Porous material forming method, system and component obtained thereby

Abstract

The present application relates to a porous material forming method, system and component obtained thereby, the method calculates a scan parameter based on a single pass molten pool size and a designed porosity, and generates a target angle therefrom, where the fill pitch of the scan parameter is at least greater than the single pass molten pool size; an energy beam is adopted to scan materials stacked layer by layer to form a first layer family, then the materials are scanned again to form a second layer family, the included angle between the first layer family and the second layer family is a target angle, scanning of the first layer family and the second layer family is executed alternately, the porous material component is formed step by step until the preparation process is finished finally, and the porous material component is obtained. Therefore, the porosity, the pore size, the pore morphology and other parameters of the porous material can be accurately controlled.

Description

Technical Field

[0001] This application relates to the field of additive manufacturing technology, and more particularly to a method for forming a porous material, a porous material forming system using the forming method, an additive manufacturing apparatus having the forming system, and a porous material member obtained thereby. Background Art

[0002] Due to its unique structural characteristics, porous materials have a wide range of applications in the field of heat dissipation. The internal pore structure helps to increase the specific surface area and heat exchange capacity of the material, making it play an important role in fields such as heat dissipation of electronic devices, thermal management systems, and heat dissipation coatings. To optimize the heat dissipation performance, key parameters such as the porosity, pore size, and their distribution of the porous material need to be precisely controlled to ensure heat dissipation efficiency, structural stability, and processing adaptability.

[0003] Currently, the preparation of porous materials usually relies on traditional processing methods such as etching, sintering, solvent evaporation, and self-assembly. For example, the chemical etching method forms pores by selectively removing specific areas of the material, but the pore size and distribution are greatly affected by the etching process and are difficult to precisely control; the sintering method forms a porous structure by controlling the bonding process of material particles, but the uniformity and connectivity of the pores are difficult to ensure; the solvent evaporation method depends on the evaporation rate of the solvent and the phase separation mechanism, and is easily affected by fluctuations in process parameters, resulting in non-uniform pore structures; in addition, the self-assembly method forms porous materials by self-assembling molecules such as adsorbents and surfactants through interactions. Although it can regulate the pore distribution to a certain extent, there are still limitations in large-scale manufacturing and structural stability, and it is difficult to meet the refined requirements for porous materials in the field of heat dissipation. Summary of the Invention

[0004] This application provides a method for forming a porous material, a porous material forming system using the forming method, an additive manufacturing apparatus having the forming system, and a porous material member obtained thereby, which can precisely control parameters such as the porosity, pore size, and pore morphology of the porous material.

[0005] In a first aspect, this application provides a method for forming a porous material, including: calculating scanning parameters according to the single-pass molten pool size and the designed porosity, and generating a target angle according to the scanning parameters and the design parameters, wherein the filling pitch of the scanning parameters is at least greater than the single-pass molten pool size; performing an energy beam scan on the layer-by-layer stacked material according to the scanning parameters to form a first layer family; performing an energy beam scan on the layer-by-layer stacked material to form a second layer family, and the included angle between the first layer family and the second layer family is the target angle; cycling the alternating scans of the first layer family and the second layer family for forming until the porous material member is completed.

[0006] In an alternative embodiment of the first aspect, when calculating the scanning parameters, the method includes: calculating the filling spacing according to the single-pass molten pool width and the target porosity: where S is the filling spacing, W m is the single-pass molten pool width, and P is the target porosity; calculating the number of scanning layers required to maintain the current layer printing according to the single-pass molten pool depth and the single-layer printing thickness: N l = D m / T l , where N l is the number of scanning layers required to maintain the current layer printing, D m is the single-pass molten pool depth, and T l is the single-layer printing thickness.

[0007] In an alternative embodiment of the first aspect, the design parameters include the designed number of layers and the designed width of the porous material component, as well as one or more initial angles and the designed rotation angle of the porous material component.

