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WO2022000865A1 - 一种原位能量控制的激光选区熔化装置及方法 - Google Patents

一种原位能量控制的激光选区熔化装置及方法 Download PDF

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Publication number
WO2022000865A1
WO2022000865A1 PCT/CN2020/121764 CN2020121764W WO2022000865A1 WO 2022000865 A1 WO2022000865 A1 WO 2022000865A1 CN 2020121764 W CN2020121764 W CN 2020121764W WO 2022000865 A1 WO2022000865 A1 WO 2022000865A1
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Prior art keywords
laser
spot
forming
flat
selective melting
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PCT/CN2020/121764
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English (en)
French (fr)
Inventor
宋长辉
刘林青
胡泽华
杨永强
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华南理工大学
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Priority to JP2023500030A priority Critical patent/JP2023532575A/ja
Publication of WO2022000865A1 publication Critical patent/WO2022000865A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/003—Apparatus, e.g. furnaces
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • 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
    • 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
    • B33Y30/00—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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/10—Pre-treatment
    • 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
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/248—Thermal after-treatment
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention belongs to the technical field of augmented material manufacturing, and in particular relates to an in-situ energy-controlled laser selective melting device and method.
  • Selective Laser Melting is an additive manufacturing technology that uses high-energy lasers to rapidly melt and solidify irradiated powders to achieve layer-by-layer molding of molded parts.
  • SLM Selective Laser Melting
  • Great thermal stress is generated inside the final structure, which causes stress deformation, cracking and other problems of the molded parts, and even leads to the failure of the molding process.
  • the molten pool formed by the powder under the action of high-energy laser is prone to spatter and other problems.
  • the existing control methods such as adding a preheating system, powder modification, adjusting process parameters (laser parameters, scanning parameters, etc.), subsequent heat treatment, etc. These problems cannot be fundamentally solved.
  • the laser beam shaping technology based on the principle of diffractive optics can transform the original laser beam into a beam with a specific spatial intensity distribution through wavefront transformation. This technology can convert a laser beam with Gaussian energy distribution into a flat-top large spot with uniform energy distribution.
  • the flat-topped large spot is applied to the powder preheating/annealing treatment of the post-forming structure in the laser selective melting process, which can effectively reduce the internal stress, cracks and other defects of the formed parts, and at the same time
  • the flat-top large light spot provides energy lower than the melting point threshold of the material, so that the original SLM optical path can be melted and formed with low energy input, which is beneficial to reduce the splash of the molten pool.
  • diffractive optical shaping elements have the advantages of small size, light weight, low cost, and high diffraction efficiency.
  • the combination of laser beam shaping technology and laser selective melting technology has broad application prospects for improving the quality of shaped parts.
  • the main purpose of the present invention is to overcome the shortcomings and deficiencies of the prior art.
  • a new flat-top large light spot is added on the basis of the original SLM.
  • the flat-top large light spot is nested and synthesized with the original SLM small light spot.
  • the largest spot is in the positive/negative defocus state on the processing plane. It is mainly used for powder preheating in the laser selective melting process/annealing treatment of the post-forming structure, which can effectively reduce the internal stress, cracks and other defects of the formed parts, while providing low
  • the energy at the melting point threshold of the material can make the original SLM optical path input lower energy to melt and form, which is beneficial to reduce the splash of the molten pool and improve the forming quality of the parts.
  • An in-situ energy-controlled laser selective melting device comprising a small spot light path device for laser selective melting molding, a new flat-top large light spot light path device, and a laser selective melting molding device, the laser selective melting molding small spot light path device, a new The flat-top large-spot light path device is arranged on the laser selective melting and forming equipment;
  • the laser selective melting and forming small spot light path device includes a first laser, a first collimator, a first scanning galvanometer, a laser fiber shaper and a first f- ⁇ mirror.
  • the laser beam is emitted by the first laser and passes through the first laser beam.
  • the collimator beam expands into the first scanning galvanometer, and finally focuses on the forming plane under the action of the first f-theta mirror for laser selective melting of powder;
  • the newly added flat-top large-spot optical path device includes a second laser, a second collimator, a second scanning galvanometer and a second f- ⁇ mirror.
  • the laser beam is emitted by the second laser and expanded through the second collimator. Then enter the laser beam shaper to shape, and then pass through the second scanning galvanometer and under the action of the second f-theta mirror, the positive/negative defocusing of the forming plane becomes a large light spot, and the preheating/annealing treatment is carried out according to the predetermined forming path.
  • the laser selective melting and forming equipment includes a painting, a first powder recovery cylinder, a forming cylinder, a lift servo motor, a powder cylinder and a second powder recovery cylinder; the first powder recovery cylinder and the second powder recovery cylinder.
  • the powder material recovery cylinder is arranged on the left and right sides of the bottom of the laser selective melting and forming equipment, and the powder coating is arranged above the forming cylinder; the powder material cylinder is arranged at the bottom of the laser selective melting and forming equipment; the lift servo motor is arranged on the molding the bottom of the cylinder;
  • the first laser is a 1064nm fiber laser
  • the second laser is a 1064nm fiber laser or a 450nm blue laser.
