A laser additive manufacturing method and system

Abstract

The application discloses a kind of methods for laser additive manufacturing, comprising the following steps: providing to be processed plate;Providing fixture system;Providing laser processing system;Clamp system clamps the second to be processed plate and the first to be processed plate form tight jointing;Start laser processing system, implement laser additive manufacturing;After completing a processing, close laser generator, laser welding head returns to starting position;Open laser generator, implement laser cutting, obtain the first laser additive manufacturing unit;Clamp system clamps the third to be processed plate and the first laser additive manufacturing unit form tight jointing;Carry out multilayer laser additive manufacturing until end.The application also provides a kind of system for laser additive manufacturing.The application has good processing process stability, high heat conduction efficiency, effectively controls the deformation of laser additive manufacturing, has the advantages such as low cost, easy to carry out pre-welding treatment, good applicability etc..

Description

Technical Field

[0001] The present invention relates to the field of additive manufacturing technology, and in particular to a laser additive manufacturing method and system. Background Art

[0002] Additive manufacturing is a digital manufacturing technology that achieves precise, moldless component formation by gradually adding and depositing materials. It transforms complex three-dimensional components into simple two-dimensional shapes through repeated layer-by-layer stacking. This avoids the significant material and energy waste associated with traditional precision machining, providing a new design approach for achieving high-performance or exceptionally high-performance critical components. This technology can also significantly shorten production cycles, reduce production costs, and lower processing and manufacturing expenses, making it a potential catalyst for transforming the manufacturing industry and promising broad application prospects.

[0003] Laser-based metal additive manufacturing methods primarily include selective laser sintering and laser direct deposition, using wire and powder as primary filler materials. While these processes can currently produce components with good performance, they still suffer from defects such as internal voids and cracks, as well as low efficiency.

[0004] The development of advanced laser light source technologies, such as annular spot fiber lasers, has brought opportunities for high-stability laser processing. These lasers can achieve high-speed, high-stability laser welding processes, and have broad application prospects in macroscopic laser processing of materials. Summary of the Invention

[0005] In response to the shortcomings of traditional laser metal additive manufacturing, the present invention provides a laser additive manufacturing method and system to improve the quality and efficiency of metal additive manufacturing.

[0006] The present invention provides a laser additive manufacturing method, characterized by comprising the following steps:

[0007] Step 1: Provide the plate to be processed and polish and clean the upper and lower surfaces of the plate to be processed;

[0008] Step 2: Providing a fixture system, the fixture system includes a fixture base, a support pad, a first induction heating component, a second induction heating component and a pressing cover;

[0009] Step 3: Providing a laser processing system, the laser processing system includes a laser generator, a first transmission optical fiber, a second transmission optical fiber, a laser welding head, a laser cutting head, a first manipulator, a second manipulator, and a shielding gas nozzle;

[0010] Step 4: The fixture system places the second plate to be processed directly above the first plate to be processed, and the first induction heating assembly and the second induction heating assembly are attached to the bottom of the first plate to be processed. The fixture system clamps the second plate to be processed and the first plate to be processed to form a tight overlap;

[0011] Step 5: Start the laser processing system, turn on the laser generator, and the laser welding head outputs the first laser beam, which irradiates the upper surface of the second plate to be processed. The shielding gas nozzle blows shielding gas, and the laser welding head moves according to the processing path to implement laser additive manufacturing;

[0012] Step 6: After completing one process, turn off the laser generator and the laser welding head returns to the starting position;

[0013] Step 7: Turn on the laser generator, and the laser cutting head outputs a second laser beam, which irradiates the upper surface of the second plate to be processed, performs laser cutting, and obtains a first laser additive manufacturing unit;

[0014] Step 8: Place the third plate to be processed directly above the first laser additive manufacturing unit. Attach the first and second induction heating assemblies to the bottom of the third plate to be processed and the side of the first laser additive manufacturing unit. Clamp the third plate to be processed and the first laser additive manufacturing unit tightly together using the fixture system. Repeat steps 6 to 8.