[0008] In an alternative embodiment of the first aspect, the target angle includes a first angle for adjusting the energy beam and a second angle for adjusting the first layer family, or a first angle for adjusting the first layer family and a second angle for adjusting the energy beam.

[0009] In an alternative embodiment of the first aspect, when generating the target angle, the target angle is divided into a first angle and a second angle. Among them, the first layer family with the first angle is formed by performing energy beam scanning on the layer-by-layer stacked materials according to the scanning parameters; the second layer family with the second angle is formed by performing energy beam scanning on the layer-by-layer stacked materials. The included angle between the first angle and the second angle is the target angle; the alternating scanning and forming of the first layer family and the second layer family are cycled until the porous material component is completed.

[0010] In an alternative embodiment of the first aspect, the first angle includes a first adjustment angle for adjusting the energy beam and / or a second adjustment angle for adjusting the forming platform, and the second angle includes a third adjustment angle for adjusting the energy beam and / or a fourth adjustment angle for adjusting the first layer family.

[0011] In an alternative embodiment of the first aspect, after generating the target angle, the method includes: constructing a preset scanning model according to the scanning parameters, the design parameters, and the target angle; performing energy beam scanning on the layer-by-layer stacked materials according to the preset scanning model to form the first layer family; performing energy beam scanning on the layer-by-layer stacked materials to form the second layer family. The included angle between the first layer family and the second layer family is the target angle; the alternating scanning and forming of the first layer family and the second layer family are cycled until the porous material component is completed.

[0012] In an alternative solution of the first aspect, after constructing the preset scanning model, the target angle is divided into a first angle and a second angle. Among them, the energy beam of the first angle is scanned layer-by-layer stacked materials according to the preset scanning model to form a first layer family; the energy beam is scanned layer-by-layer stacked materials to form a second layer family of the second angle, and the included angle between the first angle and the second angle is the target angle;

[0013] The alternate scanning and forming of the first layer family and the second layer family is cycled until the porous material component is completed.

[0014] In an alternative solution of the first aspect, the number of models included in the preset scanning model is at least half of the number of edges of the designed porous material component.

[0015] In an alternative solution of the first aspect, the preset scanning model includes at least two scanning models.

[0016] In an alternative solution of the first aspect, the method further includes: constructing a first scanning model and a second scanning model according to the rotation parameters, filling spacing and scanning layers; performing energy beam scanning on the layer-by-layer stacked materials according to the first scanning model to form a first layer family; performing energy beam scanning on the layer-by-layer stacked materials according to the second scanning model to form a second layer family, and the included angle between the first layer family and the second layer family is the target angle; cycling the alternate scanning and forming of the first layer family and the second layer family until the porous material component is completed.

[0017] In an alternative solution of the first aspect, the first layer family and the second layer family use the same or different forming materials.

[0018] In an alternative solution of the first aspect, the first angle and the second angle are set based on the initial angle. Among them, the first angle is the angle formed by rotating in the first direction relative to the initial angle; the second angle is the angle formed by rotating in the second direction relative to the initial angle.

[0019] In an alternative solution of the first aspect, the initial angle can be adjusted every preset layer family.

[0020] In the second aspect, the present application provides a component made by using the forming method described above.

[0021] In the third aspect, the present application provides a porous material forming system made by using the forming method described above.

[0022] In the fourth aspect, the present application provides an additive manufacturing device using the method described above or including the forming system. Description of the Drawings

[0023] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the present application and, together with the description, serve to explain the principles of the present application and enable a person of ordinary skill in the relevant art to make and use the present application.

[0024] Figure 1 is a schematic structural diagram of an exemplary additive manufacturing apparatus according to some embodiments of the present application.

[0025] Figure 2 is a schematic scanning diagram of an exemplary energy beam adjusting a target angle according to some embodiments of the present application.

[0026] Figure 3 is a schematic scanning diagram of an exemplary forming platform adjusting a target angle according to some embodiments of the present application.

