Selective laser melting forming complex thin-walled blade support structure, axial flow wheel and forming method

Abstract

The application provides a laser selective melting forming method for a complex thin-wall blade support structure and an axial flow wheel, and the support structure comprises a first support structure for supporting a blade pan side, a first main body support part and a first support boss, the first main body support part is located on the blade pan side and is a conformal support changing along the profile of the blade pan side, and the first main body support part is also arranged at a free end of the blade; a second support structure for supporting a blade back side, the second support structure comprises a second main body support part and a second support boss, the second main body support part is located on the blade back side and is a conformal support changing along the profile of the blade back side, and the second main body support part is also arranged at the free end of the blade; and a third support structure for supporting an inlet edge of the blade, the third support structure is arranged conformally along the leading edge of the blade. The support structure can inhibit deformation of the blade without damaging the surface of the blade.

Description

Technical Field

[0001] This invention belongs to the field of metal laser additive manufacturing, and relates to a laser selective melting forming complex thin-walled blade support structure, axial flow wheel and forming method, especially a laser selective melting forming complex thin-walled blade support structure that is easy to remove, does not reduce the surface quality of the part and can significantly reduce the deformation of the blade. Background Technology

[0002] The axial-flow impeller is a core component of the compressor system in a missile turbofan engine. It performs work on the gas by driving its flow, converting external mechanical work into the gas's thermal and mechanical energy. Its structure is as follows: Figure 1 As shown, the axial flow wheel assembly is a complex thin-walled structure, mainly composed of an axial flow disk, axial flow blades, pins, and retaining rings. The axial flow disk is a rotating body, and the axial flow blades are spatially irregular thin-walled curved surfaces. The product has a compact shape and complex structure, containing a total of 24 parts. In traditional manufacturing methods, the axial flow disk and retaining ring are machined titanium alloy parts, the pins are standard quenched and tempered steel parts, and the axial flow blades are machined stainless steel parts. The blades and disk are connected by plug-in joints, and the product is achieved through integral assembly machining. This process results in lengthy part processing steps, low material utilization, long turnaround time, and low reliability.

[0003] Selective Laser Melting (SLM) is a novel manufacturing process that uses a laser to selectively melt metal powder and then layer it to form parts. This technology is unaffected by the complexity of the parts and offers advantages such as short manufacturing cycles and low costs. It is a primary means of achieving high-performance, lightweight manufacturing and has even become an important development direction for the rapid integrated manufacturing of some missile engine core components. After adopting additive manufacturing, the part is a single piece of stainless steel printed and machined, resulting in high material utilization and reducing the number of parts from 24 to 1. Figure 2 As shown, the number of processes is greatly reduced, reliability is high, and the processing cycle can be shortened by more than half.

[0004] Laser selective melting forming of axial flow wheels offers significant advantages over traditional manufacturing methods. However, the extremely short melting and solidification of metal powder during the forming process generates immense thermal stress within the part, leading to noticeable deformation. This problem is particularly pronounced in complex thin-walled blade structures like axial flow wheels. Currently, the main solution involves adding support structures using the MAGICS software. The mainstream support addition method employs a combination of mesh supports and conical supports, such as... Figure 3 As shown, the support structure of this scheme has high strength and can significantly suppress blade deformation. However, due to the thinness of the blade, there are many protrusions and pits on the blade surface after the support is removed, resulting in poor surface quality that does not meet the design requirements. Therefore, it is urgent to design a support structure that can suppress blade deformation without damaging the blade surface. Summary of the Invention

[0005] The present invention aims to solve at least one of the technical problems existing in the prior art.

[0006] Therefore, the present invention provides a laser selective melting forming of a complex thin-walled blade support structure, an axial flow wheel, and a forming method.

[0007] The technical solution of the present invention is as follows:

[0008] According to one aspect, a support structure for complex thin-walled blades formed by laser selective melting is provided, the support structure comprising:

[0009] A first support structure is used to support the leaf-pot side of the blade. The first support structure includes a first main support part and a first support boss. The first main support part is disposed on the leaf-pot side and is a conformal support that varies along the leaf-pot side profile. One end face of the first main support part is flush with the end face of the free end of the blade. The support thickness of the first main support part does not exceed L, where L is the blade length. The first support boss is located at the end of the first main support part away from the blade side and is disposed on one end face of the first main support part.

