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WO2023077282A1 - 激光3d打印方法及激光3d打印设备 - Google Patents

激光3d打印方法及激光3d打印设备 Download PDF

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Publication number
WO2023077282A1
WO2023077282A1 PCT/CN2021/128269 CN2021128269W WO2023077282A1 WO 2023077282 A1 WO2023077282 A1 WO 2023077282A1 CN 2021128269 W CN2021128269 W CN 2021128269W WO 2023077282 A1 WO2023077282 A1 WO 2023077282A1
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WIPO (PCT)
Prior art keywords
laser
printing
powder
spot
light spot
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Application number
PCT/CN2021/128269
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English (en)
French (fr)
Inventor
刘建业
牛留辉
徐卡里
高文华
胡高峰
Original Assignee
广东汉邦激光科技有限公司
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Application filed by 广东汉邦激光科技有限公司 filed Critical 广东汉邦激光科技有限公司
Priority to PCT/CN2021/128269 priority Critical patent/WO2023077282A1/zh
Publication of WO2023077282A1 publication Critical patent/WO2023077282A1/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
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • 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
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • 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

  • This application relates to the field of 3D printing, specifically, to a laser 3D printing method and a laser 3D printing device.
  • Laser 3D printing is a manufacturing technology that uses laser light as an energy source to sequentially heat and fuse the powder laid on each layer to obtain printed parts.
  • This application aims to provide a laser 3D printing method to solve the problem of serious structural defects in the internal structure of laser printed printed parts.
  • An embodiment of the present application provides a laser 3D printing method, which includes:
  • Printing step use the printing laser to scan the laid powder, so that the powder in the scanned area is fused and formed; wherein, the output light spot of the printing laser includes an inner light spot and an outer light spot surrounding the outer periphery of the inner light spot, and the energy density of the outer light spot is less than The inner spot.
  • the energy of the inner spot is concentrated, which can better melt the powder in the irradiation area to obtain a high-quality and high-density fusion structure, and the outer spot irradiates the powder outside the irradiation area of the inner spot at the same time.
  • the use of the composite output laser can effectively reduce the printing residual stress and reduce the deformation of the printed workpiece.
  • the powder is metal powder
  • the energy density of the outer light spot is 10%-90% of the inner light spot
  • the power of the outer light spot is 50-5000W.
  • the spot diameter of the inner spot is adjustable within the range of 10-300 microns, and the spot diameter of the outer spot is adjustable within the range of 20-1000 microns.
  • the outer contour radius of the outer light spot is 2-4 times the outer contour radius of the inner light spot.
  • Multiple powder spreading devices are used to carry out multi-layer powder spreading at the same time, and along the powder spreading direction, the powder spreading device for laying the lower layer of powder is located in front of the powder spreading device for laying the upper layer of powder;
  • Multi-beam printing lasers are used to scan the simultaneously powdered multi-layer powder, and the scanning position of the printing laser of the lower layer of powder is before the powder layer of the upper layer.
  • a beam of shaping light is added to scan the surface of the printed part printed and formed by the printing step, so as to improve the surface smoothness.
  • the inner light spot and the outer light spot are configured to be able to individually control light output
  • some layers are printed in a way that both the inner spot and the outer spot emit light, and some layers are printed in a way that the inner spot does not emit light.
  • the embodiment of the present application also provides a laser 3D printing method.
  • the output light spot includes N circles of light spots arranged sequentially from inside to outside, where N is an integer greater than 2, And the energy density of the Nth circle of light spots from outside to inside is smaller than that of the N-1th circle of light spots.
  • the embodiment of the present application also provides a laser 3D printing device for implementing the aforementioned laser 3D printing method.
  • the laser 3D printing equipment includes a powder laying device for laying the powder and a laser system for generating the printing laser.
  • the laser 3D printing device in this embodiment is used to implement the aforementioned laser 3D printing method, which can efficiently print and obtain printed parts with small residual stress.