[0015] Step 9: Place the N+2th plate to be processed directly above the Nth laser additive manufacturing unit, and repeat steps 5 to 8 to perform multi-layer laser additive manufacturing until the end;

[0016] Step 10: Repeat steps 7-9 above for multiple layers of welding until the welding is completed.

[0017] Optionally, in step 1, the plate to be processed may be a magnesium alloy, an aluminum alloy, or the like.

[0018] Optionally, the thickness of the plate to be processed is 1-5 mm.

[0019] Optionally, the plate to be processed is divided into a first plate to be processed, a second plate to be processed, ..., an Nth plate to be processed, an N+1th plate to be processed, and an N+2th plate to be processed.

[0020] Optionally, in step 3, the laser generator is a ring spot fiber laser.

[0021] Optionally, in step 3, the laser welding head is a swing laser welding head.

[0022] Optionally, in step 3, the laser cutting head is a galvanometer laser cutting head.

[0023] Optionally, in step 5, the moving speed of the laser welding head is 5-20 m / min.

[0024] Optionally, in step 5, the swing amplitude of the first laser beam is 1-3 mm.

[0025] Optionally, in step 5, the oscillation frequency of the first laser beam is 50-200 Hz.

[0026] The present invention also provides a laser additive manufacturing system, including a laser processing system and a fixture system. The laser processing system includes a laser generator, a first transmission optical fiber, a second transmission optical fiber, a laser welding head, a laser cutting head, a first manipulator, a second manipulator, and a shielding gas nozzle. The laser welding head is fixedly connected to the end of the first manipulator, and the laser cutting head is fixedly connected to the end of the second manipulator; the shielding gas nozzle is fixedly connected to the laser welding head via a fixed bracket. The fixture system includes a fixture base, a support pad, a first induction heating component, a second induction heating component, and a clamping cover. The first induction heating component and the second induction heating component can move up and down and left and right; the clamping cover has a clamping function and is provided with a processing window.

[0027] Beneficial effects of the present invention:

[0028] (1) The solution of the present invention uses a clamping system to tightly overlap the plates to be processed vertically from top to bottom, similar to the overlapped joints in welding, and can obtain a laser deep melting processing mode with a pinhole effect, good processing stability, and high heat conduction efficiency. In addition, combined with laser cutting, the unprocessed area of ​​the plate to be processed (similar to the support material of traditional additive manufacturing) is removed to obtain a processed laser additive manufacturing unit; then, a first induction heating component and a second induction heating component are set to further reduce the temperature gradient between the laser additive manufacturing area and the base material of the plate to be processed and the processed laser additive manufacturing unit, thereby effectively controlling the deformation amount of laser additive manufacturing.

[0029] (2) Compared with wire-filling and powder-filling laser additive manufacturing, the laser additive manufacturing of the present invention has the following significant features: low production cost of the plate to be processed, easy pre-welding treatment, and good applicability. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 Schematic diagram of the overall layout of laser additive manufacturing in an embodiment of the present invention.

[0031] Figure 2 Schematic diagram of the arrangement of the first plate to be processed and the second plate to be processed in an embodiment of the present invention.

[0032] Figure 3 Schematic diagram of the laser cutting process in an embodiment of the present invention.

[0033] Figure 4Schematic diagram of the arrangement of the third plate to be processed and the first laser additive manufacturing unit in an embodiment of the present invention.

[0034] Figure 5 This is a flow chart of laser additive manufacturing in an embodiment of the present invention.

[0035] Figure 6 Schematic diagram of a blank obtained by laser additive manufacturing in an embodiment of the present invention.

[0036] In the figure, 1-clamp seat, 2-first induction heating component, 3-second induction heating component, 4-support pad, 5-first plate to be processed, 6-second plate to be processed, 7-pressing cover, 8-laser generator, 9-first transmission optical fiber, 10-second transmission optical fiber, 11-laser welding head, 12-laser cutting head, 13-first manipulator, 14-second manipulator, 15-first laser beam, 16-second laser beam, 17-shielding gas nozzle, 18-fixed bracket, 19-first weld, 20-third plate to be processed, 21-second weld, 22-fourth plate to be processed, 23-fifth plate to be processed, 24-third weld, 25-fourth weld.

