A printing method for a large-format multi-laser additive device

Abstract

The present application belongs to the technical field of laser additive manufacturing, and particularly relates to a high-efficiency and high-quality printing method of a large-format multi-laser additive equipment. The large-format 3*3 arrangement 9-laser printing equipment corresponds to 9 sintering areas, and each sintering area is finely divided; the laser light emission priority is set; the equipment is started, and layer-by-layer printing and layer-by-layer accumulation are performed according to the laser light emission priority and light emission principle to obtain a part. The above printing method is used to print a part on the large-format multi-laser equipment, solves the problems that the traditional laser shielding easily leads to loose defects and the forming efficiency and forming quality cannot be considered, and ensures that the forming efficiency is improved by 30% to 70% while the high-quality forming of the whole printing area of the part is guaranteed.

Description

Technical Field

[0001] This invention belongs to the field of laser additive manufacturing technology, and relates to a printing method for a large-format multi-laser additive manufacturing equipment, and more particularly to a high-efficiency, high-quality printing method for a large-format multi-laser additive manufacturing equipment. Background Technology

[0002] With the increasing complexity and size of components in next-generation aero-engines, traditional manufacturing methods are insufficient for low-cost, short-cycle manufacturing of these large and complex parts, and may even be impossible to implement. Laser additive manufacturing technology can meet the integrated forming requirements of large and complex parts. Large-format (laser scanning area of ​​600×600mm or more) multi-laser additive manufacturing equipment has been developed to address the needs of laser additive manufacturing for large and complex parts.

[0003] However, this type of equipment has the following problems in the process of forming large and complex parts: if multiple lasers are turned on at the same time, the forming efficiency of the parts can be accelerated, but the smoke and dust generated during the multi-laser scanning process can cause problems such as smoke and dust blockage in the forming chamber, which in turn can lead to metallurgical defects such as porosity and holes. In order to ensure the forming quality of the parts, the scanning method of turning on the laser one by one is often the only option, but this greatly affects the forming efficiency, especially for parts with a length and width of more than 1000mm and a height of more than 500mm, the forming time can reach more than 800 hours. Summary of the Invention

[0004] The purpose of this invention is to address the technical challenge of balancing forming quality and efficiency in large-format multi-laser additive manufacturing, and to provide a high-efficiency, high-quality printing method for large-format multi-laser additive manufacturing equipment, which can improve forming efficiency by 30-70% while ensuring high-quality forming of the entire printing area of ​​the part.

[0005] To solve this technical problem, the technical solution of the present invention is as follows:

[0006] A high-efficiency, high-quality printing method for large-format multi-laser additive manufacturing equipment includes the following steps:

[0007] Step 1: Arrange the 9 laser light sources of the laser printer in a large 3x3 pattern. Each laser head corresponds to one of the 9 sintering areas. Sintering areas 1, 4, and 7 are located upwind, while sintering areas 3, 6, and 9 are located downwind. Each sintering area is further subdivided into four rectangular sections (a, b, c, and d) parallel to the wind direction. The section (rectangular area) number consists of the sintering area number (1-9) and the section number (a, b, c, d). For example, section a of sintering area 3 is 3a.

[0008] Step 2: Set the laser emission priority for all partitions (36 partitions in total);

[0009] Step 3: Turn on the equipment and print layer by layer according to the laser emission priority and emission principle to obtain the part;

[0010] In step two, the first priority setting for laser emission is: 3a, 6a, 9a, or 3b, 6b, 9b, or 3c, 6c, 9c, or 3d, 6d, 9d.

[0011] In step two, the second priority setting for laser emission is: 2a, 5a, 8a, or 2b, 5b, 8b, or 2c, 5c, 8c, or 2d, 5d, 8d.

[0012] In step two, the third priority setting for laser emission is: 1a, 4a, 7a, or 1b, 4b, 7b, or 1c, 4c, 7c, or 1d, 4d, 7d.

[0013] In step three, during the printing process, the laser emission principle is as follows:

[0014] Initiating a scan of any partition with the highest priority:

[0015] When the second priority region is separated from the first priority region by a rectangular area, the laser in the second priority region can be turned on;

[0016] When the third priority area is separated from the first priority area by two rectangular areas, and the third priority area is separated from the second priority area by one rectangular area, the laser in the third priority area can be turned on for printing.