[0027] Figure 4 is a schematic scanning diagram of an exemplary combination of an energy beam and a forming platform adjusting a target angle according to some embodiments of the present application.

[0028] Figure 5 is a schematic scanning diagram of an exemplary energy beam adjusting a first angle and a second angle according to some embodiments of the present application.

[0029] Figure 6 is a schematic scanning diagram of an exemplary forming platform adjusting a first angle and a second angle according to some embodiments of the present application.

[0030] Figure 7 is a schematic scanning diagram of an exemplary combination of an energy beam and a forming platform adjusting a first angle and a second angle according to some embodiments of the present application.

[0031] Figure 8 is a schematic scanning diagram of an exemplary first layer family and a second layer family according to some embodiments of the present application.

[0032] Figure 9 is a schematic scanning diagram of an exemplary first layer family and a second layer family of a hexagonal member according to some embodiments of the present application.

[0033] Figure 10 is a schematic scanning diagram of an exemplary setting of a scanning model according to some embodiments of the present application.

[0034] Figure 11 is a schematic scanning diagram of an exemplary setting of multiple scanning models according to some embodiments of the present application.

[0035] Figure 12 is a schematic framework diagram of an exemplary porous material forming system according to some embodiments of the present application.

[0036] Description of the reference numerals:

[0037] 1. Additive manufacturing equipment; 2. Porous material component; 3. Porous material forming system; 4. Scanning model; 12. Powder spreading device; 13. Forming platform; 15. Optical path unit; 16. Rotating mechanism; 20. First layer family; 21. Second layer family; 22. Target angle; 40. First scanning model; 41. Second scanning model; 110. Powder storage cylinder; 111. Powder overflow cylinder; 150. Energy beam; 220. First angle; 221. Second angle; 220-1. First adjustment angle; 220-2. Second adjustment angle; 221-1. Third adjustment angle; 221-2. Fourth adjustment angle. Detailed implementation manners

[0038] Example embodiments will now be described more fully with reference to the accompanying drawings. However, the example embodiments can be implemented in various forms and should not be construed as limited to the examples set forth herein; rather, these embodiments are provided so that this application will be more complete and comprehensive, and will fully convey the concept of the example embodiments to those skilled in the art. The features, structures, or characteristics described may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of the embodiments of this application.

[0039] In order to optimize the heat dissipation performance, the key parameters of the porous material (such as porosity, pore size, pore distribution, and pore connectivity) need to be precisely controlled to ensure that the material has excellent thermal conductivity, heat dissipation efficiency, mechanical stability, and processability adaptability. For example, a higher porosity helps to enhance the flow of gas or liquid, thereby improving the convective heat transfer ability, but too high a porosity may reduce the mechanical strength of the material; the pore size and distribution uniformity directly affect the fluid transmission path and heat exchange efficiency, so precise regulation of them is the key to improving the heat dissipation performance of the porous material.

[0040] At present, the preparation of porous materials mainly relies on traditional processing methods such as etching, sintering, solvent evaporation, and self-assembly. Among them: The chemical etching method selectively removes specific regions of the material by using acid-base solutions, plasma, or electrochemical methods to form a pore structure. However, this method is greatly affected by the etching process, and it is difficult to precisely control the pore size and distribution. Moreover, the uneven etching rate may lead to unstable pore morphology, and chemical etching may introduce material damage or residual stress, affecting its long-term stability. The sintering method forms a porous structure by controlling the bonding process of material particles. This method is usually used for the preparation of metal or ceramic-based porous materials. Although the porosity can be adjusted to a certain extent, since the formation of pores during the particle sintering process depends on particle size, sintering temperature, and sintering time, it is difficult to precisely control the uniformity and connectivity of the pores. Moreover, this method often involves high-temperature treatment, which may cause material shrinkage or deformation. The solvent evaporation method utilizes the evaporation rate of the solvent and the phase separation mechanism to form a porous structure inside the material. However, this method is easily affected by fluctuations in process parameters such as the solvent evaporation rate, material viscosity, and temperature changes, resulting in non-uniform pore structures. Moreover, the selection and residue problems of the solvent may affect the performance and environmental adaptability of the final material. The self-assembly method constructs porous materials with specific pore structures through intermolecular interactions, such as the self-assembly behavior of surfactants, block copolymers, or templating agents. This method can control the pore distribution at the nanoscale. However, in the large-scale manufacturing process, it is easily prone to structural defects due to the influence of the templating agent removal process and assembly conditions. Moreover, the pore structure formed by self-assembly may be unstable under high temperature or mechanical load, limiting its reliability in engineering applications.