  • the present invention also provides an implementation method of an in-situ energy-controlled laser selective melting device, comprising the following steps:
  • the laser selective melting and forming system based on in-situ energy control provides laser selective melting and forming of a small spot laser beam and a new flat-top large spot laser beam.
  • the scanning path data and laser scanning speed of the two laser beams are consistent.
  • the laser delay parameters of the two laser beams ensure that the light is emitted at the same time and the focus scanning center position of the two laser beams is the same, so that the small spot laser beam and the flat-top large spot laser beam can keep the scanning trajectory during the SLM molding process, and the two large and small spots are in the same position.
  • the forming plane keeps coaxial nesting;
  • the laser is emitted by the first laser, passes through the first collimator, and is focused into a small spot by the first f-theta mirror on the forming and processing plane, and is subjected to the first scanning galvanometer.
  • the control of the machine moves on the molding surface according to the predetermined molding path to melt the powder material;
  • the laser is emitted by the second laser, passes through the second collimator, and is shaped by the laser beam shaper, and the second f-theta mirror acts on the forming process.
  • the plane is in a positive/negative defocus state, providing energy lower than the melting point threshold of the material, and is controlled by the second scanning galvanometer to follow the forming beam, and preheating/annealing is performed on the forming surface according to the predetermined forming path;
  • the coaxial light spot formed by the combination of the laser selective melting and forming small spot laser beam and the newly added flat-top large spot laser beam on the forming surface scans the powder bed synchronously, and jointly completes the forming process of the entire part.
  • the flat-top large-spot laser beam is required to have a sufficiently high energy density, and on the other hand, it is necessary to ensure that the timing of light emission and light closing is accurate and controllable. , the energy of the light-emitting process is stable, so as to realize the nested synthesis and synchronous scanning of the two laser beams.
  • the newly added flat-top large spot can change the positive/negative defocus distance by adjusting the magnification of the collimator to change the size of its action area on the powder bed, and at the same time, adjust the laser power to change the spot energy density.
  • the second laser is a 1064nm fiber laser or a 450nm short-wavelength blue laser.
  • the second laser is a fiber laser
  • the laser is converted into a flat-top large spot laser beam with uniform energy distribution through a laser beam shaper, and preheating is performed. /annealing treatment.
  • the flat-top large spot adopts a high-power fiber laser or a semiconductor blue laser.
  • the second laser is a blue laser
  • two sets of laser beams with different wavelengths can also be used. In situ coordinated control of energy input, increasing energy input regulation means.
  • the laser beam shaper converts the laser beam with Gaussian energy distribution into a flat-top light spot with uniform energy distribution, and adjusts the size of the flat-top light spot by adjusting the magnification of the collimator and variable focus.
  • the action mechanism of the coaxial light spot on the powder bed is that in the direction of the forward movement of the laser, the powder first passes through the preheating area with a lower temperature in the large flat-topped light spot for preheating, and then the powder is preheated in the Gaussian spot. It melts and solidifies under irradiation, and the solidified metal is irradiated with a flat-top large spot with a lower temperature for annealing treatment.
  • the flat-top large spot with uniform energy density can be remelted to further improve the forming quality of the product.
  • the solidified metal is remelted and solidified by the uniform energy spot irradiation, which can reduce the internal stress, reduce the defects of incompletely melted powder, and improve the density and surface quality.
  • the present invention has the following advantages and beneficial effects:
  • the new flat-top large-spot laser in the present invention can provide energy lower than the melting point threshold of the material. At this time, the original SLM laser beam can only input lower energy to realize the melting of metal powder, which is conducive to reducing the amount of powder micro-melting pool. Spatter behavior and micro-porosity defects inside parts;
  • the laser selective melting of the present invention forms the nested distribution of the small spot and the newly added flat-topped large spot, and the synchronous scanning and the newly added flat-topped large spot can change the size of its action area on the powder bed by positive/negative defocusing.
  • the laser energy is further controlled in time and space, and then the heat flow distribution of the molten pool and the melting/solidification rate of the molten pool are controlled, and the microstructure formation and evolution of the SLM under the non-equilibrium rapid melting and solidification mechanism are regulated;
  • the newly added flat-top large light spot in the present invention realizes the preheating treatment of powder and the annealing treatment of solidified metal during the molding process, which is beneficial to reduce the temperature gradient and reduce the internal stress of the forming, thereby reducing the deformation, cracking and other behaviors caused by stress.
  • the present invention can perform preheating/annealing treatment in real time during the molding process by adding a flat-top and large spot laser, which makes the molding process more integrated, and the means of reducing thermal stress in real time is beneficial to reducing the deformation of parts during the molding process. Possibility to improve the stability of part molding.
  • FIG. 1 is a schematic diagram of a laser selective melting device based on in-situ energy control of the present invention
  • Fig. 2 is the schematic flow chart of the laser selective melting method based on in-situ energy control of the present invention
  • FIG. 3 is a schematic diagram of a large flat-top light spot formed by positive/negative defocusing in the second optical path
  • Fig. 4 is a schematic diagram of coaxial nesting synthesis of a small spot formed by laser selective melting and a newly added large spot with a flat top;
  • Figure 5 is a schematic diagram of the energy distribution of a small spot and a newly added flat-topped large spot by laser selective melting.
