Structure-function integrated ceramic matrix composite material additive manufacturing method and device

Abstract

The invention provides a structure-function integrated ceramic matrix composite material additive manufacturing method and device.The device is composed of a powder laying mechanism, a powder box lifting mechanism, a precise powder sucking and falling mechanism, an adjustable laser printing mechanism and an overall supporting control system, metal powder is laid through the powder laying mechanism, layer-by-layer printing is achieved through the powder box lifting mechanism, and the whole supporting control system is connected with the powder box lifting mechanism; the precise powder sucking and falling mechanism achieves precise sucking of metal powder and laying of ceramic powder according to slicing information, the adjustable laser printing mechanism achieves laser sintering forming of the metal powder and the ceramic powder according to the slicing information, and the overall supporting control system provides supporting and control over movement in the printing direction for other mechanisms. A ceramic area and a metal area are determined according to the requirements of the parts, and the three-dimensional model of the parts is divided into a metal area model and a ceramic area model. According to the method, the service life of the manufactured part serving in the complex and severe environment is prolonged.

Description

Technical Field

[0001] The present invention belongs to the field of ceramic 3D printing powder laying and metal 3D printing, relates to the field of multi-material composite printing, and particularly to a method and device for additive manufacturing of structural-functional integrated ceramic-based composite materials. Background Art

[0002] The remarkable development of ceramic 3D printing technology has broadened the application scope of ceramic materials. This technology can produce complex and precise geometric structures, improve design freedom, reduce material waste, improve production efficiency, shorten product development cycle, and quickly realize the transformation from design to finished product. In addition, ceramic 3D printing can also achieve functional integration, such as combining multiple material properties in a single component to meet the needs of high-performance ceramic products in different fields. Metal 3D printing technology has become an important innovative force in the manufacturing industry. This technology can quickly produce complex and high-precision metal parts, reducing the time from design to production; providing great design freedom, and can achieve complex geometric shapes that are difficult to achieve in traditional manufacturing; reducing material waste and reducing production costs; enhancing customization capabilities to meet the needs of different industries for high-performance, lightweight and durable metal parts. With the continuous advancement of technology, metal 3D printing and ceramic 3D printing have shown broad application prospects in aerospace, medical, automotive and industrial manufacturing, and have promoted the efficiency and innovation of the manufacturing industry.

[0003] At present, many key parts require a combination of ceramics and metals to take full advantage of the unique advantages of both materials. For example, artificial joints and dental implants in the medical field combine the low friction and wear resistance of ceramics with the strength and stability of metals; turbine engine blades and thermal protection systems in aerospace combine the high temperature tolerance of ceramics with the structural support of metals; brake discs and exhaust systems in the automotive industry take advantage of the high temperature resistance of ceramics and the toughness of metals; capacitors and thermocouples in the electronics and electrical fields combine the electrical properties of ceramics with the conductivity of metals; cutting tools and molds in industrial manufacturing improve performance through the high hardness of ceramics and the toughness of metals; fuel cells and nuclear reactor parts in the energy field combine the efficient electrochemical properties of ceramics with the mechanical strength of metals. In addition, the combination of ceramics and metals is also widely used in jewelry and decorations to provide beautiful and durable products. These combinations take full advantage of the respective advantages of ceramics and metals to improve the high performance, long life and high reliability of parts. At present, the 3D printing integration technology for ceramics and metals has not been fully developed, and continuous exploration and in-depth research is needed. Summary of the invention

