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

Abstract

The application 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 support control system, the powder laying mechanism realizes laying of metal powder, the powder box lifting mechanism realizes layer-by-layer printing, the precise powder sucking and falling mechanism realizes precise sucking of metal powder and laying of ceramic powder according to slice information, the adjustable laser printing mechanism realizes laser sintering forming of metal powder and ceramic powder according to slice information, and the overall support control system provides support and control of movement of the printing direction for other mechanisms. According to part requirements, ceramic and metal areas are determined, and a three-dimensional model of the part is divided into a metal area model and a ceramic area model. The method improves the service life of parts serving in complex and harsh environments.

Description

TECHNICAL FIELD

[0001] The application belongs to the field of ceramic 3D printing powder laying and the field of metal 3D printing, relates to the field of multi-material composite printing, and particularly relates to a structural-functional integrated ceramic matrix composite material additive manufacturing method and device. BACKGROUND

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

[0003] Currently, many key parts require the combination of ceramics and metals to fully utilize 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 resistance of ceramics with the structural support of metals; brake discs and exhaust systems in the automotive industry utilize 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 electrical conductivity of metals; cutting tools and molds in industrial manufacturing enhance performance through the high hardness of ceramics and the toughness of metals; fuel cells and nuclear reactor parts in the energy field combine the high-efficiency 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, providing aesthetically pleasing and durable products. These combinations fully utilize the advantages of ceramics and metals, enhancing the high performance, long life and high reliability of the parts. Currently, the 3D printing forming integration technology for ceramics and metals has not been fully developed and further exploration and in-depth research are needed. SUMMARY

[0004] To solve the above problems, the application discloses a structure-function integrated ceramic matrix composite material additive manufacturing method and device, which is composed of a powder laying mechanism, a powder box lifting mechanism, a precise powder sucking and laying mechanism, an adjustable laser printing mechanism and an overall support control system. The powder laying mechanism realizes the laying of metal powder, the powder box lifting mechanism realizes layer-by-layer printing, the precise powder sucking and laying mechanism realizes the precise sucking of metal powder and the laying of ceramic powder according to slice information, the adjustable laser printing mechanism realizes the laser sintering forming of metal powder and ceramic powder according to slice information, and the overall support control system provides support and control of the movement of the printing direction for other mechanisms. The powder laying mechanism is composed of a lifting plate one, a powder box, an automatic lifting system one, a roller, a support one and a roller support. The powder box is fixed on a forming platform, the lifting plate one is fixedly connected to the automatic lifting system one and moves up and down in the powder box, the roller is fixed at both ends of the roller support, the roller support is fixed on the support one, and the support one is fixedly installed on a module one. The powder box lifting mechanism is composed of a powder box forming platform, a lifting plate two and an automatic lifting system two. The powder box forming platform is fixed on a metal frame, and the lifting plate two is fixed on the automatic lifting system two and moves up and down on the powder box forming platform. The precise powder sucking and laying mechanism is composed of a support two, a powder laying device, a powder sucking device, a moving support one, a moving support two, a screen, a module two and a module three. The support two is fixedly installed on the module one, the module two and the module three are fixed on the support two, the moving support one is connected to the powder laying device and the module two, the powder laying device is nested with a metal screen and connected with an ultrasonic vibrator through a bolt, the moving support two is connected to the powder sucking device and the module three, and the powder sucking device is connected with a negative pressure extraction device. The adjustable laser printing mechanism is composed of a fixed support, a fixed plate, a rotary air cylinder, a connecting plate, a laser generator one and a laser generator two. The fixed support is fixed on a basic metal frame, the fixed plate is fixed on the fixed support, the rotary air cylinder is fixedly installed on the fixed plate through a bolt, the connecting plate is fixed on the rotary air cylinder, and the laser generator one and the laser generator two are fixedly installed on the connecting plate. The overall support control system is composed of the basic metal frame and the module one, and the module one is fixedly installed on the basic metal frame.

[0005] Further, the distance between the lower surface of the powder sucking mechanism and the powder laying surface is 2mm, and the suction force is controlled within the range of the ceramic powder laying area.

[0006] Further, the temperature of the laser generated in the laser generator one is the melting temperature of the metal solution, the temperature of the laser generated in the laser generator two is the melting temperature of the ceramic powder, and the temperature generated by the laser generator needs to be adjusted when the multi-material metal particles or ceramic powder particles are melted.

[0007] Further, the vibration frequency of the ultrasonic vibration generator is, the screen mesh size is, the distance from the powder laying surface is 1mm, and the powder falling port size is 1mm.