[0010] The second support structure is used to support the back side of the blade. The second support structure includes a second main support part and a second support boss. The second main support part is disposed on the back side of the blade and is a conformal support that varies along the profile of the back side of the blade. One end face of the second main support part is flush with the end face of the free end of the blade. The support thickness of the second main support part does not exceed L, where L is the blade length. The second support boss is located at the end of the second main support part away from the blade side and is disposed on one end face of the second main support part.

[0011] The third support structure is used to support the air intake edge of the blade, and the third support structure is set in a conformal manner along the leading edge of the blade.

[0012] Furthermore, the gap between the third support structure and the first main support is 0.1-0.2 mm; the gap between the third support structure and the second main support is 0.1-0.2 mm.

[0013] Furthermore, during the forming process, when setting the third support structure, the third support structure near the blade side is offset by a set distance in a direction away from the blade side using an offset command so that the gap between the blade and the third support structure is 1-2 printing layer thicknesses.

[0014] Furthermore, the set distance is 0.04-0.08mm.

[0015] Furthermore, a plurality of through holes are formed at intervals along the blade direction on the third support structure.

[0016] Furthermore, the through-hole size is Φ0.5mm, and the hole spacing between any adjacent through holes is 0.2-2mm.

[0017] Furthermore, the thickness of both the first support boss and the second support boss is not less than 2mm.

[0018] Furthermore, the first main support portion near the blade side is chamfered on both sides to make the contact width between the first main support portion and the blade 0.15-0.35mm; the second main support portion near the blade side is also chamfered on both sides to make the contact width between the second main support portion and the blade 0.15-0.35mm.

[0019] Furthermore, the support thickness of both the first main support and the second main support is 1.5-3mm.

[0020] Furthermore, the blade is an axial flow impeller blade, and any axial flow impeller blade adopts the aforementioned support structure.

[0021] Furthermore, the support structure of any one of the axial flow wheel blades is designed as follows: based on the original first and second support structures on the blade basin side and blade back side, the thickness of the corresponding first and second support bosses is increased by more than double; wherein, the axial flow wheel blades are selected from the multiple axial flow wheel blades by the following method: determining the placement angle of the part, keeping the placement angle unchanged, and finding blades that are less than 5° from the direction of the squeegee during printing.

[0022] According to another aspect, a laser selective melting forming method for an axial flow wheel is provided, the method comprising:

[0023] Create a three-dimensional model of the axial flow wheel;

[0024] Supports are added to the three-dimensional model, wherein the axial flow impeller blades adopt the support structure described above;

[0025] Set the laser selective melting and forming process parameters and perform laser selective melting and forming;

[0026] Post-processing.

[0027] According to one aspect, an axial flow wheel is provided, which is formed by the above-described laser selective melting forming method.

[0028] The above technical solution supports the blade by designing a first, second, and third support structure. The first support structure is located on the blade head side and is set at the free end of the blade to support the blade head side, and has a specific support thickness. The second support structure is located on the blade back side and is set at the free end of the blade to support the blade back side, and also has a specific support thickness. The third support structure is set in a conformal manner along the leading edge of the blade to support the air inlet edge of the blade. Thus, the three support structures work together to support the complex thin-walled blade. This support structure has high structural strength, is easy to remove, can significantly suppress blade deformation, and the surface quality of the blade is not significantly affected after the support is removed (i.e., the blade surface is not damaged). Attached Figure Description

[0029] The accompanying drawings, which form part of this specification, are provided to further illustrate embodiments of the invention and, together with the textual description, explain the principles of the invention. It is obvious that the drawings described below are merely some embodiments of the invention, and those skilled in the art can obtain other drawings based on these drawings without any creative effort.

[0030] Figure 1 This is a schematic diagram of an axial flow wheel structure;

[0031] Figure 2 Schematic diagram of an additive manufacturing structure for an axial flow wheel;

[0032] Figure 3 The existing solution uses a combination of grid support and conical support.

[0033] Figure 4 This is a schematic diagram of the first support structure provided in an embodiment of the present invention;

[0034] (a) First support structure; (b) First support structure on the leaf basin side

[0035] Figure 5 This is a schematic diagram of the second support structure provided in an embodiment of the present invention;

[0036] (a) Second support structure; (b) Second support structure on the back of the blade.

[0037] Figure 6 This is a schematic diagram of the third support structure provided in an embodiment of the present invention;

[0038] Figure 7 A schematic diagram of the optimized first support structure and second support structure provided in an embodiment of the present invention;

[0039] The above figures include the following reference numerals:

[0040] 10. First support structure; 11. First main support part; 12. First support boss; 20. Second support structure; 21. Second main support part; 22. Second support boss; 30. Third support structure. Detailed Implementation

[0041] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. 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 a part of the embodiments of the present invention, and not all of them. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. 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.