[0004] To solve the above problems, the present invention discloses a method and device for additive manufacturing of structural-functional integrated ceramic-based composite materials. The device consists of a powder spreading mechanism, a powder box lifting mechanism, a precise powder suction and powder dropping mechanism, an adjustable laser printing mechanism and an overall support control system. The powder spreading mechanism realizes the laying of metal powder, the powder box lifting mechanism realizes layer-by-layer printing, the precise powder suction and powder dropping mechanism realizes the precise absorption of metal powder and the laying of ceramic powder according to slicing information, the adjustable laser printing mechanism realizes laser sintering of metal powder and ceramic powder according to slicing information, and the overall support control system provides support for other mechanisms and control of movement in the printing direction. The powder spreading mechanism consists of a lifting plate 1, a powder box, an automatic lifting system 1, a roller, a bracket 1 and a roller bracket. The powder box is fixed on the forming platform. The lifting plate 1 is fixedly connected to the automatic lifting system 1 and moves up and down in the powder box. Both ends of the roller are fixed on the roller bracket, and the roller bracket is fixed on the bracket 1. The bracket 1 is fixedly installed on the module 1; the powder box lifting mechanism consists of a powder box forming platform, a lifting plate 2 and an automatic lifting system 2. The powder box forming platform is fixed on a metal frame, and the lifting plate 2 is fixed on the automatic lifting system 2 and moves up and down on the powder box forming platform; the precise powder suction and powder dropping mechanism consists of a bracket 2, a powder dropper, a powder suction device, a mobile bracket 1, a mobile bracket 2, a screen, and a module. The invention relates to a laser printing mechanism, which is composed of a fixed bracket, a fixed plate, a rotating cylinder, a connecting plate, a laser generator 1 and a laser generator 2. The fixed bracket is fixed on the basic metal frame, the fixed plate is fixed on the fixed bracket, the rotating cylinder is fixed on the fixed plate by bolts, the connecting plate is fixed on the rotating cylinder, and the laser generator 1 and the laser generator 2 are fixed on the connecting plate. The overall support control system is composed of a basic metal frame and a module 1, and the module 1 is fixedly mounted on the basic metal frame.

[0005] Furthermore, the lower surface of the powder suction mechanism is 2 mm away from the powder spreading surface, and the suction force is controlled within the range capable of sucking out the ceramic powder spreading area; Furthermore, the temperature generated by the laser in the laser generator 1 is the temperature at which the metal solution melts, and the temperature generated by the laser in the laser generator 2 is the temperature at which the ceramic powder melts. If melting of multi-material metal particles or ceramic powder particles is performed, the temperature generated by the laser generator needs to be adjusted; Furthermore, the vibration frequency of the ultrasonic vibration generator is, the mesh size of the screen is, the distance from the powder spreading surface is 1mm, and the size of the powder falling opening is 1mm; A method for additive manufacturing of structural-functional integrated ceramic-based composite materials, the method comprising: determining ceramic and metal regions according to component requirements, and dividing the component three-dimensional model into a metal region model and a ceramic region model. Slice the divided model, use a powder spreading mechanism to drop metal powder, use a powder scraping mechanism to level the surface, then control the powder suction mechanism to absorb powder from the ceramic printing area, and then control the ultrasonic vibration generator to vibrate and drop ceramic powder. At the same time, control the laser generator 1 to work according to the metal slicing information and the laser generator 2 to work according to the ceramic slicing information to reduce stress generation. Repeat the above steps until the overall printing is completed; Furthermore, when dividing the three-dimensional model of the part, a mechanical interlocking structure should be set to increase the interface bonding strength, such as using a serrated or wavy interface or a nested structure to further improve the overall stability of the part; Furthermore, ceramic or metal powders of various materials can be printed. The laser melting temperatures set for metal powders and ceramic powders of different materials are different. The particle sizes of the two materials are close, which produces a better sintering effect. At the same time, the thermal expansion coefficients of the two materials should be as close as possible to reduce stress accumulation at the interface; Furthermore, when the ceramic area is melted and cooled into a semi-solid state, the next metal powder spreading is carried out with an interval of 30 to 60 seconds.

[0006] Furthermore, the absorbed metal can be recycled into the powder box, and if multiple materials are used, the metal powders can be recycled separately; After adopting the above technical solution, the beneficial effects of the present invention are: 1. The integrated forming technology of ceramics and metals can enhance structural integrity, improve thermal expansion matching, increase durability and life, and optimize overall performance.

[0007] 2. Integrated forming eliminates interface weaknesses, reduces manufacturing steps and assembly processes, and improves production efficiency and precision. This technology also allows the design of complex geometric shapes, provides greater design freedom, and achieves lighter weight and higher strength, which is particularly suitable for the aerospace and automotive industries.