  • the laser system includes a laser, an optical system, a vibrating mirror and a focusing lens sequentially connected by an optical path; the laser is used to generate laser light, the optical system is used to collimate and expand the laser beam, and the vibrating mirror is used to control the The scanning position, the focusing lens is used to focus the laser to form the printing laser, and the output light spot is formed at the scanning position.
  • FIG. 1 is a schematic diagram of the output spot of the printing laser in the embodiment of the present application.
  • Fig. 2 is a schematic diagram of the overlap mode of a plurality of output spots in Fig. 1;
  • FIG. 3 is a schematic diagram of another output spot of the embodiment of the present application.
  • Fig. 4 is a schematic diagram of the usage state of the laser 3D printing device according to the embodiment of the present application.
  • the embodiment of the present application provides a laser 3D printing method, including a printing step: using a printing laser to scan the laid powder, so that the powder in the scanned area is fused and formed; the output spot 10 of the printing laser includes an inner spot 11 and an outer periphery of the inner spot 11 The outer spot 12, the energy density of the outer spot 12 is smaller than the inner spot 11.
  • the shape of the output light spot 10 can be referred to FIG. 1 .
  • the composite output spot 10 with different inner and outer energy densities is used for printing, the energy of the inner spot 11 is concentrated, and the powder in the irradiated area can be better melted to obtain a high-quality and high-density fusion structure.
  • the outer spot 12 irradiates the inner spot 11 at the same time.
  • the powder on the periphery of the area can effectively flatten the heat-affected area, making the balance transition between the printing area and the unirradiated powder cold area, which is conducive to the smoothness of powder fusion.
  • the use of the composite output laser can effectively reduce the printing residual stress, reduce the deformation of the printed workpiece, effectively reduce the microcracks of laser 3D printing, and reduce the pores of laser 3D printing.
  • the outer spot 12 and the inner spot 11 form an output spot 10 that can act synchronously.
  • the outer spot 12 first passes through a larger range of powder cold area, and the inner spot 11 then passes through a wider range.
  • the synchronous scanning of the inner and outer spots 12 can complete the scanning step of the composite illumination, and the operation efficiency is high; and the irradiation interval of the synchronous scanning of the inner and outer spots 12 is small, avoiding the need
  • the interval time after the previous laser beam irradiation is long and there is heat loss that affects the effect of the first treatment, or it is necessary to use the previous laser beam irradiation with higher energy for the first treatment, which affects the properties of the powder and the scanning fusion forming of the laser.
  • a shaping beam is added to scan the surface of the printed part printed and formed by the printing step, so as to improve the surface finish, such as to make the surface finish Ra ⁇ 2.0 microns.
  • the powder is metal powder
  • the laser 3D printing method is a laser selective melting technology applied to metal.
  • the energy density of the outer light spot 12 is set to be 10%-90% of that of the inner light spot 11, and the power of the outer light spot reaches 50-5000W.
  • the energy density of the outer spot 12 and the energy density of the inner spot 11 are higher than 90%, the irradiated area of the outer spot 12 presents a significant powder melting state, and the outer spot 12 and the powder cold area outside it (referring to the untreated area) There will be a large temperature drop gradient between the powder area receiving laser energy), so that there will be a large internal stress in the formed print; The temperature drop gradient is large, and the powder in the irradiation area of the outer spot 12 is difficult to be effectively treated first, which affects the overall forming quality.
  • the energy density of the outer spot 12 is set to be 10%-90% of that of the inner spot 11, the residual stress of the printed part meets the requirements of general metal printed parts, and there is no need for complicated post-processing procedures.
  • the specific percentage value can be determined according to factors such as the reflectivity of the printing powder material. For example, for high reflectivity materials, a larger percentage can be used; otherwise, a smaller percentage can be used.
  • the laser energy absorption rate is beneficial to the printing and forming of copper alloy powder.