[0042] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0043] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0044] like Figure 1-2As shown, in one embodiment of the present invention, a support structure for complex thin-walled blades formed by laser selective melting is provided. This support structure includes a first support structure 10, a second support structure 20, and a third support structure 30. The first support structure 10 is used to support the blade's blade base side. The first support structure 10 includes a first main support portion 11 and a first support boss 12. The first main support portion 11 is disposed on the blade base side and is a conformal support that varies along the blade base side profile. One end face of the first main support portion 11 is flush with the end face of the free end of the blade. The support thickness of the first main support portion 11 does not exceed L, where L is the blade length. The first support boss 12 is located at the end of the first main support portion 11 away from the blade side and is disposed on the first main support portion 11. On one side end face of the body support portion 11; the second support structure 20 is used to support the back side of the blade, the second support structure 20 includes a second main support portion 21 and a second support boss 22, the second main support portion 21 is disposed on the back side of the blade and is a conformal support that varies along the back side profile, one side end face of the second main support portion 21 is flush with the end face of the free end of the blade, and the support thickness of the second main support portion 21 does not exceed L, where L is the blade length; the second support boss 22 is located at the end of the second main support portion 21 away from the blade side and is disposed on one side end face of the second main support portion 21; the third support structure 30 is used to support the air intake edge of the blade, and the third support structure 30 is conformally disposed along the leading edge of the blade.

[0045] Those skilled in the art will know that the back of a blade refers to the outward convex surface of the blade, the leaf basin refers to the outward concave surface of the blade, and the leading edge is the part of the blade's air intake side that connects the leaf basin and the back of the blade.

[0046] In this embodiment of the invention, the free end of the blade refers to the end of the blade that is not connected to other components.

[0047] That is, in this embodiment of the invention, the first main support 11 and the second main support 21 are respectively located on both sides of the blade. The first main support 11 is located on the blade base side and is designed to follow the shape of the blade base side surface. The second main support 21 is located on the blade back side and is designed to follow the shape of the blade back side surface. Both the first main support 11 and the second main support 21 are located on one side of the free end of the blade, and their end faces are flush with the end face of the free end of the blade. The support thickness does not exceed L. It can be seen that this embodiment of the invention designs a support structure at the free end of the blade. In addition, to ensure the support strength, a first support boss 12 and a second support boss 22 are designed for reinforcement. At the same time, a third support structure 30 is designed to support the air intake edge of the blade. The third support structure 30 is designed to follow the shape of the leading edge of the blade. It can be seen that, unlike the combination mode of existing blade mesh support and conical support, this embodiment of the invention does not directly design a support structure on the blade surface, which can avoid the presence of many protrusions and pits on the blade surface after the support is removed.

[0048] Preferably, the first support boss 12 and the first main support portion 11 are designed to conform to the shape of the end away from the blade side, and their edges are flush; the second support boss 22 and the second main support portion 21 are designed to conform to the shape of the end away from the blade side, and their edges are flush.

[0049] By applying the above configuration, the blade is supported by a first, second, and third support structure. The first support structure is located on the blade head side and is set at the free end of the blade to support the blade head side, and has a specific support thickness. The second support structure is located on the blade back side and is set at the free end of the blade to support the blade back side, and also has a specific support thickness. The third support structure is set in a conformal manner along the leading edge of the blade to support the air inlet edge of the blade. Thus, the three support structures work together to support the complex thin-walled blade. This support structure has high structural strength, is easy to remove, can significantly suppress blade deformation, and the surface quality of the blade is not significantly affected after the support is removed (i.e., the blade surface is not damaged).

[0050] In the above embodiments, in order to ensure support strength, the thickness of the first support boss 12 and the second support boss 22 is not less than 2mm.

[0051] In the above embodiments, in order to facilitate the removal of the first support structure and the second support structure, the two sides of the first main support portion 11 near the blade are chamfered so that the contact width between the first main support portion 11 and the blade is 0.15-0.35mm; the two sides of the second main support portion 21 near the blade are also chamfered so that the contact width between the second main support portion 21 and the blade is 0.15-0.35mm.

[0052] Preferably, the support thickness of the first main support part 11 and the second main support part 21 is 1.5-3mm.