[0041] Therefore, in order to be able to precisely control parameters such as the porosity, pore size, and pore morphology of porous materials, this application uses additive manufacturing technology to form porous materials. The working principle of the additive manufacturing equipment 1 adopted in this application is to use energy beams 150 such as laser beams, electron beams, or plasma beams to selectively sinter or melt the material layer laid on the forming platform 13, thereby solidifying specific regions and layer by layer constructing the target component. The material usually appears in the form of solid particles, and the most common is metal materials such as stainless steel, copper, and aluminum alloys. In addition, ceramics, plastics, resins, and composite materials can also be used to manufacture three-dimensional components of different materials.

[0042] In order to achieve a fine printing effect, the additive manufacturing equipment 1 selectively heats each layer of material through the energy beam 150 generated by the optical path unit 15, and uses laser sintering (SLS) or laser melting (SLM) technology to melt or solidify the material in the forming area. The uncured material continues to act as a support structure or is used to form the basis for the next layer. After each layer of printing is completed, the forming platform 13 will descend a certain distance to facilitate the laying of a new material layer, and finally form the entire target component.

[0043] The core components of the additive manufacturing device 1 include a mechanical structure, an optical path unit 15, and a control system. The mechanical structure is responsible for material supply, layer-by-layer construction, and precise movement of the platform; the optical path unit 15 generates an energy beam 150 to heat or cure the material; while the control system coordinates the operation of each component of the device to ensure the smooth progress of the printing process. Based on the computer model data, the control system adjusts the printing parameters and monitors the sensor feedback in real time to optimize the printing quality and accuracy.

[0044] The mechanical structure of the additive manufacturing device 1 generally includes a forming chamber, a powder supply device, a powder spreading device 12, a forming platform 13, and a lifting device. The powder supply device stores and transports the materials required for manufacturing, which usually includes at least one powder storage cylinder 110 and an overflow powder cylinder 111. The powder spreading device 12 ensures that the materials are evenly distributed on the forming plane. Usually, a scraper-type or roller-type powder spreader is used. The scraper pushes the materials flat, and the roller spreads the powder by rolling. Moreover, the height of the powder spreading device 12 must be precisely synchronized with the forming platform 13. Usually, a stepper motor or a servo motor is used for height adjustment to ensure that the thickness of each layer of material is consistent. The forming chamber is the main space for material forming during the entire additive manufacturing process, providing a controlled environment to protect the quality of the materials and components during the manufacturing process. The forming platform 13 is the basis for carrying the workpiece and forming layer by layer. The distance between the forming platform 13 and the optical path unit 15 is precisely controlled by the forming lifting device. After each printing layer is completed, the lifting device lowers the forming platform 13 by a certain distance to lay new materials in preparation for the next layer of printing.

[0045] Specifically referring to Figure 1 As shown in the figure, the figure shows a schematic structural diagram of an exemplary additive manufacturing device 1 according to some embodiments of the present application. In some embodiments of the present application, the present application relates to a method for forming a porous material for an additive manufacturing device 1, which includes: S1: Calculating scanning parameters according to the single-pass melt pool size and the designed porosity, and generating a target angle 22 according to the scanning parameters and the design parameters; S2: Using the laying device of the additive manufacturing device 1 to stack the materials layer by layer to the forming area, and then scanning the stacked materials layer by layer with the energy beam 150 to form a first layer family 20, and adjusting the energy beam 150 and / or the first layer family 20 to the target angle 22 after scanning. At the same time, using the laying device of the additive manufacturing device 1 to stack the materials of the next layer family layer by layer to the forming area; S3: Scanning the stacked materials layer by layer with the energy beam 150 to form a second layer family 21, and adjusting the energy beam 150 and / or the second layer family 21 to the initial angle of the next scanning round after scanning; S4: Repeating the alternating scanning and forming steps of S2 and S3 until the porous material component 2 is completed.