  • A-laser selective melting and forming small spot laser beam B-new flat-top large spot laser beam; B1-forming powder preheating area; B2-solidified metal annealing treatment area; R-energy threshold required for melting point of powder material.
  • an in-situ energy-controlled laser selective melting device in this embodiment includes a small spot light path device for laser selective melting, a new flat-top large spot light path device, and a laser selective melting and molding equipment.
  • the small spot light path device for melting molding and the newly added flat-top large-spot light path device are set on the laser selective melting and molding equipment; in this embodiment, a new flat-top large light spot for synchronous scanning is added to provide energy below the melting point threshold of the powder to carry out powder processing.
  • the preheating/solidification rate is regulated, and the formed metal is annealed to reduce the temperature gradient and reduce the internal stress of the forming, thereby reducing the deformation, cracking and other behaviors caused by the stress.
  • the laser selective melting and forming small spot optical path device includes a first laser 1, a first collimator 2, a first scanning galvanometer 3 and a first f- ⁇ mirror 8, and the laser beam is emitted by the first laser 1, The beam expands through the first collimator 2 and enters the first scanning galvanometer 3, and finally is focused on the forming plane under the action of the first f-theta mirror 8 to perform laser selective melting of the powder.
  • the newly added flat-top large-spot optical path device includes a second laser 7, a second collimator 6, a second scanning galvanometer 4, a laser fiber shaper 5 and a second f-theta mirror 9, and the laser beam is composed of
  • the second laser 7 emits, expands the beam through the second collimator 6 and then enters the laser beam shaper 5 for shaping, then passes through the second scanning galvanometer 4 and is positive/negative on the shaping plane under the action of the second f- ⁇ mirror 9
  • the coke is a large spot, and the preheating/annealing treatment is carried out according to the predetermined molding path.
  • the laser selective melting and forming equipment includes a plastering brush 11, a first powder material recovery cylinder 12, a forming cylinder 13, a lift servo motor 14, a powder material cylinder 15 and a second powder material recovery cylinder 16; the first powder material recovery cylinder 16;
  • the material recovery cylinder 12 and the second powder material recovery cylinder 16 are arranged on the left and right sides of the bottom of the laser selective melting and forming equipment, and the powder coating 11 is arranged above the forming cylinder 13; the powder material cylinder 15 is arranged on the laser selective melting and forming equipment.
  • the bottom of the forming cylinder; the lifting servo motor 14 is arranged at the bottom of the forming cylinder, and the forming part 10 is formed at the final forming cylinder.
  • the first laser is a 1064nm fiber laser
  • the second laser is a 1064 nm fiber laser or a 450 nm blue laser.
  • the present invention proposes a kind of laser selective melting technology and method of in-situ energy control, and the specific embodiment comprises the following steps:
  • Step 1 The laser selective melting and forming system based on in-situ energy control provides laser selective melting and forming small spot laser beam A (first optical path) and newly added flat-top large spot laser beam B (second optical path);
  • the scanning path data of the beam and the laser scanning speed are kept the same.
  • the small spot laser beam can be flat-topped and the large spot can be made.
  • the scanning trajectory of the laser beam is kept synchronized during the SLM forming process, and the two large and small light spots are coaxially nested on the forming processing plane;
  • Step 2 Laser selective melting and forming of small spot laser beam A in the process of melting powder, the laser is emitted by the first laser (1064nm fiber laser), passes through the first collimator, and is focused by the first f-theta mirror on the forming and processing plane.
  • the small spot is controlled by the first scanning galvanometer to move on the forming surface according to the predetermined forming path to melt the powder material;
  • Step 3 During the preheating/annealing process of the newly added flat-top large-spot laser beam B, the laser is emitted by the second laser (1064nm fiber laser or 450nm blue laser), passes through the second collimator, and is laser beam shaped by the laser beam shaper Shaping, the second f-theta mirror acts on the forming processing plane to be in a positive/negative defocus state (as shown in Figure 3), provides energy lower than the melting point threshold R of the material, and is controlled by the second scanning galvanometer to follow the forming beam , preheating/annealing is carried out on the forming surface according to the predetermined forming path;
  • the second laser 1064nm fiber laser or 450nm blue laser
  • Step 4 The powder bed is synchronously scanned by the coaxial light spot formed by the laser selective melting and forming of the small spot laser beam A and the newly added flat-top large spot laser beam B on the forming surface, and the forming process of the entire part is completed together.
  • the flat-top large spot with uniform energy density can be remelted to further improve the forming quality of the product.
  • the laser parameters of the flat-top and large spot are set to use a larger energy input to achieve the melting point of the material. Reduce incompletely melted powder defects, etc., improve density, surface quality, etc.
  • the laser is required to have a sufficiently high energy density;
  • the energy is stable to realize the nested synthesis and synchronous scanning of the two laser beams.
  • the nesting and synchronous scanning of the two laser beam spots can be realized by adjusting the light-emitting and closing delay of the laser.
  • the newly added flat-topped large light spot in step 1 can change the size of its active area on the powder bed by changing the distance of positive/negative defocusing.
  • the size of the new flat-top large spot can be determined according to the physical properties of the powder material, the scanning distance, and the splashing of the molten pool.