  • the scanning of the outer spot 12 can make the copper alloy powder form a complex micro-nano composite structure, thereby increasing its ability to absorb the laser energy provided by the inner spot 11 .
  • the spot diameter of the inner spot 11 is adjustable in the range of 10-300 microns
  • the spot diameter of the outer spot 12 is adjustable in the range of 20-1000 microns
  • the adjustment method can be through the existing laser system implementation, and will not be repeated here.
  • the outer contour radius of the outer spot 12 is 2-4 times the outer contour radius of the inner spot 11 . In this way, the outer spot 12 can act on the powder within a suitable range around the inner spot 11 in advance to obtain a gentler heat-affected zone.
  • the multiple printing lasers acting on a single layer of powder at the same time, and the multiple printing lasers are respectively used to print a plurality of subregions 14 of the printing range of the layer, and the subregions printed by adjacent printing lasers 14 partially coincides at the junction.
  • the single-layer printing range is divided into four partitions 14, and the four partitions 14 are distributed in a matrix.
  • the corresponding printing lasers have four beams, which are used for printing respectively.
  • Adjacent subregions 14 are partially overlapped at the junctions to form overlapping regions 13 , so that the printed structures of each subregion 14 can be better fused together.
  • the division of division 14 can also be 1 ⁇ 2, 1 ⁇ 3, 2 ⁇ 1 or other n ⁇ m (n and m are positive integers) matrix distribution division form , and can also adopt circular division or other suitable division forms.
  • the inner light spot 11 and the outer light spot 12 are configured to be able to individually control the light output; in each printed layer, some layers are printed in a way that both the inner light spot 11 and the outer light spot 12 emit light, and some layers The layer is printed in such a way that the inner spot 11 does not emit light. For example, after every several layers (such as 1 layer, 2 layers, 3 layers or more layers) the inner and outer spots 12 emit light and print at the same time, one or several layers of inner spots 11 are inserted and printed without light.
  • the outer light spot 12 is used to act on the surface of the formed part at intervals of several layers, so as to achieve heat treatment effects such as structure regulation and surface hardening of the printed part.
  • the output light spot 10 of the printing laser can also be set as N circles of light spots sequentially arranged from inside to outside, N is an integer greater than 2, and from The energy density of the Nth circle of light spots from outside to inside is smaller than that of the N-1th circle of light spots.
  • the energy density (of the innermost light spot) is 10%-90% of that of the second circle of light spots 10b.
  • multiple powder spreading devices 51 are used to carry out multi-layer powder spreading at the same time, and in the powder spreading direction Y1, the powder spreading device 51 for laying the lower layer of powder is located at the upper layer
  • the front of the powder spreading device 51 of the powder; the multi-beam printing laser 57 is used to scan the multi-layer powder that is simultaneously powder spreading, and the scanning position of the printing laser 57 of the powder of the lower layer is before the powder spreading device 51 of the upper layer.
  • the embodiment of the present application also provides a laser 3D printing device 50 for implementing the aforementioned laser 3D printing method.
  • the laser 3D printing device 50 comprises a powder laying device 51 for laying down the powder and a laser system 52 for generating printing laser light 57 .
  • the laser 3D printing device 50 in this embodiment is used to implement the aforementioned laser 3D printing method, which can efficiently print and obtain printed parts with small residual stress.
  • the laser system 52 includes a laser 53, an optical system 54, a vibrating mirror 55, and a focusing lens 56 that are sequentially connected by an optical path; the laser 53 is used to generate laser light, and the optical system 54 is used to modify the laser light, collimate and expand the beam etc., the vibrating mirror 55 is used to control the scanning position of the laser, the focusing lens 56 is used to focus the laser to form a printing laser 57 , and form an output light spot 10 at the scanning position.
  • the specific structure of the optical path system 54 that can realize processing such as correction, collimation and beam expansion can be set with reference to the schemes recorded in the prior art.