[0017] Following this principle, the printing process continues until all nine lasers have completed the printing task for their respective sintering areas.

[0018] In step three, during the printing process, when a certain partition has no printing task, the laser in that partition will not emit light.

[0019] The printing method for each layer of powder follows the principles described above, printing and stacking layer by layer to obtain the final part.

[0020] Furthermore, the large-format multi-laser additive manufacturing equipment uses laser selective melting additive manufacturing as the additive manufacturing method.

[0021] Furthermore, by using the above printing method to print parts on large-format multi-laser equipment, the problems of easy porosity defects caused by laser obstruction in traditional methods and the inability to balance forming efficiency and forming quality are solved. While ensuring high-quality forming of the entire printing area of ​​the part, the forming efficiency can be improved by 30-70%.

[0022] The beneficial effects of this invention are:

[0023] The following benefits can be achieved by using this printing method to print parts in large format using multi-laser additive manufacturing equipment:

[0024] 1. The laser emission priority and laser emission principle designed in the printing method provided by this invention are particularly suitable for forming large-format parts, especially parts with a length and width of more than 1000mm and a height of more than 500mm. It can ensure high-quality forming of the entire printing area of ​​the part while improving the forming efficiency by 30-70%.

[0025] 2. The method of spacing the laser light emission areas in the printing method provided by the present invention solves the problem that laser obstruction in traditional printing methods can easily lead to defects such as looseness and lack of fusion; Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the partitioning in this invention;

[0027] Figure 2 This is a schematic diagram of the first step of laser light extraction in Embodiment 1 of the present invention;

[0028] Figure 3 This is a schematic diagram of the second step of laser light extraction in Embodiment 1 of the present invention;

[0029] Figure 4 This is a schematic diagram of the third step of laser light extraction in Embodiment 1 of the present invention;

[0030] Figure 5 This is a schematic diagram of the fourth step of laser light extraction in Embodiment 1 of the present invention;

[0031] Figures 6-9 This is a schematic diagram of the fifth step of laser light extraction in Embodiment 1 of the present invention;

[0032] Figure 10 This is a schematic diagram of the first step of laser light extraction in Embodiment 2 of the present invention;

[0033] Figure 11 This is a schematic diagram of the second step of laser light extraction in Embodiment 2 of the present invention;

[0034] Figure 12 This is a schematic diagram of the third step of laser light extraction in Embodiment 2 of the present invention;

[0035] Figure 13 This is a schematic diagram of the fourth step of laser light extraction in Embodiment 2 of the present invention;

[0036] Figure 14 This is a schematic diagram of the fifth step of laser beam extraction in Embodiment 2 of the present invention;

[0037] Figures 15-17 This is a schematic diagram of the sixth step of laser light emission in Embodiment 2 of the present invention. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] The present invention provides a high-efficiency, high-quality printing method for a large-format multi-laser additive manufacturing equipment, comprising the following steps:

[0040] Step 1: Arrange the 9 laser light sources of the laser printer in a large 3x3 pattern, with each laser head corresponding to one of the 9 sintering areas, as shown below. Figure 1 As shown, sintering areas 1, 4, and 7 are located upwind, while sintering areas 3, 6, and 9 are located downwind. Each sintering area is further subdivided: each sintering area is divided into four rectangular zones, a, b, c, and d, with the zone direction parallel to the wind direction. The zone (rectangular zone) number consists of the sintering area number 1-9 and the zone number a, b, c, d; for example, zone a of sintering area 3 is 3a.

[0041] Step 2: Set the laser emission priority for all partitions (36 partitions in total) as follows;

[0042] Laser emission priority settings: 3a, 6a, 9a, or 3b, 6b, 9b, or 3c, 6c, 9c, or 3d, 6d, 9d.

[0043] The second priority setting for laser beam emission is: 2a, 5a, 8a, or 2b, 5b, 8b, or 2c, 5c, 8c, or 2d, 5d, 8d.

[0044] The third priority setting for laser beam emission is: 1a, 4a, 7a, or 1b, 4b, 7b, or 1c, 4c, 7c, or 1d, 4d, 7d.