  • the laser described in step 3 can be selected from a fiber laser and a short-wavelength blue laser.
  • the laser is a fiber laser
  • the laser can be converted into a flat-top large-spot laser beam with uniform energy distribution through a laser beam shaper, and preheat/ Annealing treatment;
  • the laser is a blue laser, in addition to the same process as the fiber laser, the energy input can also be controlled in situ by two sets of laser beams with different wavelengths, and the energy input regulation means can be added.
  • the laser beam shaper described in step 3 can convert the laser beam with Gaussian energy distribution into a flat-top light spot with uniform energy distribution, and the size of the flat-top light spot can be adjusted by a collimator.
  • the mechanism of action of the coaxial light spot on the powder bed described in steps 1 and 4 is that in the direction of the forward movement of the laser, the powder first passes through the preheating area B1 with a lower temperature in the flat-top large light spot for preheating treatment, Then, it is melted and solidified under the irradiation of the Gaussian spot, and the solidified metal is annealed again through the solidified metal annealing treatment area B2 in the flat-top large spot with a lower temperature (as shown in Figure 4 and Figure 5).
  • the preheating/annealing treatment can be performed in real time during the molding process, which makes the molding process more integrated, and the means of reducing thermal stress in real time is beneficial to reduce the possibility of deformation of the parts during the molding process. , to improve the stability of parts forming.
  • a new flat-top large spot of synchronous scanning is added, and the powder preheating/solidifying metal annealing treatment is performed below the powder melting point threshold, which is beneficial to reduce the temperature gradient and reduce the forming internal stress , thereby reducing deformation, cracking and other behaviors caused by stress; at the same time, it provides an energy input lower than the melting point threshold of the material.
  • the original SLM small spot only needs to provide a lower energy input to complete the melting of the material, which is conducive to improving the splash of the molten pool. and the occurrence of micro-porosity and other undesirable situations.