  • powder spreader 51 has two groups, is respectively used to spread the powder of upper layer and the powder of lower layer; Lower powder.
  • the irradiation position of the printing laser 57 generated by the laser system 52 located in front of the powder laying direction Y1 is located between the front and rear powder laying devices 51, and irradiates on the lower layer of powder, and forms a scanned and fused fusion in the lower layer on its scanning path.
  • Area Q1 the printing laser 57 generated by the laser system 52 located behind the powder spreading direction Y1 is irradiated behind the powder spreading device 51 at the rear, and irradiates on the upper layer of powder, forming a scanned and fused upper layer on its scanning path
  • the fusion region Q1 of the upper and lower layers is fused and connected between layers, thereby obtaining an integrated structure.
  • the scanning position of the printing laser 57 generated by the laser system 52 moves up by one unit (the number of layers in one scan*the thickness of each layer) and continues to scan until the print is completed.
  • the laser 3D printing method and the laser 3D printing device 50 of some implementations of the examples of the present application can efficiently print printed parts with small residual stress and small deformation of the workpiece, and some of the implementations are additionally suitable for high reflectivity. Printing of materials.

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Abstract

一种激光3D打印方法，包括打印步骤：采用打印激光扫描铺设的粉末，使被扫描区域的粉末熔合成形；其中，所述打印激光的输出光斑（10）包括内光斑（11）和围于内光斑外周的外光斑（12），所述外光斑的能量密度小于所述内光斑。以及一种用于实施前述的激光3D打印方法的激光3D打印设备。上述方法和设备能够有效降低打印残余应力，减小打印工件形变，有效减少激光3D打印微裂纹，减少激光3D打印孔隙，提升打印效率。

Description

激光3D打印方法及激光3D打印设备 技术领域
本申请涉及3D打印领域，具体而言，涉及激光3D打印方法及激光3D打印设备。
背景技术