[0008] 3. This method and device can accurately control the absorption of ceramic powder and the laying of metal powder, which can realize the effective combination of ceramics and metal according to the requirements of parts, improve the service life of parts serving in complex and harsh environments, further promote the development of complex parts like 3D printing, and promote the production of high-end parts and equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 This is the overall diagram of the multi-material ceramic-metal composite forming device; Figure 2 It is the left view of the multi-material ceramic-metal composite forming device; Figure 3 It is a rear view of the multi-material ceramic-metal composite forming device; Figure 4 It is a top view of a multi-material ceramic-metal composite forming device; Figure 5 for Figure 4 Screenshot of A-A in the middle; Figure 6 for Figure 5 The enlarged view of point B in the middle; Figure 7 A flow chart of the additive manufacturing method for structure-function integrated ceramic matrix composites; Figure 8 It is a structure used for the junction of metal and ceramic in multi-material ceramic-metal composite forming.

[0010] List of reference numerals: Description of the drawings: 101, lifting plate 1; 102, powder box; 103, automatic lifting system 1; 104, roller; 105, bracket 1; 106, roller bracket; 201, powder box forming platform; 202, lifting plate 2; 203 automatic lifting system 2; 301 bracket 2; 302, powder dropper; 303, powder absorber; 304, mobile bracket 1; 305, mobile bracket 2; 306, screen; 307, module 2; 308, module 3; 401, fixed bracket; 402, fixed plate; 403, rotating cylinder; 404, connecting plate; 405, laser generator 1; 406, laser generator 2; 501, basic metal frame; 502, module 1. DETAILED DESCRIPTION

[0011] The present invention is further explained below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention. It should be noted that the words "front", "rear", "left", "right", "upper" and "lower" used in the following description refer to directions in the accompanying drawings, and the words "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0012] like Figure 1-6As shown, the structural-functional integrated ceramic-based composite material additive manufacturing method and device of this embodiment are composed of a powder spreading mechanism, a powder box lifting mechanism, a precise powder suction and powder dropping mechanism, an adjustable laser printing mechanism and an overall support control system. The powder spreading mechanism realizes the laying of metal powder, the powder box lifting mechanism realizes layer-by-layer printing, the precise powder suction and powder dropping mechanism realizes the precise absorption of metal powder and the laying of ceramic powder according to the slicing information, the adjustable laser printing mechanism realizes the laser sintering of metal powder and ceramic powder according to the slicing information, and the overall support control system provides support for other mechanisms and control of movement in the printing direction. The powder spreading mechanism consists of a lifting plate 1, a powder box, an automatic lifting system 1, a roller, a bracket 1 and a roller bracket. The powder box is fixed on the forming platform. The lifting plate 1 is fixedly connected to the automatic lifting system 1 and moves up and down in the powder box. Both ends of the roller are fixed on the roller bracket, and the roller bracket is fixed on the bracket 1. The bracket 1 is fixedly installed on the module 1; the powder box lifting mechanism consists of a powder box forming platform, a lifting plate 2 and an automatic lifting system 2. The powder box forming platform is fixed on a metal frame, and the lifting plate 2 is fixed on the automatic lifting system 2 and moves up and down on the powder box forming platform; the precise powder suction and powder dropping mechanism consists of a bracket 2, a powder dropper, a powder suction device, a mobile bracket 1, a mobile bracket 2, a screen, and a module. The invention relates to a laser printing mechanism, which is composed of a fixed bracket, a fixed plate, a rotating cylinder, a connecting plate, a laser generator 1 and a laser generator 2. The fixed bracket is fixed on the basic metal frame, the fixed plate is fixed on the fixed bracket, the rotating cylinder is fixed on the fixed plate by bolts, the connecting plate is fixed on the rotating cylinder, and the laser generator 1 and the laser generator 2 are fixed on the connecting plate. The overall support control system is composed of a basic metal frame and a module 1, and the module 1 is fixedly mounted on the basic metal frame.