  • the present invention realizes the temporal and spatial distribution of laser energy based on the in-situ energy control method, which is of great significance for regulating the coagulation rate and thus regulating tissue evolution. Therefore, the present invention can effectively reduce the defects generated in the process of forming parts, and can also control the solidification rate and regulate the evolution of the structure, which has a significant role in stably and efficiently forming high-performance parts and promoting the wide application of additive manufacturing technology.

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Abstract

一种原位能量控制的激光选区熔化装置，包括激光选区熔化成型小光斑光路装置、新增平顶大光斑光路装置和激光选区熔化成型设备，所述激光选区熔化成型小光斑光路装置、新增平顶大光斑光路装置设置在激光选区熔化成型设备上；新增一路同步扫描的平顶大光斑，提供粉末熔点阈值以下能量，进行粉末预热/凝固速率调控，并对成形的金属进行退火处理。以及一种原位能量控制的激光选区熔化装置的实现方法。通过新增的一路同步扫描的平顶大光斑，降低温度梯度，减少成形内应力，从而减少应力导致的变形、开裂等行为；同时因提供了低于材料熔点阈值的能量输入，原SLM小光斑仅需提供较低能量输入即可完成材料的熔化，有利于改善熔池飞溅及微气孔产生等不良情况。

Description

一种原位能量控制的激光选区熔化装置及方法 技术领域
本发明属于増材制造的技术领域，具体涉及一种原位能量控制的激光选区熔化装置及方法。
背景技术
激光选区熔化技术(SLM)是一种通过高能激光使受辐照粉末快速熔化快速凝固而实现成型零件层层成型的增材制造技术。在激光选区熔化成型过程中，粉末床在高斯分布的激光光斑照射下形成的微熔池内部由于热量分布不均匀(传热过程不均匀)及其导致的传质过程不平衡，容易使冷却凝固后的组织结构内部产生极大的热应力，从而使成型零件出现应力变形、开裂等问题，甚至导致成型过程失败。另外，粉末在高能激光的作用下形成的熔池容易产生飞溅等问题，现有的调控手段如加装预热系统、粉末改性、调节工艺参数(激光参数、扫描参数等)、后续热处理等无法从根本上解决这些问题。
随着激光光束整形技术的发展，将其与激光选区熔化技术结合，有效解决激光选区熔化成型过程的高应力、高飞溅问题成为可能。基于衍射光学原理的激光光束整形技术，能够通过波前变换，将原始激光束整形为按特定空间强度分布的光束。该技术可以把高斯能量分布的激光束转化为能量均匀分布的平顶大光斑。基于原位能量控制理念，在原SLM基础上将该平顶大光斑运用于激光选区熔化过程中的粉末预热/成型后组织的退火处理，可以有效降低成型零件的内应力、裂纹等缺陷，同时该平顶大光斑提供低于材料熔点阈值的能量，使原SLM光路输入较低能量即可熔化成型，有利于减少熔池飞溅。目前，衍射光学整 形元件具有体积小、重量轻、造价低、衍射效率高等优点，将激光光束整形技术与激光选区熔化技术结合对于改善成型零件质量具有广阔的应用前景。
2020年2月，美国劳伦斯利弗莫尔国家实验室顶级期刊Acta Materialia新发表研究表明，可以改变激光光斑时空分布来定制3D打印组织和性能。不同形状的光斑形貌对于凝固组织的生长和微观组织的形成有极大影响，这为激光3D打印开辟了一条新的路径。但仅仅改变光斑形貌控制激光能量的方式仍然比较单一，幅度有限。
发明内容
本发明的主要目的在于克服现有技术的缺点与不足，基于原位能量控制的理念，在原SLM基础上新增一路平顶大光斑，该平顶大光斑与原SLM小光斑嵌套合成，平顶大光斑在加工平面为正/负离焦状态，主要用于激光选区熔化过程中的粉末预热/成型后组织的退火处理，可以有效降低成型零件的内应力、裂纹等缺陷，同时提供低于材料熔点阈值的能量，使原SLM光路输入较低能量即可熔化成型，有利于减少熔池飞溅，提升零件成型质量。
为了达到上述目的，本发明采用以下技术方案：
一种原位能量控制的激光选区熔化装置，包括激光选区熔化成型小光斑光路装置、新增平顶大光斑光路装置和激光选区熔化成型设备，所述激光选区熔化成型小光斑光路装置、新增平顶大光斑光路装置设置在激光选区熔化成型设备上；
所述激光选区熔化成型小光斑光路装置包括第一激光器、第一准直器、第一扫描振镜、激光光纤整形器和第一f-θ镜，激光束由第一激光器发出，经过第一准直器扩束进入第一扫描振镜，最终在第一f-θ镜作用下聚焦于成型平面进行 激光选区熔化粉末；
所述新增平顶大光斑光路装置包括第二激光器、第二准直器、第二扫描振镜和第二f-θ镜，激光束由第二激光器发出，经过第二准直器扩束后进入激光光束整形器整形，然后经过第二扫描振镜并在第二f-θ镜作用下在成型平面正/负离焦为大光斑，按照预定成型路径进行预热/退火处理。
