and the laminated thickness is 0.03 mm. For example, it is expressed as Compared to the distance of , the distance of the part with the existing laminated layer below is not only several times or more, but can be tens to hundreds of times, so it takes up a very large area. Heat is input into the second heat input area 9 at a higher energy density than the first heat input area 8.
図５及び図６に示すように、第２の入熱エリアは、上述式により端部１１から境界位置１２までに渡り設定され、下層に既積層がある部分も含み設定される。この結果一般的に放熱性が劣悪であるオーバーハング面のＺ方向距離が十分に確保される。当該実施例においては、銅合金粉末を使用した０．０３ｍｍの層で、第１の入熱エリアには１４４，２３（Ｊ／ｍｍ３）、第２の入熱エリアには４７６．１９（Ｊ／ｍｍ３）のエネルギー密度で入熱が行われている。ほぼ３．３倍のエネルギー密度であり、２倍以上、好ましくは３倍以上の高いエネルギー密度が精密な造形を実現に資する。なお、通常のレーザー溶融法と同様に、形状をかたどる枠部分はエリア部分と別の設定（高いエネルギー密度の入力）が行われる。このときも、第１の入熱エリアの枠よりも第２の入熱エリアの枠の方が高いエネルギー密度の入熱が行われる。 As shown in FIGS. 5 and 6, the second heat input area is set from the end portion 11 to the boundary position 12 using the above-mentioned formula, and is set to include a portion where there is an already laminated layer below. As a result, a sufficient distance in the Z direction of the overhang surface, which generally has poor heat dissipation, is ensured. In this example, a 0.03 mm layer using copper alloy powder has a power of 144.23 (J/mm 3 ) in the first heat input area and 476.19 (J/mm 3 ) in the second heat input area. Heat input is performed at an energy density of /mm 3 ). The energy density is approximately 3.3 times higher, and an energy density higher than 2 times, preferably 3 times or more contributes to realizing precise modeling. Note that, similar to the normal laser melting method, the frame portion that shapes the shape is set differently from the area portion (high energy density input). At this time as well, heat input with a higher energy density is performed in the frame of the second heat input area than in the frame of the first heat input area.
図７は、上記例にて製造された造形物の写真（側面）、およびオーバーハング部の拡大写真である。オーバーハング部において、成形の正確さが実現され、欠陥は見受けられなかった。本例においては、ベースプレートにオーステナイト系ステンレス鋼ベースプレートを使用しており、内部充填率９９．８０％近傍まで達し、成形の正確さだけでなく、品質も非常に高い。ただし、Ｃｕベースプレートの場合も、９９．５０％近傍まで達しており、本発明の方法の有利性が確認された。 FIG. 7 is a photograph (side view) of the model manufactured in the above example and an enlarged photograph of the overhang portion. In the overhang part, molding accuracy was achieved and no defects were observed. In this example, an austenitic stainless steel base plate is used as the base plate, and the internal filling rate is close to 99.80%, and not only the accuracy of molding but also the quality is very high. However, in the case of the Cu base plate as well, it reached nearly 99.50%, confirming the advantage of the method of the present invention.
図８は、本発明の方法により製造された造形物を２例示している。産業界で要求される造形物はこのように複雑であり、０度の角度を含めた大小多くのオーバーハング部を有している。本発明によれば、これら新たな形状物を、高品質に効率的にレーザー溶融法により可能となる。 FIG. 8 shows two examples of shaped objects manufactured by the method of the present invention. The molded objects required in the industrial world are thus complex and have many overhang parts of various sizes, including angles of 0 degrees. According to the present invention, these new shapes can be produced efficiently and with high quality by laser melting.
１ 造形物
２～５ オーバーハング部
６ 底部
７ サポート
８ 第１の入熱エリア
９ 第２の入熱エリア
１０ レーザー機器
１１ 端部
１２ 境界位置
1 Modeled object 2 to 5 Overhang part 6 Bottom part 7 Support 8 First heat input area 9 Second heat input area 10 Laser device 11 End part 12 Boundary position
Claims (7)
前記積層造形物は、ベースプレートと仰角方向の傾斜角度を有するオーバーハング部を有し、オーバーハング部を有する少なくとも１つの層において、第１の入熱エリアと、第２の入熱エリアを設定し、
第１の入熱エリアは下層に造形部のないエリアを含まず、第２の入熱エリアは下層に造形部のないエリアを含み、第１の入熱エリアのレーザー走査速度及びハッチ間隔に対し、第２の入熱エリアのレーザー走査速度及びハッチ間隔が小さいことを特徴とする製造方法。 Using a metal additive manufacturing device equipped with a mechanism that spreads metal powder onto a base plate and a mechanism that irradiates laser light to predetermined positions, the powder is repeatedly irradiated with laser light, melted and solidified, and then laminated. A method for manufacturing a copper or copper alloy laminate product, the method comprising:
The laminate-molded article has an overhang part having an inclination angle in the elevation direction with respect to the base plate, and a first heat input area and a second heat input area are set in at least one layer having the overhang part. ,
The first heat input area does not include an area without a built-in part in the lower layer, and the second heat input area includes an area without a built-in part in the lower layer, and the laser scanning speed and hatch spacing of the first heat input area , a manufacturing method characterized in that the laser scanning speed and hatch interval of the second heat input area are small.
前記積層造形物は、ベースプレートと仰角方向の傾斜角度を有するオーバーハング部を有し、オーバーハング部を有する少なくとも１つの層において、第１の入熱エリアと、第２の入熱エリアを設定し、The laminate-molded article has an overhang part having an inclination angle in the elevation direction with respect to the base plate, and a first heat input area and a second heat input area are set in at least one layer having the overhang part. ,
第１の入熱エリアは下層に造形部のないエリアを含まず、第２の入熱エリアは下層に造形部のないエリアを含み、第１の入熱エリアのレーザー走査速度及びハッチ間隔に対し、第２の入熱エリアのレーザー走査速度及びハッチ間隔を小さくする設定を含むことを特徴とする方法。The first heat input area does not include an area without a built-in part in the lower layer, and the second heat input area includes an area without a built-in part in the lower layer, and the laser scanning speed and hatch spacing of the first heat input area , a method comprising: setting a laser scanning speed and a hatch spacing of the second heat input area to be small;
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