[0053] That is, in the embodiments of the present invention, the thickness of the first main support part 11 and the second main support part 21 is much smaller than the length of the axial flow wheel blade, that is, in the embodiments of the present invention, a support structure is provided at the end of the blade.

[0054] In the above embodiments, in order to facilitate the removal of the third support structure, the gap between the third support structure 30 and the first main support is 0.1-0.2mm; the gap between the third support structure 30 and the second main support is 0.1-0.2mm.

[0055] In the above embodiments, in order to ensure the forming of the blade and the easy removal of the third support structure, during the forming process, when setting the third support structure 30, the third support structure 30 near the blade side is offset by a set distance in the direction away from the blade side by an offset command so that the gap between the blade and the third support structure 30 is 1-2 printing layer thicknesses.

[0056] Preferably, the set distance is 0.04-0.08 mm.

[0057] In the above embodiment, in order to facilitate the removal of the third support structure, a plurality of through holes are formed on the third support structure 30 along the blade direction at intervals.

[0058] Preferably, the through hole size is Φ0.5mm, and the hole spacing between any adjacent through holes is 0.2-2mm.

[0059] According to one embodiment of the present invention, the blade is an axial flow impeller blade, and any axial flow impeller blade adopts the support structure.

[0060] As a specific embodiment, the support structure for any axial flow turbine blade can be designed in the following manner:

[0061] Leaf basin side anti-deformation support structure design, namely the first support structure 10 design:

[0062] Using 3D modeling software such as UG, a conformal support is generated along the blade's blade tip profile. The support end face is flush with the blade end face, and the support thickness is 1.5-3.5mm. The sides of the support near the blade are chamfered to ensure a contact width of 0.15-0.35mm between the support and the blade. Furthermore, a support boss with a thickness of at least 2mm is added to the side of the support furthest from the blade. Figure 4 As shown;

[0063] The design of the blade back side anti-deformation support structure, namely the design of the second support structure 20:

[0064] Using 3D modeling software such as UG, a conformal support is generated along the profile of the blade's back side. The support end face is flush with the blade end face, and the support thickness is 1.5-3mm. The sides of the support near the blade are chamfered to ensure a contact width of 0.15-0.35mm between the support and the blade. Support bosses with a thickness of at least 2mm are added to the solid support away from the blade side. Figure 5 As shown;

[0065] Intake side conformal support structure design, namely the third support structure 30 design:

[0066] Using 3D modeling software such as UG, a conformal support is generated along the blade profile variation at the air intake edge. The gap between this support and the supports on both sides of the blade housing / back is 0.1-0.2mm. Using the offset command, the solid support near the blade is offset by a distance of 0.04-0.08mm away from the blade side, ensuring a gap of 1-2 printing layer thicknesses between the blade and the solid support. Along the blade profile direction, Φ0.5mm holes are generated on the solid support, with a hole spacing of 0.2-2mm. Figure 6 As shown.

[0067] In the above embodiments, in order to further optimize the support structure, further ensure support strength and save processing costs, the support structure of any one of the axial flow wheel blades is further designed as follows: based on the original first support structure 10 and second support structure 20 on the blade basin side and blade back side, the thickness of the corresponding first support boss 12 and second support boss 22 is increased by more than double; wherein, the axial flow wheel blades are selected from the multiple axial flow wheel blades by the following method: determine the placement angle of the part, keep the placement angle unchanged, and find blades that are less than 5° from the direction of the squeegee during printing.

[0068] Specifically, this embodiment of the invention also includes auxiliary optimization of the structural design: determining the placement angle of the parts, keeping this placement angle constant, identifying four blades that are less than 5° from the direction of the squeegee during printing, and increasing the thickness of the support bosses on the support structures corresponding to these four blades by more than double, based on the existing anti-deformation support structures on the blade base side and blade back side. The final solution is as follows: Figure 7 As shown.

[0069] Preferably, after completing the design of the blade basin-side anti-deformation support structure, the blade back-side anti-deformation support structure, the air intake edge conformal support structure, and the auxiliary optimization structure, they should be exported separately from the axial flow wheel when generating the STL file to ensure that the software recognizes the axial flow wheel and the support structure as different parts during printing.

[0070] Preferably, the anti-deformation support structure on the blade basin side, the anti-deformation support structure on the blade back side, the air intake edge shape-preserving support structure, and the auxiliary optimization structure should have rounded corners on the parts with an angle of less than 5° to the scraper to reduce the jamming phenomenon during printing.

[0071] The following specific embodiments and comparative examples illustrate the effect of the support structure of the present invention.