进一步的，所述激光选区熔化成型设备包括铺粉刷、第一粉料回收缸、成形缸、升降伺服电机、粉料缸和第二粉料回收缸；所述第一粉料回收缸和第二粉料回收缸设置在激光选区熔化成型设备底部的左右两侧，所述铺粉刷设置在成型缸上方；所述粉料缸设置在激光选区熔化成型设备的底部；所述升降伺服电机设置在成型缸底部；
所述第一激光器为1064nm光纤激光器；
所述第二激光器为1064nm光纤激光器或450nm蓝光激光器。
本发明还提供了一种原位能量控制的激光选区熔化装置的实现方法，包括下述步骤：
基于原位能量控制的激光选区熔化成型系统提供了激光选区熔化成型小光斑激光束与新增平顶大光斑激光束，两路激光束的扫描路径数据以及激光扫描速度保持一致，同时通过调节两路激光束的激光延时参数保证同时出光并使两路激光束的聚焦扫描中心位置相同，使小光斑激光束和平顶大光斑激光束在SLM成型过程中扫描轨迹保持同步，且两大小光斑在成型加工平面保持同轴嵌套；
激光选区熔化成型小光斑激光束熔化粉末过程中，激光由第一激光器发射，经过第一准直器，由第一f-θ镜作用在成型加工平面聚焦成小光斑，受第一扫描振镜的控制按照预定成型路径在成型加工表面进行移动，使粉末材料熔化；
新增平顶大光斑激光束进行预热/退火过程中，激光由第二激光器发射，经过第二准直器，由激光光束整形器进行激光整形，由第二f-θ镜作用在成型加工平面为正/负离焦状态，提供低于材料熔点阈值的能量，并由第二扫描振镜控制跟随成型光束，在成型加工表面按照预定成型路径进行预热/退火处理；
由激光选区熔化成型小光斑激光束与新增平顶大光斑激光束在成型加工表面组合而成的同轴光斑对粉末床进行同步扫描，共同完成整个零件的成型过程。
进一步的，所述的基于原位能量控制的激光选区熔化成型系统中，一方面要求平顶大光斑激光束具有足够高的能量密度，另一方面要保证出光、闭光的时序准确、可控，出光过程能量稳定，以实现两激光束的嵌套合成与同步扫描。
进一步的，所述的新增平顶大光斑通过调节准直器的放大倍数来改变正/负离焦的距离改变其在粉床上作用区域的大小，同时通过调节激光功率大小来改变光斑能量密度。
进一步的，所述第二激光器为1064nm光纤激光器或450nm短波长蓝光激光器，当第二激光器为光纤激光器时，激光通过激光光束整形器转换为能量均匀分布的平顶大光斑激光束，进行预热/退火处理。
进一步的，所述平顶大光斑采用大功率光纤激光器或采用半导体蓝光激光器，当第二激光器为蓝光激光器时，除了可实现上述与光纤激光器相同的过程，还可通过两组不同波长的激光束原位协同控制能量输入，增加能量输入调控手段。
进一步的，所述激光光束整形器将高斯能量分布的激光束转换为均匀能量分布的平顶光斑，并通过调节准直器的放大倍数，可变焦点调节平顶光斑的大小尺寸。
进一步的，所述的同轴光斑对粉末床的作用机理为，在激光向前移动的方 向，粉末先经过平顶大光斑内温度较低的预热区域进行预热处理，然后在高斯光斑的照射下熔化凝固，凝固的金属再次经过温度较低的平顶大光斑照射进行退火处理。
进一步的，在双激光同步成形完成后，平顶大光斑均匀能量密度光斑可以进行重熔，进一步提升产品的成形质量，重熔时，通过设定平顶大光斑的激光参数使其采用更大的能量输入以达到材料熔点，重熔过程通过均匀能量的光斑辐照使已凝固金属重新熔化凝固，可降低内应力、减少未完全熔化粉末缺陷，并提升致密度、表面质量。
本发明与现有技术相比，具有如下优点和有益效果：
1、本发明中新增平顶大光斑激光可以提供低于材料熔点阈值的能量，此时原SLM激光束仅输入较低能量即可实现金属粉末的熔化，这有利于减少粉末微熔池的飞溅行为与零件内部的微气孔缺陷；
2、本发明激光选区熔化成型小光斑与新增平顶大光斑的嵌套分布且同步扫描、新增平顶大光斑可通过正/负离焦方式改变其在粉床上作用区域的大小，这进一步从时间和空间上控制激光能量，进而控制熔池的热流分布以及熔池熔化/凝固速率，调控SLM在非平衡快速熔化凝固机制下的组织形成与演变；
3、本发明新增平顶大光斑在成型过程中实现对粉末的预热处理及凝固金属的退火处理，有利于降低温度梯度，减少成形内应力，从而减少应力导致的变形、开裂等行为。
4、本发明通过新增平顶大光斑激光可在成型过程中实时进行预热/退火处理，这使成型过程更加集成化，而且实时减少热应力的手段有利于减少零件在成型过程中发生变形可能性，提高零件成型的稳定性。
附图说明
图1是本发明基于原位能量控制的激光选区熔化装置示意图；
图2是本发明基于原位能量控制的激光选区熔化方法的流程示意图；
图3是第二光路中通过正/负离焦方式形成平顶大光斑示意图；
图4是激光选区熔化成型小光斑与新增平顶大光斑的同轴嵌套合成示意图；
图5是激光选区熔化成型小光斑与新增平顶大光斑的能量分布示意图。
附图标号说明：1-第一激光器；2-第一准直器；3-第一扫描振镜；4-第二扫描振镜；5-激光光束整形器；6-第二准直器；7-第二激光器；8-第一f-θ镜；9-第二f-θ镜；10-成型零件；11-铺粉刷；12-第一粉料回收缸；13-成形缸；14-升降伺服电机；15-粉料缸；16-第二粉料回收缸；
其中：A-激光选区熔化成型小光斑激光束；B-新增平顶大光斑激光束；B1-成形粉末预热区域；B2-凝固金属退火处理区域；R-粉末材料熔点所需能量阈值。
具体实施方式
下面结合实施例及附图对本发明作进一步详细的描述，但本发明的实施方式不限于此。
实施例