[0046] Specifically, the single-pass molten pool size includes the width and depth dimensions of the single-pass molten pool. The designed porosity is set by the designer according to the design requirements of the porous material component 2. The scanning parameters at least include the filling spacing and the number of scanning layers. The design parameters include the designed number of layers and the designed width of the porous material component 2, one or more initial angles, and the designed rotation angle of the porous material component 2. Among them, the one or more initial angles refer to the initial angles for forming in each scanning round. When there is one initial angle, the initial angles of each scanning round are the same. If there are multiple initial angles, the initial angles of each scanning round are set by the designer according to actual requirements. The designed rotation angle includes the device to be rotated and the target angle 22 of the rotation of this device. Specifically, this device can be just the optical path unit 15 of the additive manufacturing device 1 that emits the energy beam 150, can also be just the forming platform 13 of the additive manufacturing device 1, or can also be a combination of the optical path unit 15 and the forming platform 13; the target angle 22 is the included angle between the formed first layer family 20 and the second layer family 21. When rotating, it can be rotated in the clockwise direction or the counterclockwise direction. Among them, the number of scanning tracks designed for the first layer family 20 and the number of scanning tracks designed for the second layer family 21 can be the same or different; the forming materials used for the first layer family 20 and the second layer family 21 can be the same or different.

[0047] During the actual implementation process of this application, the rotation of the energy beam 150 can be to make the optical path unit 15 of the additive manufacturing device 1 emit the energy beam 150 at a required angle. Thus, if the optical path unit 15 is used to emit the energy beam 150 at a required angle, then the angles of the rotation of the energy beam 150 described in all of this application refer to the angles at which the energy beam 150 is emitted at these angles.

[0048] During the actual implementation of this application, the rotation of the target angle 22 can also be achieved by setting only the optical path unit 15 to rotate, or setting only the forming platform 13 to rotate. It can also be set to rotate a part of the optical path unit 15 by the target angle 22 and rotate another part of the forming platform 13 by the target angle 22. Thus, as long as the target angle 22 that can form the included angle between the first layer family 20 and the second layer family 21 can be rotated, the specific rotating device can be set arbitrarily according to the needs of the designer. In this application, the rotation of the forming platform 13 and the optical path unit 15 is achieved by the designer installing a rotating mechanism 16 on the forming platform 13 and the optical path unit 15 to drive the rotation of the forming platform 13 and the optical path unit 15 through the rotating mechanism 16. The rotating mechanism 16 can be any form of rotation drive structure as long as it can rotate the forming platform 13 and the optical path unit 15, including but not limited to pneumatic devices, electric devices, hydraulic devices, etc. Specifically, it is set by the designer according to actual needs. In this application, the existing rotating platform driven by a servo motor can be referred to. Thus, if the optical path unit 15 is rotated, the angle of rotation of the energy beam 150 described in all parts of this application refers to the angle at which the energy beam 150 is emitted after the optical path unit 15 rotates.

[0049] Therefore, in this application, the width W of the molten pool formed by single-pass scanning during the metal selective laser melting (SLM) process is first obtained through experiments or simulations. m And the depth D of the molten pool m , and then according to the set target porosity P, the filling spacing S is calculated so that the porosity of a single layer meets the design requirements. Furthermore, according to the depth D of the molten pool m And the printing layer thickness T l The number of layers N required for printing while maintaining the current filling spacing is calculated l To ensure that the overall porosity meets the design requirements. Specifically, the calculation process of the filling spacing is as follows:

[0050] Furthermore, the number of scanning layers required for printing the current layer is calculated: N l = D m / T l .