[0013] The lower surface of the powder suction mechanism is 2 mm away from the powder spreading surface, and the suction force is controlled within the range capable of sucking out the ceramic powder spreading area; The temperature generated by the laser in the laser generator 1 is the temperature at which the metal solution melts, and the temperature generated by the laser in the laser generator 2 is the temperature at which the ceramic powder melts. If melting of multi-material metal particles or ceramic powder particles is performed, the temperature generated by the laser generator needs to be adjusted; Among them, the vibration frequency of the ultrasonic vibration generator is, the mesh size of the screen is, the distance from the powder spreading surface is 1mm, and the size of the powder falling opening is 1mm; A method for additive manufacturing of structural-functional integrated ceramic-based composite materials, the method comprising: determining ceramic and metal regions according to component requirements, and dividing the component three-dimensional model into a metal region model and a ceramic region model. Slice the divided model, use a powder spreading mechanism to drop metal powder, use a powder scraping mechanism to level the surface, then control the powder suction mechanism to absorb powder from the ceramic printing area, and then control the ultrasonic vibration generator to vibrate and drop ceramic powder. At the same time, control the laser generator 1 to work according to the metal slicing information and the laser generator 2 to work according to the ceramic slicing information to reduce stress generation. Repeat the above steps until the overall printing is completed; Among them, when dividing the three-dimensional model of the part, a mechanical interlocking structure should be set to increase the interface bonding strength, such as using a serrated, wavy interface or a nested structure to further improve the overall stability of the part; Among them, ceramic or metal powders of various materials can be printed. The laser melting temperatures set for metal powders and ceramic powders of different materials are different. The particle sizes of the two materials are close, which produces a better sintering effect. At the same time, the thermal expansion coefficients of the two materials should be as close as possible to reduce stress accumulation at the interface; Among them, the next metal powder spreading is carried out when the ceramic area melts and cools into a semi-solid state, with an interval of 30 to 60 seconds.

[0014] The absorbed metal can be recycled into the powder box, and if multiple materials of metal powder are used, they can be recycled separately.

[0015] Additive manufacturing methods for structural-functional integrated ceramic matrix composites, such as Figure 7-8 As shown, the forming of the part needs to reduce the weight of the part and make a part of the area corrosion-resistant. Therefore, some areas in the middle are set as ceramic printing areas according to the requirements, and some areas are set as metal printing areas. The three-dimensional model of the component is divided into a metal area model and a ceramic area model. The divided model is sliced ​​into ceramic printing slices and metal printing slices. The powder spreading mechanism drops metal powder according to the metal printing slices, and the surface is leveled by the powder scraping mechanism. The powder suction mechanism is controlled to absorb powder from the ceramic printing area according to the ceramic printing slices, and the ultrasonic vibration generator is controlled to vibrate and drop ceramic powder according to the ceramic printing slices. At the same time, the laser generator 1 is controlled to work according to the metal slice information and the laser generator 2 is controlled to work according to the ceramic slice information to reduce stress generation. When the ceramic area is melted and cooled into a semi-solid state, the next metal powder spreading is carried out, and the interval time is 30~60s. Repeat the above steps until the overall printing is completed; The technical means disclosed in the scheme of the present invention are not limited to the technical means disclosed in the above-mentioned implementation mode, but also include technical schemes composed of any combination of the above technical features.

Claims

1. A structural-functional integrated ceramic matrix composite material additive manufacturing device, characterized by: The device is composed of a powder spreading mechanism, a powder box lifting mechanism, a precise powder suction and powder dropping mechanism, an adjustable laser printing mechanism and an overall support control system. The powder box lifting mechanism is located inside the overall support control system. The powder spreading mechanism, the precise powder suction and powder dropping mechanism and the adjustable laser printing mechanism are located above the powder box lifting mechanism and supported by the overall support control system. In the powder spreading direction, the powder spreading mechanism, the precise powder suction and powder dropping mechanism and the adjustable laser printing mechanism are used. The powder spreading mechanism spreads metal powder, the powder box lifting mechanism prints layer by layer, the precise powder suction and powder dropping mechanism absorbs metal powder and spreads ceramic powder according to slicing information, the adjustable laser printing mechanism performs laser sintering of metal powder and ceramic powder according to slicing information, and the overall support control system provides support for other mechanisms and controls movement in the printing direction. The overall support control system is composed of a basic metal frame (501) and a module one (502), and the module one (502) is fixedly mounted on the basic metal frame (501).

2. The structure-function integrated ceramic matrix composite material additive manufacturing device according to claim 1, characterized in that: The powder spreading mechanism is composed of a lifting plate 1 (101), a powder box (102), an automatic lifting system 1 (103), a roller (104), a bracket 1 (105) and a roller bracket (106). The powder box (102) is fixed on the forming platform. The lifting plate 1 (101) is fixedly connected to the automatic lifting system 1 (103) and moves up and down in the powder box (102). Both ends of the roller (104) are fixed on the roller bracket (106). The roller bracket (106) is fixed on the bracket 1 (105). The bracket 1 (105) is fixedly installed on the module 1.