如图1所示，本实施例一种原位能量控制的激光选区熔化装置，包括激光选区熔化成型小光斑光路装置、新增平顶大光斑光路装置和激光选区熔化成型设备，所述激光选区熔化成型小光斑光路装置、新增平顶大光斑光路装置设置在激光选区熔化成型设备上；在本实施例中，新增一路同步扫描的平顶大光斑，提供粉末熔点阈值以下能量，进行粉末预热/凝固速率调控，并对成形的金属进行退火处理，降低温度梯度，减少成形内应力，从而减少应力导致的变形、开裂等行为。
进一步的，所述激光选区熔化成型小光斑光路装置包括第一激光器1、第一准直器2、第一扫描振镜3和第一f-θ镜8，激光束由第一激光器1发出，经过第一准直器2扩束进入第一扫描振镜3，最终在第一f-θ镜8作用下聚焦于成型平面进行激光选区熔化粉末。
进一步的，所述新增平顶大光斑光路装置包括第二激光器7、第二准直器6、第二扫描振镜4、激光光纤整形器5和第二f-θ镜9，激光束由第二激光器7发出，经过第二准直器6扩束后进入激光光束整形器5整形，然后经过第二扫描振镜4并在第二f-θ镜9作用下在成型平面正/负离焦为大光斑，按照预定成型路径进行预热/退火处理。
进一步的，所述激光选区熔化成型设备包括铺粉刷11、第一粉料回收缸12、成形缸13、升降伺服电机14、粉料缸15和第二粉料回收缸16；所述第一粉料回收缸12和第二粉料回收缸16设置在激光选区熔化成型设备底部的左右两侧，所述铺粉刷11设置在成型缸13上方；所述粉料缸15设置在激光选区熔化成型设备的底部；所述升降伺服电机14设置在成型缸底部，成型零件10在最终成型缸处进行成型操作。
更进一步的，本实施例中，所述第一激光器为1064nm光纤激光器；
更进一步的，本实施例中，所述第二激光器为1064nm光纤激光器或450nm蓝光激光器。
如图2-5所示，本发明提出一种原位能量控制的激光选区熔化技术与方法，具体实施方式包括下述步骤:
步骤一：基于原位能量控制的激光选区熔化成型系统提供了激光选区熔化成型小光斑激光束A(第一光路)与新增平顶大光斑激光束B(第二光路)；使两路激光束的扫描路径数据以及激光扫描速度保持一致，同时通过调节两路激 光束的激光延时参数保证同时出光并使两路激光束的聚焦扫描中心位置相同，可使小光斑激光束和平顶大光斑激光束在SLM成型过程中扫描轨迹保持同步，且两大小光斑在成型加工平面保持同轴嵌套；
步骤二：激光选区熔化成型小光斑激光束A熔化粉末过程中，激光由第一激光器(1064nm光纤激光器)发射，经过第一准直器，由第一f-θ镜作用在成型加工平面聚焦成小光斑，受第一扫描振镜的控制按照预定成型路径在成型加工表面进行移动，使粉末材料熔化；
步骤三：新增平顶大光斑激光束B进行预热/退火过程中，激光由第二激光器(1064nm光纤激光器或450nm蓝光激光器)发射，经过第二准直器，由激光光束整形器进行激光整形，由第二f-θ镜作用在成型加工平面为正/负离焦状态(如图3所示)，提供低于材料熔点阈值R的能量，并由第二扫描振镜控制跟随成型光束，在成型加工表面按照预定成型路径进行预热/退火处理；
步骤四：由激光选区熔化成型小光斑激光束A与新增平顶大光斑激光束B在成型加工表面组合而成的同轴光斑对粉末床进行同步扫描，共同完成整个零件的成型过程。
在双激光同步成形完成后，平顶大光斑均匀能量密度光斑可以进行重熔，进一步提升产品的成形质量。重熔时，通过设定平顶大光斑的激光参数使其采用更大的能量输入以达到材料熔点，重熔过程通过均匀能量的光斑辐照使已凝固金属重新熔化凝固，可降低内应力、减少未完全熔化粉末缺陷等，提升致密度、表面质量等。
进一步的，步骤一所述的基于原位能量控制的激光选区熔化成型系统中，一方面要求激光具有足够高的能量密度，另一方面要保证出光、闭光的时序准确、可控，出光过程能量稳定，以实现两激光束的嵌套合成与同步扫描。在实 际成型过程中可通过调节激光的出光、闭光延时实现两激光束光斑的嵌套与同步扫描。
进一步的，步骤一所述的新增平顶大光斑可通过改变正/负离焦的距离改变其在粉床上作用区域的大小。新增平顶大光斑的尺寸可根据粉末材料的物性、扫描间距、熔池飞溅情况等确定。
进一步的，步骤三所述的激光器可选光纤激光器和短波长蓝光激光器，当激光器为光纤激光器时，激光可通过激光光束整形器转换为能量均匀分布的平顶大光斑激光束，进行预热/退火处理；当激光器为蓝光激光器时，除了可实现上述与光纤激光器相同的过程，还可通过两组不同波长的激光束原位协同控制能量输入，增加能量输入调控手段。
进一步的，步骤三所述的激光光束整形器可以将高斯能量分布的激光束转换为均匀能量分布的平顶光斑，并可以通过准直器可以调节平顶光斑的大小尺寸。
进一步的，步骤一、四所述的同轴光斑对粉末床的作用机理为，在激光向前移动的方向，粉末先经过平顶大光斑内温度较低的预热区域B1进行预热处理，然后在高斯光斑的照射下熔化凝固，凝固的金属再次经过温度较低的平顶大光斑内的凝固金属退火处理区域B2进行退火处理(如图4、图5所示)。因此，通过新增平顶大光斑激光可在成型过程中实时进行预热/退火处理，这使成型过程更加集成化，而且实时减少热应力的手段有利于减少零件在成型过程中发生变形可能性，提高零件成型的稳定性。
如上所述，本发明通过在原有SLM基础上，新增一路同步扫描的平顶大光斑，在粉末熔点阈值以下进行粉末预热/凝固金属的退火处理，有利于降低温度梯度，减少成形内应力，从而减少应力导致的变形、开裂等行为；同时提供低 于材料熔点阈值的能量输入，此时原SLM小光斑仅需提供较低能量输入即可完成材料的熔化，这有利于改善熔池飞溅及微气孔产生等不良情况。另外，本发明基于原位能量控制的方式，实现了激光能量的时间与空间分布，这对于调控凝固速率进而调控组织演变具有重大意义。因此，本发明在有效降低成型零件过程中产生缺陷的同时，还可以实现凝固速率的控制进而调控组织演变，对于稳定、高效地成型高性能零件，推动增材制造技术的广泛应用有重大作用。