[0008] The method comprises the following steps: determining ceramic and metal regions according to part requirements, dividing a three-dimensional model of the part into a metal region model and a ceramic region model, slicing the divided model, performing metal powder laying by a powder laying mechanism, performing surface leveling by a powder scraping mechanism, controlling a powder suction mechanism to suck ceramic powder from the printing region, controlling an ultrasonic vibration generator to vibrate and drop ceramic powder, and controlling a laser generator to work according to metal slice information and ceramic slice information to reduce stress generation.

[0009] Further, when the three-dimensional model of the part is divided, a mechanical interlocking structure should be set to increase the interface bonding strength, such as using a sawtooth-shaped, wavy interface or a nested structure, to further improve the overall stability of the part.

[0010] Further, ceramic or metal powder of multiple materials can be printed, and the laser melting temperatures of metal powder and ceramic powder of different materials are different. The particle sizes of the two materials are close to produce better sintering effect. Meanwhile, the thermal expansion coefficients of the two materials should be as close as possible to reduce stress accumulation at the interface.

[0011] Further, the next metal powder laying is performed when the ceramic region is melted and cooled into a semi-solid state, and the interval time is 30-60s.

[0012] Further, the sucked metal can be recycled into the powder laying box, and if multiple material metal powder is used, it can be recycled separately.

[0013] After the above technical solutions are adopted, the beneficial effects of the present application are as follows:

[0014] 1. The integrated forming technology of ceramic and metal can enhance the structural integrity, improve the thermal expansion matching, improve the durability and life, and optimize the overall performance.

[0015] 2. The integrated forming eliminates the interface weakness, reduces the manufacturing steps and assembly processes, improves the production efficiency and precision. This technology also allows the design of complex geometries, provides greater design freedom, and achieves lighter weight and higher strength, especially suitable for aerospace and automotive industries.

[0016] 3. The method and device precisely control the suction of ceramic powder and the laying of metal powder, which can realize the effective combination of ceramic and metal according to the part requirements, improve the life of parts serving in complex and harsh environments, further promote the development of complex parts in the direction of 3D printing, and promote the production of high-end parts and equipment. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1Figure 1 is a perspective view of a multi-material ceramic metal composite forming device;

[0018] Figure 2 Figure 2 is a left side view of a multi-material ceramic metal composite forming device;

[0019] Figure 3 Figure 3 is a rear view of a multi-material ceramic metal composite forming device;

[0020] Figure 4 Figure 4 is a top view of a multi-material ceramic metal composite forming device;

[0021] Figure 5 Figure 5 is a cross-sectional view of the device taken along line A-A; Figure 4

[0022] Figure 6 is an enlarged view of the device taken along line B; Figure 6 Figure 5

[0023] Figure 7 Figure 7 is a flow chart of a structure-function integrated ceramic matrix composite material additive manufacturing method;

[0024] Figure 8 Figure 8 is a structure used in the combination of metal and ceramic in a multi-material ceramic metal composite forming device.

[0025] LIST OF REFERENCE NUMBERS:

[0026] BRIEF DESCRIPTION OF DRAWINGS: 101, lifting plate one; 102, powder box; 103, automatic lifting system one; 104, roller; 105, support one; 106, roller support; 201, powder box forming platform; 202, lifting plate two; 203, automatic lifting system two; 301, support two; 302, powder falling device; 303, powder suction device; 304, moving support one; 305, moving support two; 306, screen; 307, module two; 308, module three; 401, fixed support; 402, fixed plate; 403, rotary cylinder; 404, connecting plate; 405, laser generator one; 406, laser generator two; 501, base metal frame; 502, module one. DETAILED DESCRIPTION

[0027] The present application will be further clarified by the following examples, which should be considered as merely illustrative of the present application and not limiting thereof. It should be noted that the terms "front", "rear", "left", "right", "upper" and "lower" as used in the following description refer to the directions in the drawings, and the terms "inner" and "outer" refer to the directions toward or away from the geometric center of a particular component.