[0051] Specifically, in this application, the filling spacing refers to the spacing between two adjacent passes. One pass refers to a single-pass structure formed by melting and solidifying the molten pool along the set scanning path, and its width is determined by energy beam parameters, material properties, and process conditions. The setting of the filling spacing affects the porosity, forming accuracy, and mechanical properties of the material. It is calculated based on the target porosity and the width of the molten pool to ensure uniform material distribution during the forming process and meet the expected performance requirements.

[0052] Refer to Figure 2 As shown in Figure 2Shows a schematic diagram of a scan that only adjusts the energy beam to the target angle for some embodiments of the present application. In an example of the present application, assume that the width W of a single-pass molten pool m is 50 microns, the depth D of a single-pass molten pool m is 90 microns, the target porosity P is 50%, the single-layer printing thickness T l is 30 microns, only the energy beam 150 is set to rotate, the target angle 22 is the included angle of 90° between the first layer family 20 and the second layer family 21 and the rotation angle of each scan round remains unchanged. From the above, it can be obtained that the filling pitch S = 50 / (1 - 0.5) = 100 microns, that is, the filling pitch between each scan track is set to 100 μm, which can ensure that the porosity of a single layer is 50%; thus, the number of layers N l required to maintain the current filling pitch = 90 / 30 = 3. In this example, after the material is laid by the powder spreading device 12, according to the number of scan tracks required for the designed first layer family 20, one or more energy beam 150 scans are performed on the stacked material layer by layer to form the first layer family 20. After the scan, the energy beam 150 is rotated clockwise by 90°, and then according to the number of scan tracks required for the designed second layer family 21, one or more energy beam 150 scans are performed on the stacked material layer by layer to form the second layer family 21. After the scan, the energy beam 150 is adjusted to the initial angle of each scan round, and the first layer family 20 and the second layer family 21 of each scan round are formed in this cycle until the porous material member 2 is completed.

[0053] Thus, referring to Figure 3 shown Figure 3 Shows a schematic diagram of a scan that only adjusts the forming platform to the target angle for some embodiments of the present application. In an example of the present application, based on the above example, only the forming platform 13 is set to rotate, the target angle 22 is set to the included angle of 90° between the first layer family 20 and the second layer family 21 and the rotation angle of each scan round remains unchanged. Thus, in this example, after the material is laid by the powder spreading device 12, according to the number of scan tracks required for the designed first layer family 20, one or more energy beam 150 scans are performed on the stacked material layer by layer to form the first layer family 20. After the scan, the forming platform 13 is rotated clockwise by 90° to rotate the formed first layer family 20 clockwise by 90°, and then according to the number of scan tracks required for the designed second layer family 21, one or more energy beam 150 scans are performed on the stacked material layer by layer to form the second layer family 21. After the scan, the forming platform 13 is adjusted to the initial angle of each scan round, and the first layer family 20 and the second layer family 21 of each scan round are formed in this cycle until the porous material member 2 is completed.

[0054] Referring to Figure 4 shown Figure 4Shown is a schematic scanning diagram of an exemplary embodiment of the present application for adjusting a part of an energy beam to a target angle and another part of a forming platform to a target angle. In an example of the present application, based on the above example, the energy beam 150 and the forming platform 13 are set to rotate in combination, and a part of the target angle 22 is allocated to each of the energy beam 150 and the forming platform 13. The target angle 22 is set to the included angle of 90° between the first layer family 20 and the second layer family 21, and the rotation angle of each scanning round remains unchanged. Among them, the energy beam 150 rotates counterclockwise by 45°, and the forming platform 13 rotates clockwise by 45°. Thus, in this example, after the material is laid by the powder laying device 12, according to the number of scanning paths required for the designed first layer family 20, the stacked material is scanned by the energy beam 150 for one or more paths to form the first layer family 20. After the scanning, the forming platform 13 is rotated clockwise by 45° to rotate the formed first layer family 20 clockwise by 45° and at the same time rotate the energy beam 150 counterclockwise by 45°. Then, according to the number of scanning paths required for the designed second layer family 21, the stacked material is scanned by the energy beam 150 for one or more paths to form the second layer family 21. At this time, the second layer family 21 and the first layer family 20 meet the requirement of an included angle of 90°. After the scanning, the forming platform 13 is adjusted to the initial angle of each scanning round, and this cycle is repeated for the forming of the first layer family 20 and the second layer family 21 in each scanning round until the porous material member 2 is completed.