激光3D打印为以激光为能量源，依次将各层铺设的粉末加热熔合，从而得到打印件的制造技术。
申请人已知的激光打印技术中，存在得到的打印件内部存在较严重的结构缺陷，有时需要采用复杂的后处理工艺来缓解或消除这些缺陷。
发明内容
本申请旨在提供一种激光3D打印方法，以解决激光打印的打印件内部结构存在较严重结构缺陷的问题。
本申请的实施例是这样实现的：
本申请实施例提供一种激光3D打印方法，其包括：
打印步骤：采用打印激光扫描铺设的粉末，使被扫描区域的粉末熔合成形；其中，所述打印激光的输出光斑包括内光斑和围于内光斑外周的外光斑，所述外光斑的能量密度小于所述内光斑。
本方案中，通过采用内外能量密度不同的复合输出光斑进行打印，内光斑能量集中，能够较好地熔化照射区粉末得到高质量高密度熔合结构，外光斑同时照射内光斑照射区外围的粉末，有效平缓热影响区，使打印区与未被照射的粉末冷区域平衡过渡，有利于粉末熔合平整；并且，采用该复合输出激光能够有效降低打印残余应力，减小打印工件形变。
在一种可能的实施方式中：
所述粉末为金属粉末，所述外光斑的能量密度为所述内光斑的10％-90％，外光斑功率为50-5000W。
在一种可能的实施方式中：
所述内光斑的光斑直径在10-300微米范围内可调，所述外光斑的光斑直径在20-1000微米范围内可调。
在一种可能的实施方式中：
所述外光斑的外轮廓半径为所述内光斑的外轮廓半径的2-4倍。
在一种可能的实施方式中：
同时作用于单层粉末的所述打印激光有多束，多束所述打印激光分别用于打印该层打印范围的多个分区，且相邻的所述打印激光所打印的分区在交界处部分重合。
在一种可能的实施方式中：
采用多个铺粉装置同时进行多层铺粉，且在沿铺粉方向上，铺设较下层粉末的铺粉装置位于铺设较上层粉末的铺粉装置的前方；
采用多束打印激光对同时铺粉的多层粉末进行扫描，且较下层的粉末的打印激光的扫描位置在其上一层的铺粉装置之前。
在一种可能的实施方式中：
在所述打印步骤之后，增加一束整形光束，用于对通过所述打印步骤打印成形的打印件进行表面扫描，以提高表面光洁度。
在一种可能的实施方式中：
所述内光斑和所述外光斑被配置成能够各自单独控制出光；
所打印的各层中，部分层采用内光斑和外光斑均出光的方式打印，部分层采用内光斑不出光的方式打印。
本申请实施例还提供一种激光3D打印方法，在前述所述激光3D打印 方法的基础上，使所述输出光斑包括由内到外依次围设的N圈光斑，N为大于2的整数，且从外到内的第N圈光斑能量密度小于第N-1圈光斑。
本申请实施例还提供一种激光3D打印设备，用于实施前述的激光3D打印方法。所述激光3D打印设备包括用于铺设所述粉末的铺粉装置和用于生成所述打印激光的激光系统。
本实施例中的激光3D打印设备用于实施前述的激光3D打印方法，其能够高效地打印得到残余应力小的打印件。
在一种可能的实施方式中：
所述激光系统包括依次光路连接的激光器、光路系统、振镜和聚焦透镜；所述激光器用于产生激光，所述光路系统用于对激光进行准直扩束，所述振镜用于控制激光的扫描位置，所述聚焦透镜用于聚焦激光以形成所述打印激光，在扫描位置形成所述输出光斑。
附图说明
为了更清楚地说明本申请实施例的技术方案，下面将对实施例中所需要使用的附图作简单地介绍，应当理解，以下附图仅示出了本申请的某些实施例，因此不应被看作是对范围的限定，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他相关的附图。
图1为本申请实施例中的打印激光的输出光斑的示意图；
图2为多个图1的输出光斑的重合方式示意图；
图3为本申请实施例的另一种输出光斑的示意图；
图4为本申请实施例的激光3D打印设备的使用状态示意图。
主要元件符号说明：
输出光斑 10
内光斑 11
外光斑 12
重合区 13
分区 14
第一圈光斑 10a
第二圈光斑 10b
第三圈光斑 10c
3D打印设备 50
铺粉装置 51
激光系统 52
激光器 53
光路系统 54
振镜 55
聚焦透镜 56
打印激光 57
熔合区域 Q1
铺粉方向 Y1
具体实施方式
为使本申请实施例的目的、技术方案和优点更加清楚，下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例是本申请一部分实施例，而不是全部的实施例。通常在此处附图中描述和示出的本申请实施例的组件可以以各种不同的配置来布置和设计。