[0028] As Figures 1-6 ​​As shown, the structure-function integrated ceramic matrix composite material additive manufacturing method and device of the embodiment, the device is composed of powder laying mechanism, powder box lifting mechanism, precise powder sucking and laying mechanism, adjustable laser printing mechanism and overall support control system, the powder laying mechanism realizes the laying of metal powder, the powder box lifting mechanism realizes layer-by-layer printing, the precise powder sucking and laying mechanism realizes the precise sucking of metal powder and the laying of ceramic powder according to slice information, the adjustable laser printing mechanism realizes the laser sintering forming of metal powder and ceramic powder according to slice information, and the overall support control system provides support and control of the movement of the printing direction for other mechanisms. The powder laying mechanism is composed of lifting plate 1, powder box, automatic lifting system 1, roller, support 1 and roller support, 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, the roller is fixed at both ends of the roller support, the roller support is fixed on the support 1, and the support 1 is fixedly installed on the module 1; the powder box lifting mechanism is composed of powder box forming platform, lifting plate 2 and automatic lifting system 2, the powder box forming platform is fixed on the metal frame, 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 sucking and laying mechanism is composed of support 2, powder dropping device, powder sucking device, moving support 1, moving support 2, screen, module 2 and module 3, the support 2 is fixedly installed on the module 1, the module 2 and the module 3 are fixed on the support 2, the moving support 1 is connected to the powder dropping device and the module 2, the powder dropping device is nested with a metal screen and connected with an ultrasonic vibrator through a bolt, the moving support 2 is connected to the powder sucking device and the module 3, and the powder sucking device is connected with a negative pressure extraction device; the adjustable laser printing mechanism is composed of fixed support, fixed plate, rotary air cylinder, connecting plate, laser generator 1 and laser generator 2, the fixed support is fixed on the basic metal frame, the fixed plate is fixed on the fixed support, the rotary air cylinder is fixedly installed on the fixed plate through a bolt, the connecting plate is fixed on the rotary air cylinder, and the laser generator 1 and the laser generator 2 are fixedly installed on the connecting plate. The overall support control system is composed of the basic metal frame and the module 1, and the module 1 is fixedly installed on the basic metal frame.

[0029] The distance between the lower surface of the powder sucking mechanism and the powder laying surface is 2 mm, and the suction force is controlled within the range of the ceramic powder laying area.

[0030] The temperature of the laser generated in the laser generator 1 is the melting temperature of the metal solution, the temperature of the laser generated in the laser generator 2 is the melting temperature of the ceramic powder, and the temperature generated by the laser generator needs to be adjusted when melting multi-material metal particles or ceramic powder particles.

[0031] The vibration frequency of the ultrasonic vibration generator is, the screen mesh size is, the distance from the powder laying surface is 1 mm, and the powder dropping port size is 1 mm.

[0032] The structure-function integrated ceramic matrix composite material additive manufacturing method comprises the following steps: determining ceramic and metal regions according to part requirements, dividing a three-dimensional model of the part into a metal region model and a ceramic region model. The divided model is sliced, a powder laying mechanism lays metal powder, a powder scraping mechanism levels the surface, a powder suction mechanism is controlled to suck ceramic powder from the ceramic printing area, an ultrasonic vibration generator is controlled to vibrate and drop ceramic powder, a laser generator one is controlled to work according to metal slice information, and a laser generator two is controlled to work according to ceramic slice information to reduce stress generation. The above steps are repeated until the overall printing is completed.

[0033] In the step of dividing the three-dimensional model of the part, a mechanical interlocking structure is arranged to increase the interface bonding strength, such as a zigzag, wavy interface or a nested structure, to further improve the overall stability of the part.

[0034] In the step of dividing the three-dimensional model of the part, a mechanical interlocking structure is arranged to increase the interface bonding strength, such as a zigzag, wavy interface or a nested structure, to further improve the overall stability of the part.

[0035] In the step of dividing the three-dimensional model of the part, a mechanical interlocking structure is arranged to increase the interface bonding strength, such as a zigzag, wavy interface or a nested structure, to further improve the overall stability of the part.

[0036] In the step of dividing the three-dimensional model of the part, a mechanical interlocking structure is arranged to increase the interface bonding strength, such as a zigzag, wavy interface or a nested structure, to further improve the overall stability of the part.

[0037] The structure-function integrated ceramic matrix composite material additive manufacturing method comprises the following steps: determining ceramic and metal regions according to part requirements, dividing a three-dimensional model of the part into a metal region model and a ceramic region model. The divided model is sliced, a powder laying mechanism lays metal powder, a powder scraping mechanism levels the surface, a powder suction mechanism is controlled to suck ceramic powder from the ceramic printing area, an ultrasonic vibration generator is controlled to vibrate and drop ceramic powder, a laser generator one is controlled to work according to metal slice information, and a laser generator two is controlled to work according to ceramic slice information to reduce stress generation. The above steps are repeated until the overall printing is completed. Figures 7-8 The structure-function integrated ceramic matrix composite material additive manufacturing method comprises the following steps: determining ceramic and metal regions according to part requirements, dividing a three-dimensional model of the part into a metal region model and a ceramic region model. The divided model is sliced, a powder laying mechanism lays metal powder, a powder scraping mechanism levels the surface, a powder suction mechanism is controlled to suck ceramic powder from the ceramic printing area, an ultrasonic vibration generator is controlled to vibrate and drop ceramic powder, a laser generator one is controlled to work according to metal slice information, and a laser generator two is controlled to work according to ceramic slice information to reduce stress generation. The above steps are repeated until the overall printing is completed.