3. The structure-function integrated ceramic matrix composite material additive manufacturing device according to claim 1, characterized in that: The powder box lifting mechanism is composed of a powder box forming platform (201), a second lifting plate (202) and a second automatic lifting system (203). The powder box forming platform (201) is fixed on a metal frame, and the second lifting plate (202) is fixed on the second automatic lifting system (203) and moves up and down on the powder box forming platform (201).

4. The structure-function integrated ceramic matrix composite material additive manufacturing device according to claim 1, characterized in that: The precise powder suction and powder dropping mechanism comprises a bracket 2 (301), a powder dropper (302), a powder absorber (303), a movable bracket 1 (304), a movable bracket 2 (305), a screen (306), a module 2 (307), and a module 3 (308). The bracket 2 (301) is fixedly mounted on the module 1 (502). The module 2 (307) and the module 3 (308) are fixed on the bracket 2 (301). The movable bracket 1 (304) connects the powder dropper (303) and the module 2 (307). A metal screen is embedded in the powder dropper (302) and an ultrasonic vibrator is externally connected by bolts. The movable bracket 2 (305) connects the powder absorber (303) and the module 3 (308). The powder absorber (303) is externally connected to a negative pressure device.

5. The structure-function integrated ceramic matrix composite material additive manufacturing device according to claim 1, characterized in that: The adjustable laser printing mechanism is composed of a fixed bracket (401), a fixed plate (402), a rotating cylinder (403), a connecting plate (404), a first laser generator (405) and a second laser generator (406). The fixed bracket (401) is fixed to a base metal frame, the fixed plate (402) is fixed to the fixed bracket (401), the rotating cylinder (403) is fixedly mounted on the fixed plate (402) by bolts, the connecting plate (404) is fixed to the rotating cylinder (403), and the first laser generator (405) and the second laser generator (406) are fixedly mounted on the connecting plate (404).

6. The multi-material ceramic-metal composite forming device according to claim 1, characterized in that: The lower surface of the powder suction mechanism is 2mm away from the powder spreading surface, and the suction force is controlled within the range that can suck out the ceramic powder spreading area; the temperature generated by the laser in the laser generator one is the temperature at which the metal solution melts, and the temperature generated by the laser in the laser generator two is the temperature at which the ceramic powder melts. If multi-material metal particles or ceramic powder particles are melted, the temperature generated by the laser generator needs to be adjusted.

7. The structure-function integrated ceramic matrix composite material additive manufacturing device according to claim 1, characterized in that: The ultrasonic vibration generator is a high-frequency, low-amplitude vibration, the width of the powder drop opening is 6 mm, and the distance from the powder spreading surface is 1 mm.

8. A method for additive manufacturing of a structural-functional integrated ceramic matrix composite material, characterized in that: The following steps are involved: Step 1: Determine the ceramic and metal areas according to the component requirements, and divide the component 3D model into a metal area model and a ceramic area model; Step 2: Classify and slice the divided models to determine the metal area model slices and the ceramic area model slices; Step 3: Then, the roller is used to spread ceramic powder, the powder suction mechanism is controlled to suck powder from the ceramic printing area, and then the ultrasonic vibration generator is controlled to vibrate and drop the ceramic powder, and at the same time, the laser generator 1 is controlled to perform sintering according to the metal slice information and the laser generator 2 is controlled to perform sintering according to the ceramic slice information; Step 4: Repeat the above steps until the entire printing is completed; Repeat the above steps until the entire printing is completed.

9. The method for additive manufacturing of a structural-functional integrated ceramic matrix composite material according to claim 8, characterized in that: When dividing the three-dimensional model of the part, a mechanical interlocking structure should be set to increase the interface bonding strength, wherein the mechanical interlocking structure adopts a serrated or wavy interface or a nested structure.

10. The method for additive manufacturing of a structural-functional integrated ceramic matrix composite material according to claim 8, characterized in that: For printing ceramic or metal powders of various materials in step 3, the laser melting temperatures set for metal powders and ceramic powders of different materials are different; the next metal powder spreading is carried out when the ceramic area is melted and cooled into a semi-solid state, and the interval time is 30~60s.

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