[0045] Step 3, during the printing process, the laser emission principle is as follows:

[0046] Initiating a scan of any partition with the highest priority:

[0047] When the second priority region is separated from the first priority region by a rectangular area, the laser in the second priority region can be turned on;

[0048] When the third priority area is separated from the first priority area by two rectangular areas, and the third priority area is separated from the second priority area by one rectangular area, the laser in the third priority area can be turned on for printing.

[0049] Following this principle, the printing process continues until all nine lasers have completed the printing task for their respective sintering areas.

[0050] The printing method for each layer of powder follows the principles described above, printing and stacking layer by layer to obtain the final part.

[0051] The following describes the printing process of the light emission principle and partition priority of the present invention with reference to specific embodiments.

[0052] Example 1:

[0053] The specific steps of a high-efficiency, high-quality printing method for large-format multi-laser additive manufacturing equipment are as follows:

[0054] 1. The large-format multi-laser forming equipment selected is model EP-M1250. The part material is TA15 titanium alloy, and the part scanning area is 1100*1100mm. The forming process parameters are set as follows: laser power 300~400W, scanning speed 1000~1500mm / s, scanning interval 0.10~0.15mm, and powder thickness 0.04~0.06mm;

[0055] 2. Based on the 3*3 arrangement of 9 lasers in the equipment, corresponding to 9 sintering areas, each sintering area is finely divided into zones: sintering areas 1, 4, and 7 are located at the upwind end, and sintering areas 3, 6, and 9 are located at the downwind end.

[0056] 3. According to the present invention, the four partitions a, b, c, and d of the sintering zone and their priority settings are as follows; the printing process is as follows, such as... Figures 2-9 As shown, the area with diagonal lines is the area being printed.

[0057] 4. While starting the 3a, 6a, and 9a partition scanning with the laser light emission priority, the partition printing sequence is initiated according to the laser light emission principle described above:

[0058] The first step involves separating the second priority regions (2c, 5c, 8c) from the first priority regions (3a, 6a, 9a) by a rectangular area. The lasers in both the second and first priority regions are then simultaneously activated for scanning. Figure 2 );

[0059] The second step involves separating the third priority regions (1c, 4c, 7c) from the second priority regions (2a, 5a, 8a) by one rectangular area. The lasers in both the third and second priority regions are then simultaneously activated for scanning. Figure 3 );

[0060] The third step involves separating the second priority region (2d, 5d, 8d) from the first priority region (3b, 6b, 9b) by a rectangular area, and simultaneously activating the lasers in both the second and first priority regions for scanning. Figure 4 );

[0061] Fourth step: The third priority region (1d, 4d, 7d) and the second priority region (2b, 5b, 8b) are separated by a rectangular area. The lasers in the second priority region and the first priority region are simultaneously activated for scanning. Figure 5 );

[0062] 5. Fifth step: Since the second priority region has been scanned, and the unscanned partitions in the third priority region do not meet the condition of being separated from the unscanned partitions in the first priority region by two rectangular regions, the scanning is completed in the following order: partitions 3c, 6c, 9c; partitions 3d, 6d, 9d; partitions 1a, 5a, 7a; partitions 1b, 5b, 7b. The current layer printing then ends. Figures 6-9 ).

[0063] 6. Each layer of powder is printed according to the above priority, layer by layer, until the final part is obtained.

[0064] 7. In comparison, the forming efficiency of the printed parts is 60% higher than that of traditional printing methods, while the mechanical properties are good and the dimensional accuracy is within ±1.6mm.

[0065] Example 2:

[0066] The specific steps of a high-efficiency, high-quality printing method for large-format multi-laser additive manufacturing equipment are as follows:

[0067] 1. The large-format multi-laser forming equipment selected is model EP-M1250. The part is a large-size ring structure with a diameter of 1030mm, and the material is GH3625 nickel-based high-temperature alloy. The forming process parameters are set as follows: laser power 250~300W, scanning speed 800~1200mm / s, scanning interval 0.10~0.15mm, and powder thickness 0.04~0.06mm;

[0068] 2. Based on the 3*3 arrangement of 9 lasers in the equipment, corresponding to 9 sintering areas, each sintering area is finely divided into zones: sintering areas 1, 4, and 7 are located at the upwind end, and sintering areas 3, 6, and 9 are located at the downwind end.