[0037] 100-First laser additive manufacturing unit. Specific implementation plan

[0038] The following will be combined with the attached Figure 1-6 The technical solution of the present invention is described in detail with reference to specific embodiments.

[0039] This embodiment provides a laser additive manufacturing method, comprising the following steps:

[0040] Step 1: Prepare a first plate 5 to be processed, a second plate 6 to be processed, a third plate 20 to be processed, a fourth plate 22 to be processed, and a fifth plate 23 to be processed from 2 mm thick magnesium alloy plates, and grind and clean the upper and lower surfaces of the plates to be processed;

[0041] Step 2: providing a fixture system, the fixture system including a fixture base 1, a first induction heating component 2, a second induction heating component 3, a support block 4 and a pressing cover plate 7;

[0042] Step 3: Provide a laser processing system, which includes a laser generator 8, a first transmission optical fiber 9, a second transmission optical fiber 10, a laser welding head 11, a laser cutting head 12, a first manipulator 13, a second manipulator 14, and a shielding gas nozzle 17;

[0043] Optionally, the laser generator 8 is a ring spot fiber laser, the laser welding head 11 is a swing laser welding head, and the laser cutting head 12 is a galvanometer laser cutting head;

[0044] Step 4: The clamping system places the second plate to be processed 6 directly above the first plate to be processed 5, and the first induction heating assembly 2 and the second induction heating assembly 3 are aligned with the bottom of the first plate to be processed 5. The clamping system clamps the second plate to be processed 6 and the first plate to be processed 5 to form a tight overlap;

[0045] Optionally, the first induction heating component 2 and the second induction heating component 3 have an input voltage of 200-350V, an input current of 3-15A, and an oscillation frequency of 1-20kHz;

[0046] Step 5: Start the laser processing system, turn on the laser generator 8, and the laser welding head 11 outputs the first laser beam 15. The first laser beam 15 irradiates the upper surface of the second plate 6 to be processed. The shielding gas nozzle 17 blows shielding gas. The laser welding head 11 moves according to the processing path to implement laser additive manufacturing.

[0047] Optionally, the moving speed of the laser welding head 11 is 5-20 m / min, the laser power of the first laser beam 15 is 2000-5000 W, the spot size is 0.8-2 mm, the swing amplitude is 1-3 mm, and the swing frequency of the first laser beam 15 is 50-200 Hz;

[0048] Step 6: After completing one processing, the laser generator 8 is turned off and the laser welding head 11 returns to the starting position.

[0049] Step 7: Turn on the laser generator 8 , and the laser cutting head 12 outputs the second laser beam 16 . The second laser beam 16 irradiates the upper surface of the second plate 6 to be processed, performs laser cutting, and obtains the first laser additive manufacturing unit 100 .

[0050] Optionally, the laser power of the second laser beam 16 is 4000-5000 W, and the spot size is 0.3-0.5 mm.

[0051] Step 8: Place the third plate to be processed 20 directly above the first laser additive manufacturing unit 100, and fit the first induction heating component 2 and the second induction heating component 3 to the bottom of the third plate to be processed 20 and the side of the first laser additive manufacturing unit 100. The clamping system clamps the third plate to be processed 20 and the first laser additive manufacturing unit 100 to form a tight overlap, and repeat steps 6 to 8.

[0052] Optionally, the first induction heating component 2 and the second induction heating component 3 have an input voltage of 200-550V, an input current of 3-15A, and an oscillation frequency of 1-20kHz.

[0053] Step 9: Place the N+2th plate to be processed directly above the Nth laser additive manufacturing unit, and repeat steps 5 to 8 to perform multi-layer laser additive manufacturing until the end.