因此，以下对在附图中提供的本申请的实施例的详细描述并非旨在限制要求保护的本申请的范围，而是仅仅表示本申请的选定实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。
应注意到：相似的标号和字母在下面的附图中表示类似项，因此，一旦某一项在一个附图中被定义，则在随后的附图中不需要对其进行进一步定义和解释。
在本申请的描述中，需要说明的是，若出现术语“中心”、“上”、“下”、 “左”、“右”、“竖直”、“水平”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，或者是该发明产品使用时惯常摆放的方位或位置关系，仅是为了便于描述本申请和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本申请的限制。此外，本申请的描述中若出现术语“第一”、“第二”等仅用于区分描述，而不能理解为指示或暗示相对重要性。
此外，本申请的描述中若出现术语“水平”、“竖直”等术语并不表示要求部件绝对水平或悬垂，而是可以稍微倾斜。如“水平”仅仅是指其方向相对“竖直”而言更加水平，并不是表示该结构一定要完全水平，而是可以稍微倾斜。
实施例
本申请实施例提供一种激光3D打印方法，包括打印步骤：采用打印激光扫描铺设的粉末，使被扫描区域的粉末熔合成形；打印激光的输出光斑10包括内光斑11和围于内光斑11外周的外光斑12，外光斑12的能量密度小于内光斑11。输出光斑10的形状可参见图1。
本实施例中，通过采用内外能量密度不同的复合输出光斑10进行打印，内光斑11能量集中，能够较好地熔化照射区粉末得到高质量高密度熔合结构，外光斑12同时照射内光斑11照射区外围的粉末，有效平缓热影响区，使打印区与未被照射的粉末冷区域平衡过渡，有利于粉末熔合平整。并且，采用该复合输出激光能够有效降低打印残余应力，减小打印工件形变，有效减少激光3D打印微裂纹，减少激光3D打印孔隙。
本实施例中的外光斑12和内光斑11构成能够同步作用的输出光斑10，在沿扫描路径移动的过程中，外光斑12先经过较大范围的粉末冷区域，内光斑11随后经过范围较小的已被外光斑12作用的区域，同步扫描的内外光斑12只需一次扫描即可完成复合光照的扫描步骤，操作效率高；且同步扫描的内外光斑12的照射间隔小，避免如一些已知技术中在先的激光束照 射后间隔时间较长而存在热量损耗影响先处理效果，或者需要使用更高能量的在先激光束照射进行先处理而影响粉末性质和后激光的扫描熔合成形。
在一些实施方式中，在打印步骤之后，增加一束整形光束，用于对对通过打印步骤打印成形的打印件进行表面扫描，以提高表面光洁度，如使表面光洁度达到Ra≤2.0微米。
在本实施例的一种实施方式中，粉末为金属粉末，对应地该激光3D打印方法为应用于金属的激光选区熔化技术。此时，本实施例设置外光斑12的能量密度为内光斑11的10％-90％，外光斑的功率达到50-5000W。试验测得，在外光斑12的能量密度和内光斑11能量密度的百分比高于90％时，外光斑12照射区域呈现显著的粉末熔融态，且在外光斑12和其外的粉末冷区域(指未接收激光能量的粉末区域)之间将存在较大的温降梯度，而使成形的打印件存在较大内应力；在该百分比低于10％时，内光斑11和外光斑12照射区之间温降梯度较大，且外光斑12的照射区的粉末难以被有效先处理，影响整体成形质量。而当设置外光斑12的能量密度为内光斑11的10％-90％时，得到的打印件残余应力符合一般金属打印件的需求，无需为此进行复杂的后处理工序。具体的百分比取值，可以按打印粉末材料的反射率等因素确定。如，对于高反射率材料，可采用较大的百分比；反之则可以采用较小的百分比。
例如，打印如铜合金等激光高反射率粉末材料时，采用该内外复合的打印激光，并设置外光斑12的能量密度为内光斑11的40％-90％时，能有效提高铜合金粉末的激光能量吸收率，有利于铜合金粉末打印成形。申请人分析发现，通过该性质的打印激光，外光斑12的扫描，可使铜合金粉末形成复杂的微米-纳米复合结构，从而增加其对内光斑11提供的激光能量的吸收能力。当然，因打印过程影响因素复杂，导致提高吸收能力的还可能 有其他因素。