[0072] Example 1

[0073] 1) Use 3D modeling software such as UG to generate conformal supports that vary along the blade's blade side profile. The support end face is flush with the blade end face, and the support thickness is 2mm. Chamfer the two sides of the support near the blade side so that the contact width between the support and the blade is 0.2mm. Add a support boss with a thickness of 2.5mm to the solid support away from the blade side.

[0074] 2) Use 3D modeling software such as UG to generate conformal supports that vary along the back surface of the blade. The support end face is flush with the blade end face and the support thickness is 2mm. Chamfer the two sides of the support near the blade side so that the contact width between the support and the blade is 0.2mm. Add a support boss with a thickness of 2.5mm to the solid support away from the blade side.

[0075] 3) Use 3D modeling software such as UG to generate conformal supports that vary along the blade profile of the air intake edge. The gap between this support and the supports on both sides of the basin / back is 0.15mm. Use the offset command to offset the solid support near the blade side by 0.04mm away from the blade side. Along the blade profile direction, generate 0.5mm holes on the solid support with a hole spacing of 0.8mm.

[0076] 4) Determine the placement angle of the parts and keep the placement angle unchanged. Find four blades that are less than 5° from the direction of the squeegee during printing. Based on the existing anti-deformation support structure on the blade basin side and blade back side, increase the thickness of the support boss on the support structure corresponding to these four blades from 2.5mm to 5mm.

[0077] The support structure in Example 1 is self-supporting and forms a shape. The support is tightly connected to the blade, and the blade structure does not warp severely. The printing process is completed smoothly, and an experienced fitter removes the support. It is found that the anti-deformation support on the blade basin side, the anti-deformation support on the blade back side, and the conformal support on the air intake side are relatively easy to remove from the blade. They can be manually removed without the need for tools. After removing the support, the blade surface is intact and there is no residual support. After detection by a 3D scanner, the maximum deformation of the blade is 0.3mm.

[0078] Comparative Example 1

[0079] The only differences from Example 1 are: 1) the contact width between the support and the blade is 1mm, 2) the contact width between the support and the blade is 1mm, and 3) the solid support near the blade is offset by 0.01mm away from the blade by the offset command.

[0080] Compared to the support structure in Example 1, which is self-supporting and tightly connected to the blade, the blade structure does not warp significantly, and the printing process is completed smoothly, the removal of the supports was performed by an experienced fitter. It was found that the anti-deformation supports on the blade base side, blade back side, and inlet edge conformal supports were difficult to remove from the blades and could not be removed manually. Machining removal was difficult due to alignment issues, noticeable blade vibration, and difficulty in ensuring blade thickness uniformity. This demonstrates the importance of designing the contact width and offset distance between the support and the blade, which must be kept within a certain range.

[0081] Comparative Example 2

[0082] Using 3D modeling software such as UG, a conformal support is generated along the side profile of the blade. The end face of the support is flush with the end face of the blade, and the support thickness is 2mm. The two sides of the support near the blade are chamfered so that the contact width between the support and the blade is 0.1mm. A support boss with a thickness of 2.5mm is added to the solid support away from the blade.

[0083] Using 3D modeling software such as UG, a conformal support is generated along the profile of the blade back side. The support end face is flush with the blade end face, and the support thickness is 2mm. The two sides of the support near the blade are chamfered so that the contact width between the support and the blade is 0.1mm. A support boss with a thickness of 2.5mm is added to the solid support away from the blade side.

[0084] Using 3D modeling software such as UG, a conformal support is generated along the blade profile variation of the air intake edge. The gap between this support and the supports on both sides of the basin / back is 0.15mm. The solid support near the blade side is offset by 0.2mm away from the blade side using the offset command. Along the blade profile direction, Φ0.5mm holes are generated on the solid support with a hole spacing of 0.8mm.

[0085] Compared with Example 2, the support structure and blade connection strength is lower. During the printing process, the blade warps slightly and the blade jams multiple times. As the printing process continues, the thermal stress gradually increases, and the blades with a blade angle of less than 5° completely separate from the blades, causing the printing to be interrupted.

[0086] According to another embodiment, a laser selective melting forming method for an axial flow wheel is also provided, the method comprising:

[0087] Create a three-dimensional model of the axial flow wheel;

[0088] Supports are added to the three-dimensional model, wherein the axial flow impeller blades adopt the support structure described above;

[0089] Set the laser selective melting and forming process parameters and perform laser selective melting and forming;

[0090] Post-processing.