上述实施例为本发明较佳的实施方式，但本发明的实施方式并不受上述实施例的限制，其他的任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化，均应为等效的置换方式，都包含在本发明的保护范围之内。

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  1. 一种原位能量控制的激光选区熔化装置，其特征在于，包括激光选区熔化成型小光斑光路装置、新增平顶大光斑光路装置和激光选区熔化成型设备，所述激光选区熔化成型小光斑光路装置、新增平顶大光斑光路装置设置在激光选区熔化成型设备上；
    所述激光选区熔化成型小光斑光路装置包括第一激光器、第一准直器、第一扫描振镜、激光光纤整形器和第一f-θ镜，激光束由第一激光器发出，经过第一准直器扩束进入第一扫描振镜，最终在第一f-θ镜作用下聚焦于成型平面进行激光选区熔化粉末；
    所述新增平顶大光斑光路装置包括第二激光器、第二准直器、第二扫描振镜和第二f-θ镜，激光束由第二激光器发出，经过第二准直器扩束后进入激光光束整形器整形，然后经过第二扫描振镜并在第二f-θ镜作用下在成型平面正/负离焦为大光斑，按照预定成型路径进行预热/退火处理。
  2. 根据权利要求1所述一种原位能量控制的激光选区熔化装置，其特征在于，所述激光选区熔化成型设备包括铺粉刷、第一粉料回收缸、成形缸、升降伺服电机、粉料缸和第二粉料回收缸；所述第一粉料回收缸和第二粉料回收缸设置在激光选区熔化成型设备底部的左右两侧，所述铺粉刷设置在成型缸上方；所述粉料缸设置在激光选区熔化成型设备的底部；所述升降伺服电机设置在成型缸底部；
    所述第一激光器为1064nm光纤激光器；
    所述第二激光器为1064nm光纤激光器或450nm蓝光激光器。
  3. 一种原位能量控制的激光选区熔化装置的实现方法，其特征在于，包括下述步骤：
    基于原位能量控制的激光选区熔化成型系统提供了激光选区熔化成型小光斑激光束与新增平顶大光斑激光束，两路激光束的扫描路径数据以及激光扫描速度保持一致，同时通过调节两路激光束的激光延时参数保证同时出光并使两路激光束的聚焦扫描中心位置相同，使小光斑激光束和平顶大光斑激光束在SLM成型过程中扫描轨迹保持同步，且两大小光斑在成型加工平面保持同轴嵌 套；
    激光选区熔化成型小光斑激光束熔化粉末过程中，激光由第一激光器发射，经过第一准直器，由第一f-θ镜作用在成型加工平面聚焦成小光斑，受第一扫描振镜的控制按照预定成型路径在成型加工表面进行移动，使粉末材料熔化；
    新增平顶大光斑激光束进行预热/退火过程中，激光由第二激光器发射，经过第二准直器，由激光光束整形器进行激光整形，由第二f-θ镜作用在成型加工平面为正/负离焦状态，提供低于材料熔点阈值的能量，并由第二扫描振镜控制跟随成型光束，在成型加工表面按照预定成型路径进行预热/退火处理；
    由激光选区熔化成型小光斑激光束与新增平顶大光斑激光束在成型加工表面组合而成的同轴光斑对粉末床进行同步扫描，共同完成整个零件的成型过程。
  4. 根据权利要求1所述一种原位能量控制的激光选区熔化装置的实现方法，其特征在于，所述的基于原位能量控制的激光选区熔化成型系统中，一方面要求平顶大光斑激光束具有足够高的能量密度，另一方面要保证出光、闭光的时序准确、可控，出光过程能量稳定，以实现两激光束的嵌套合成与同步扫描。
  5. 根据权利要求1所述一种原位能量控制的激光选区熔化装置的实现方法，其特征在于，所述的新增平顶大光斑通过调节准直器的放大倍数来改变正/负离焦的距离改变其在粉床上作用区域的大小，同时通过调节激光功率大小来改变光斑能量密度。
  6. 根据权利要求1所述一种原位能量控制的激光选区熔化装置的实现方法，其特征在于，所述第二激光器为1064nm光纤激光器或450nm短波长蓝光激光器，当第二激光器为光纤激光器时，激光通过激光光束整形器转换为能量均匀分布的平顶大光斑激光束，进行预热/退火处理。
  7. 根据权利要求1所述一种原位能量控制的激光选区熔化装置的实现方法，其特征在于，所述平顶大光斑采用大功率光纤激光器或采用半导体蓝光激光器，当第二激光器为蓝光激光器时，除了可实现上述与光纤激光器相同的过程，还可通过两组不同波长的激光束原位协同控制能量输入，增加能量输入调控手段。
  8. 根据权利要求1所述一种原位能量控制的激光选区熔化装置的实现方法， 其特征在于，所述激光光束整形器将高斯能量分布的激光束转换为均匀能量分布的平顶光斑，并通过调节准直器的放大倍数，可变焦点调节平顶光斑的大小尺寸。
  9. 根据权利要求1所述一种原位能量控制的激光选区熔化装置的实现方法，其特征在于，所述的同轴光斑对粉末床的作用机理为，在激光向前移动的方向，粉末先经过平顶大光斑内温度较低的预热区域进行预热处理，然后在高斯光斑的照射下熔化凝固，凝固的金属再次经过温度较低的平顶大光斑照射进行退火处理。
  10. 根据权利要求1所述一种原位能量控制的激光选区熔化装置的实现方法，其特征在于，在双激光同步成形完成后，平顶大光斑均匀能量密度光斑可以进行重熔，进一步提升产品的成形质量，重熔时，通过设定平顶大光斑的激光参数使其采用更大的能量输入以达到材料熔点，重熔过程通过均匀能量的光斑辐照使已凝固金属重新熔化凝固，可降低内应力、减少未完全熔化粉末缺陷，并提升致密度、表面质量。
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