[0069] 3. According to the present invention, the four partitions a, b, c, and d of the sintering zone and their priority settings are as follows; the printing process is as follows, such as... Figures 10-17 As shown:

[0070] 4. While starting the 3a, 6a, and 9a partition scanning with the laser light emission priority, the partition printing sequence is initiated according to the laser light emission principle described above:

[0071] First, when the second priority areas 2c, 5c (no printing task, no light output), and 8c (no printing task, no light output) are separated from the first priority areas 3a (no printing task, no light output), 6a, and 9a by a rectangular area, the lasers in the second and first priority areas can be activated simultaneously for scanning. The third priority area 7b is separated from the first priority area 6a by two rectangular areas, also satisfying the light output condition. See [link to relevant documentation]. Figure 10 ;

[0072] In the second step, areas 2b and 5b in the second priority zone do not emit light due to no printing tasks; only area 8b emits light. At this point, the light-emitting areas that meet the conditions are 4d, 7d, and 3c. See [link / details]. Figure 11 ;

[0073] In the third step, light is emitted from priority zones 3b, 6b, and 9b. At this point, there are no zones in the second and third priority zones that meet the light emission conditions. (See...) Figure 12 ;

[0074] Step 4: The first priority area 3c has finished printing but is not producing light; 6c and 9c are producing light. At this point, the area meeting the conditions for light production is 1b. See [link / reference]. Figure 13 ;

[0075] Step 5: In the first priority area, 3D printing has no tasks and no light is emitted; 6D and 9D printing emit light. At this point, the area that meets the conditions for emitting light is 1C. See [link / reference]. Figure 14 ;

[0076] Step 6: The first and second priority areas have been printed. The third priority area is scanned according to the light output order of partitions 1a and 4a, 4c and 7c, and 4b. Printing of the current layer ends. See below. Figures 15-17 .

[0077] 5. The printing method for each layer of powder is carried out according to the above priority, printing layer by layer and stacking layer by layer to obtain the final part.

[0078] 6. In comparison, the forming efficiency of the printed parts is 50% higher than that of traditional printing methods, while the mechanical properties are good and the dimensional accuracy is within ±1.5mm.

[0079] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and these modifications or substitutions should be covered within the protection scope of the present invention.

Claims

1. A printing method for a large-format multi-laser additive manufacturing system, characterized in that, Includes the following steps: Step 1: Arrange the 9 laser light sources of the laser printer in a large 3x3 pattern. The 9 laser heads correspond to 9 sintering areas. Sintering areas 1, 4, and 7 are located upwind, while sintering areas 3, 6, and 9 are located downwind. Each sintering area is further subdivided into four equal sections: a, b, c, and d. The subdivision direction is parallel to the wind direction. The subdivision number consists of the sintering area number 1-9 and the subdivision number a, b, c, and d. Step 2: Set the laser emission priority for all partitions; First priority settings: 3a, 6a, 9a, or 3b, 6b, 9b, or 3c, 6c, 9c, or 3d, 6d, 9d; Second priority settings: 2a, 5a, 8a, or 2b, 5b, 8b, or 2c, 5c, 8c, or 2d, 5d, 8d; The third priority setting is: 1a, 4a, 7a, or 1b, 4b, 7b, or 1c, 4c, 7c, or 1d, 4d, 7d. Step 3: Turn on the equipment and print layer by layer according to the laser emission priority and principle to obtain the part; during the printing process, the laser emission principle is as follows: While initiating a scan of any partition with the highest priority: When the second priority region is separated from the first priority region by a rectangular area, the laser in the second priority region can be turned on; When the third priority region is separated from the first priority region by two rectangular regions, and the third priority region is separated from the second priority region by one rectangular region, the laser in the third priority region can start printing; following this principle, printing can continue until all nine lasers have completed the printing task for their respective sintering regions.

2. The method according to claim 1, characterized in that: In step three, during the printing process, when a certain partition has no printing task, the laser in that partition will not emit light.

3. The method according to claim 1, characterized in that: In step three, each layer of powder is printed according to the light emission principle, and is printed and accumulated layer by layer to obtain the final part.

4. The method according to claim 1, characterized in that: The large format refers to a laser scanning area of ​​600×600mm or larger.

5. The method according to claim 1, characterized in that: The additive manufacturing method used is laser selective melting additive manufacturing.

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