[0054] like Figure 1 As shown, an embodiment of the present invention further provides a laser additive manufacturing system, including a laser processing system and a fixture system, wherein the laser processing system includes a laser generator 8, a first transmission optical fiber 9, a second transmission optical fiber 10, a laser welding head 11, a laser cutting head 12, a first manipulator 13, a second manipulator 14 and a shielding gas nozzle 17. The laser welding head 11 is fixedly connected to the end of the first manipulator 13, and the laser cutting head 12 is fixedly connected to the end of the second manipulator 14; the shielding gas nozzle 17 is fixedly connected to the laser welding head 11 through a fixed bracket 18. The fixture system includes a fixture base 1, a first induction heating component 2, a second induction heating component 3, a support pad 4 and a clamping cover plate 7. The first induction heating component 2 and the second induction heating component 3 can move up and down and left and right; the clamping cover plate 7 has a clamping function, and a processing window is opened on the clamping cover plate 7.

[0055] With respect to the prior art, the embodiments of the present invention have the following characteristics.

[0056] This embodiment utilizes a fixture system to tightly overlap the plates to be processed vertically, similar to overlapped joints in welding. This allows for a deep laser penetration process with a pinhole effect, resulting in excellent process stability and high heat conduction efficiency. Furthermore, laser cutting is combined to remove the unprocessed area of ​​the plate to be processed (similar to the support material in traditional additive manufacturing) to obtain a processed laser additive manufacturing unit. A first induction heating assembly 2 and a second induction heating assembly 3 are then provided to further reduce the temperature gradient between the laser additive manufacturing area, the base material of the plate to be processed, and the processed laser additive manufacturing unit, effectively controlling the amount of deformation in laser additive manufacturing.

[0057] In addition, compared with wire-filled and powder-filled laser additive manufacturing, the laser additive manufacturing of this embodiment has the remarkable characteristics of low production cost of the plate to be processed, easy pre-welding treatment, and good applicability.

Claims

1. A laser additive manufacturing method, characterized in that: The steps include: Step 1: Provide the plate to be processed and polish and clean the upper and lower surfaces of the plate to be processed; Step 2: Providing a fixture system, the fixture system includes a fixture base, a support pad, a first induction heating component, a second induction heating component and a pressing cover; Step 3: Providing a laser processing system, the laser processing system includes a laser generator, a first transmission optical fiber, a second transmission optical fiber, a laser welding head, a laser cutting head, a first manipulator, a second manipulator, and a shielding gas nozzle; Step 4: The fixture system places the second plate to be processed directly above the first plate to be processed, and the first induction heating assembly and the second induction heating assembly are attached to the bottom of the first plate to be processed. The fixture system clamps the second plate to be processed and the first plate to be processed to form a tight overlap; Step 5: Start the laser processing system, turn on the laser generator, and the laser welding head outputs the first laser beam, which irradiates the upper surface of the second plate to be processed. The shielding gas nozzle blows shielding gas, and the laser welding head moves according to the processing path to implement laser additive manufacturing; Step 6: After completing one process, turn off the laser generator and the laser welding head returns to the starting position; Step 7: Turn on the laser generator, and the laser cutting head outputs a second laser beam, which irradiates the upper surface of the second plate to be processed, performs laser cutting, and obtains a first laser additive manufacturing unit; Step 8: Place the third plate to be processed directly above the first laser additive manufacturing unit. Attach the first and second induction heating assemblies to the bottom of the third plate to be processed and the side of the first laser additive manufacturing unit. Clamp the third plate to be processed and the first laser additive manufacturing unit tightly together using the fixture system. Repeat steps 6 to 8. Step 9: Place the N+2th plate to be processed directly above the Nth laser additive manufacturing unit, and repeat steps 5 to 8 to perform multi-layer laser additive manufacturing until the end.

2. The laser additive manufacturing method according to claim 1, characterized in that: The plates to be processed are magnesium alloy and aluminum alloy.

3. The laser additive manufacturing method according to claim 1, characterized in that: The laser generator is a ring spot fiber laser.

4. The laser additive manufacturing method according to claim 1, characterized in that: The laser welding head is a swing laser welding head.

5. The laser additive manufacturing method according to claim 1, characterized in that: The laser cutting head is a galvanometer laser cutting head.

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