本实施例中，可选地，内光斑11的光斑直径在10-300微米范围内可调，外光斑12的光斑直径在20-1000微米范围内可调，调节方式可以通过现有的激光系统实现，在此不赘述。可选地，外光斑12的外轮廓半径为内光斑11的外轮廓半径的2-4倍。如此，外光斑12可以预先作用于内光斑11外周合适范围内的粉末，获得更平缓的热影响区。
在一种可能的实施方式中，同时作用于单层粉末的打印激光有多束，多束打印激光分别用于打印该层打印范围的多个分区14，且相邻的打印激光所打印的分区14在交界处部分重合。例如图2示出的(图中用输出光斑10指示打印激光位置)，单层打印范围划分为四个分区14，四个分区14呈矩阵分布，对应的打印激光有四束，分别用于打印各个分区14。相邻分区14在交界处部分重合，形成重合区13，以使各分区14打印后的结构能够较好地熔合在一起。除图2示出的2×2分区14划分形式外，分区14的划分还可以是1×2、1×3、2×1或其他n×m(n和m为正整数)矩阵分布划分形式，还可以采用圆周划分或其他合适的划分形式。
在一种可选的实施方式中，内光斑11和外光斑12被配置成能够各自单独控制出光；所打印的各层中，部分层采用内光斑11和外光斑12均出光的方式打印，部分层采用内光斑11不出光的方式打印。例如，每隔若干层(如1层、2层、3层或更多层)的内外光斑12同时出光打印之后，插入1层或几层内光斑11不出光的形式打印。该实施方式中，每间隔几层使用外光斑12单独作用在成形件表面，达到打印件组织调控、表面加硬等热处理效应。
配合参见图3，在前述具有内外两层光斑的打印激光的基础上，打印激光的输出光斑10还可设置为由内到外依次围设的N圈光斑，N为大于2的整数，且从外到内的第N圈光斑能量密度小于第N-1圈光斑。如图3示出 的，N＝3，第一圈光斑10a(最外层的光斑)的能量密度为第二圈光斑10b(中间圈的光斑)的10％-90％，第三圈光斑10c(最内层的光斑)的能量密度为第二圈光斑10b的10％-90％。
配合参见图4，本实施例中，可选地，采用多个铺粉装置51同时进行多层铺粉，且在沿铺粉方向Y1上，铺设较下层粉末的铺粉装置51位于铺设较上层粉末的铺粉装置51的前方；采用多束打印激光57对同时铺粉的多层粉末进行扫描，且较下层的粉末的打印激光57的扫描位置在其上一层的铺粉装置51之前。
通过该设置，可以同时打印多层，进一步提高打印效率。
配合参见图4，本申请实施例还提供一种激光3D打印设备50，用于实施前述的激光3D打印方法。激光3D打印设备50包括用于铺设粉末的铺粉装置51和用于生成打印激光57的激光系统52。本实施例中的激光3D打印设备50用于实施前述的激光3D打印方法，其能够高效地打印得到残余应力小的打印件。在一些实施方式中，激光系统52包括依次光路连接的激光器53、光路系统54、振镜55和聚焦透镜56；激光器53用于产生激光，光路系统54用于对激光进行修正、准直扩束等处理，振镜55用于控制激光的扫描位置，聚焦透镜56用于聚焦激光以形成打印激光57，在扫描位置形成输出光斑10。其中，光路系统54可实现修正、准直扩束等处理的具体结构可参照已有技术记载的方案设置。
如图4示出的，铺粉装置51有两组，分别用于铺较上层的粉末和较下层的粉末；对应的激光系统52有两组，且分别产生用于扫描较上层的粉末和较下层粉末。位于铺粉方向Y1前方的激光系统52产生的打印激光57的照射位置位于前后铺粉装置51之间，并照射在较下层粉末上，其扫描路径上形成被扫描而熔合的位于较下层的熔合区域Q1；位于铺粉方向Y1后方的激光系统52产生的打印激光57照射位置位于后方的铺粉装置51之后， 并照射在较上层粉末上，其扫描路径上形成被扫描而熔合的位于较上层的熔合区域Q1，上下层的熔合区域Q1在层间熔合连接，从而得到一体的结构。
在一次多层扫描完成后，激光系统52生成的打印激光57的扫描位置上移一个单位(一次扫描层数*每层层厚)继续后续扫描直至打印件打印完成。
综合以上描述，本申请实施例的一些实施方案的激光3D打印方法及激光3D打印设备50能够高效地打印得到残余应力小、工件形变小的打印件，且其中部分实施方式还额外适于高反材料的打印成形。