[0038] The technical means disclosed in the present application are not limited to the technical means disclosed in the above-mentioned embodiments, and include technical solutions composed of any combination of the above technical features.

Claims

1. A structure-function integrated ceramic matrix composite additive manufacturing device, characterized in that: The device consists of a powder spreading mechanism, a powder box lifting mechanism, a precision powder suction and dispensing 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 precision powder suction and dispensing mechanism, and the adjustable laser printing mechanism are located above the powder box lifting mechanism and supported by the overall support control system. The powder spreading mechanism, the precision powder suction and dispensing mechanism, and the adjustable laser printing mechanism are arranged in the powder spreading direction. The powder spreading mechanism spreads metal powder, the powder box lifting mechanism performs layer-by-layer printing, the precision powder suction and dispensing mechanism precisely picks up metal powder and spreads ceramic powder according to the slice information, and the adjustable laser printing mechanism performs laser sintering of metal and ceramic powders according to the slice information. The overall support control system provides support for the other mechanisms and controls the movement in the printing direction. The overall support control system consists of a basic metal frame (…). The precision powder suction and dropping mechanism consists of a support (301), a powder dropper (302), a powder suction device (303), a movable support (304), a movable support (305), a screen (306), a module (307), and a module (308). The support (301) is fixedly installed on the module (502), and the modules (307) and (308) are fixed on the support (301). The movable support (304) connects the powder dropper (302) and the module (307). The powder dropper (302) is nested with a metal screen and connected to an ultrasonic vibration generator via bolts. The movable support (305) connects the powder suction device (303) and the module (308). The powder suction device (303) is connected to a negative pressure device. The adjustable laser printing mechanism consists of a fixed bracket (401), a fixed plate (402), a rotary cylinder (403), a connecting plate (404), a laser generator one (405), and a laser generator two (406). The fixed bracket (401) is fixed on the basic metal frame, the fixed plate (402) is fixed on the fixed bracket (401), the rotary cylinder (403) is fixed on the fixed plate (402) by bolts, the connecting plate (404) is fixed on the rotary cylinder (403), and the laser generator one (405) and laser generator two (406) are fixed on the connecting plate (404). 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 melting temperature of the metal solution, and the temperature generated by the laser in the laser generator two is the melting temperature of the ceramic powder. If melting of multi-material metal particles or ceramic powder particles is required, the temperature generated by the laser generator needs to be adjusted.

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

3. The structure-function integrated ceramic matrix composite additive manufacturing apparatus according to claim 1, characterized in that: The powder box lifting mechanism consists 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 the basic 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 additive manufacturing apparatus according to claim 1, characterized in that, The ultrasonic vibration generator is a high-frequency, low-amplitude vibrator, and the width of the powder drop nozzle is 6mm, with a distance of 1mm from the powder surface.

5. The additive manufacturing method for structural-functional ceramic matrix composite materials using the structural-functional integrated ceramic matrix composite material additive manufacturing apparatus according to any one of claims 1-4, characterized in that: Includes the following steps: Step 1: Determine the ceramic and metal regions based on the component requirements, and divide the 3D model of the component into a metal region model and a ceramic region model; Step 2: Classify and slice the divided model into metal region model slices and ceramic region model slices; Step 3: Then the powder spreading mechanism applies metal powder according to the metal printing slice, controls the powder suction mechanism to suction powder to the ceramic printing area, and controls the ultrasonic vibration generator to vibrate and drop ceramic powder. At the same time, controls laser generator one to sinter and form according to the metal slice information and laser generator two to sinter according to the ceramic slice information. Step 4: Repeat the above steps until the entire print job is finished; repeat the above steps until the entire print job is finished.

6. The additive manufacturing method for structural-functional integrated ceramic matrix composite materials according to claim 5, characterized in that: When dividing the 3D model of a part, a mechanical interlocking structure should be set to increase the interface bonding strength. The mechanical interlocking structure can adopt a sawtooth or wavy interface or a nested structure.

7. The additive manufacturing method for structure-function integrated ceramic matrix composite materials according to claim 5, characterized in that, For printing ceramic or metal powders of various materials in step 3, the laser melting temperature is set differently for different metal powders and ceramic powders; when the ceramic area melts and cools into a semi-solid state, the next metal powder layer is laid, with an interval of 30~60 seconds.

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