[0091] In this embodiment of the invention, the specific means of establishing the three-dimensional model of the axial flow wheel, setting the laser selective melting forming process parameters and performing laser selective melting forming and post-processing are all conventional means in the art, and will not be described in detail here. The key to this embodiment of the invention lies in how to design the support structure of the axial flow wheel blades, that is, to adopt the blade support structure of the above embodiment.

[0092] According to another embodiment, an axial flow wheel is also provided, which is formed by the laser selective melting forming method described above.

[0093] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0094] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0095] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A laser selective melting forming support structure for complex thin-walled blades, characterized in that, The support structure includes: A first support structure is used to support the leaf-pot side of the blade. The first support structure includes a first main support part and a first support boss. The first main support part is disposed on the leaf-pot side and is a conformal support that varies along the leaf-pot side profile. One end face of the first main support part is flush with the end face of the free end of the blade. The support thickness of the first main support part does not exceed L, where L is the blade length. The first support boss is located at the end of the first main support part away from the blade side and is disposed on one end face of the first main support part. The second support structure is used to support the back side of the blade. The second support structure includes a second main support part and a second support boss. The second main support part is disposed on the back side of the blade and is a conformal support that varies along the profile of the back side of the blade. One end face of the second main support part is flush with the end face of the free end of the blade. The support thickness of the second main support part does not exceed L, where L is the blade length. The second support boss is located at the end of the second main support part away from the blade side and is disposed on one end face of the second main support part. The third support structure is used to support the air intake edge of the blade, and the third support structure is set in a conformal manner along the leading edge of the blade.

2. The laser selective melting forming complex thin-walled blade support structure according to claim 1, characterized in that, The thickness of both the first support boss and the second support boss is not less than 2mm.

3. A laser selective melting forming complex thin-walled blade support structure according to claim 1 or 2, characterized in that, The first main support portion near the blade side is chamfered on both sides to make the contact width between the first main support portion and the blade 0.15-0.35mm; the second main support portion near the blade side is also chamfered on both sides to make the contact width between the second main support portion and the blade 0.15-0.35mm.

4. The laser selective melting forming complex thin-walled blade support structure according to claim 3, characterized in that, The support thickness of both the first and second main support parts is 1.5-3mm.

5. The laser selective melting forming complex thin-walled blade support structure according to claim 4, characterized in that, The gap between the third support structure and the first main support is 0.1-0.2 mm; the gap between the third support structure and the second main support is 0.1-0.2 mm.

6. The laser selective melting forming complex thin-walled blade support structure according to claim 3, characterized in that, During the forming process, when setting the third support structure, the third support structure near the blade side is offset by a set distance in a direction away from the blade side using an offset command so that the gap between the blade and the third support structure is 1-2 printing layer thicknesses.

7. The laser selective melting forming complex thin-walled blade support structure according to claim 6, characterized in that, The set distance is 0.04-0.08mm.

8. A laser selective melting forming complex thin-walled blade support structure according to claim 1 or 6, characterized in that, Multiple through holes are formed at intervals along the blade direction on the third support structure.

9. A laser selective melting forming support structure for complex thin-walled blades according to claim 8, characterized in that, All through holes are Φ0.5mm in size, and the spacing between any two adjacent through holes is 0.2-2mm.

10. A laser selective melting forming support structure for complex thin-walled blades according to claim 1, characterized in that, The blades are axial flow impeller blades, and all axial flow impeller blades adopt the aforementioned support structure.

11. A laser selective melting forming support structure for complex thin-walled blades according to claim 10, characterized in that, The support structure of any one of the axial flow wheel blades is further designed as follows: based on the original first and second support structures on the blade basin side and blade back side, the thickness of the corresponding first and second support bosses is increased by more than double; wherein, the axial flow wheel blades are selected from the multiple axial flow wheel blades by the following method: determine the placement angle of the part, keep the placement angle unchanged, and find blades that are less than 5° from the direction of the squeegee during printing.

12. A method for selective laser melting and forming of an axial-flow wheel, characterized in that, The method includes: Create a three-dimensional model of the axial flow wheel; Supports are added to the three-dimensional model, wherein the axial flow wheel blades adopt the support structure described in any one of claims 1-11; Set the laser selective melting and forming process parameters and perform laser selective melting and forming; Post-processing.

13. An axial-flow impeller, characterized in that, The axial flow wheel is formed using the laser selective melting forming method described in claim 12.

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