以上所述仅为本申请的优选实施例而已，并不用于限制本申请，对于本领域的技术人员来说，本申请可以有各种更改和变化。凡在本申请的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本申请的保护范围之内。

Claims (10)

  1. 一种激光3D打印方法，其特征在于，包括：
    打印步骤：采用打印激光扫描铺设的粉末，使被扫描区域的粉末熔合成形；其中，所述打印激光的输出光斑包括内光斑和围于内光斑外周的外光斑，所述外光斑的能量密度小于所述内光斑。
  2. 根据权利要求1所述的激光3D打印方法，其特征在于：
    所述粉末为金属粉末，所述外光斑的能量密度为所述内光斑的10％-90％，所述外光斑功率为50-5000W。
  3. 根据权利要求2所述的激光3D打印方法，其特征在于：
    所述内光斑的光斑直径在10-300微米范围内可调，所述外光斑的光斑直径在20-1000微米范围内可调。
  4. 根据权利要求1-3任一项所述的激光3D打印方法，其特征在于：
    同时作用于单层粉末的所述打印激光有多束，多束所述打印激光分别用于打印该层打印范围的多个分区，且相邻的所述打印激光所打印的分区在交界处部分重合。
  5. 根据权利要求1-3任一项所述的激光3D打印方法，其特征在于：
    采用多个铺粉装置同时进行多层铺粉，且在沿铺粉方向上，铺设较下层粉末的铺粉装置位于铺设较上层粉末的铺粉装置的前方；
    采用多束打印激光对同时铺粉的多层粉末进行扫描，且较下层的粉末的打印激光的扫描位置在其上一层的铺粉装置之前。
  6. 根据权利要求1所述的激光3D打印方法，其特征在于：
    在所述打印步骤之后，增加一束整形光束，用于对通过所述打印步骤打印成形的打印件进行表面扫描，以提高表面光洁度。
  7. 根据权利要求1所述的激光3D打印方法，其特征在于：
    所述内光斑和所述外光斑被配置成能够各自单独控制出光；
    所打印的各层中，部分层采用内光斑和外光斑均出光的方式打印，部分层采用内光斑不出光的方式打印。
  8. 一种激光3D打印方法，其特征在于：
    在权利要求1-7任一项所述激光3D打印方法的基础上，使所述输出光斑包括由内到外依次围设的N圈光斑，N为大于2的整数，且从外到内的第N圈光斑能量密度小于第N-1圈光斑。
  9. 一种激光3D打印设备，其特征在于，用于实施权利要求1-8任一项所述的激光3D打印方法；
    所述激光3D打印设备包括用于铺设所述粉末的铺粉装置和用于生成所述打印激光的激光系统。
  10. 根据权利要求9所述的激光3D打印设备，其特征在于：
    所述激光系统包括依次光路连接的激光器、光路系统、振镜和聚焦透镜；所述激光器用于产生激光，所述光路系统用于对激光进行准直扩束，所述振镜用于控制激光的扫描位置，所述聚焦透镜用于聚焦激光以形成所述打印激光，在扫描位置形成所述输出光斑。
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CN116883400A (zh) * 2023-09-07 2023-10-13 山东大学 一种激光选区熔化过程中的铺粉孔隙率预测方法及系统
CN116883400B (zh) * 2023-09-07 2023-11-21 山东大学 一种激光选区熔化过程中的铺粉孔隙率预测方法及系统
CN117047130A (zh) * 2023-10-11 2023-11-14 杭州爱新凯科技有限公司 一种先预热后保温的金属3d打印方法
CN117047130B (zh) * 2023-10-11 2024-02-02 杭州爱新凯科技有限公司 一种先预热后保温的金属3d打印方法
CN117428210A (zh) * 2023-12-20 2024-01-23 中国商用飞机有限责任公司 多激光选区熔融搭接方法
CN117428210B (zh) * 2023-12-20 2024-03-08 中国商用飞机有限责任公司 多激光选区熔融搭接方法

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