[0055] In some examples of the present application, a single-pass molten pool can be used to form a porous material. By this method, a porous material member 2 with the smallest rod diameter can be achieved. The smallest characteristic entity structure depends on the optical path unit 15 and the material particle conditions. For example, when using a conventional powder material of 15 - 53 μm and an optical path unit 15 with a spot diameter of 60 - 80 μm, the smallest rod diameter that can be formed is 120 μm, which is also the width of a single-pass molten pool. If the equipment needs to use powder within 20 μm and a 30 - μm spot, the smallest rod diameter that can be formed may be 50 μm. The width of the above single-pass molten pool determines the characteristic size of the smallest filled entity. However, in some applications, a filled entity larger than the smallest molten pool can be achieved. In this case, the width of the filled entity can be controlled by setting the filling spacing between multiple molten pools. For example, when using a conventional powder of 15 - 53 μm and an equipment with a spot diameter of 60 - 80 μm, and a filled entity of 300 μm is required, three-layer printing can be set, and the printing filling spacing is set to 100 μm. The above settings are specifically set by the designer according to the additive manufacturing equipment 1 and materials during actual implementation.

[0056] By adopting the above technical solution, the use of the fixed-angle strategy can improve the consistency of regular pores and is applicable to applications with high uniformity requirements. Through the combined rotation strategy, regular or irregular pores can be formed, and the deviation between scanning layers can be reduced, thereby optimizing the pore structure of the porous material component 2 and improving the overall structural strength, fatigue resistance, and impact resistance of the porous material component 2.

[0057] In an example of the present application, based on the above example, the target angle 22 can be divided into a first angle 220 and a second angle 221, and the first angle 220 and the second angle 221 can be set based on the initial angle. Among them, the first angle 220 is the angle formed by rotating in the first direction relative to the initial angle, and the second angle 221 is the angle formed by rotating in the second direction relative to the initial angle; thus, after the first angle 220 and the second angle 221 are rotated, the formed target angle 22 is the included angle between the first layer family 20 and the second layer family 21. Among them, the first direction and the second direction can be either the clockwise direction or the counterclockwise direction, and the first direction and the second direction can be the same or different.

[0058] In the actual implementation process, the first angle 220 and the second angle 221 cooperate to form the target angle 22 of the included angle between the first layer family 20 and the second layer family 21; during actual scanning and printing, the first angle 220 can be set to 0, the second angle 221 can be set to the target angle 22, or the first angle 220 can be set to the target angle 22 and the second angle 221 can be set to 0; it is also possible to rotate the first angle 220 clockwise by a part of the target angle 22 based on the initial angle, and rotate the second angle 221 counterclockwise by another part of the target angle 22 based on the initial angle, or rotate the first angle 220 clockwise by a part of the target angle 22 based on the initial angle, and rotate the second angle 221 clockwise again by another part of the target angle 22 based on the initial angle and on the basis of the first angle 220; it is also possible to set a progressive angle change for the first angle 220 and the second angle 221, and increase the first angle 220 and decrease the second angle 221 every time a set number of scanning rounds is passed; it is also possible to set an over-target angle 22 and an angle compensation for the first angle 220 and the second angle 221, that is, make the first angle 220 exceed the target angle 22 and perform corresponding angle compensation on the second angle 221, or make the second angle 221 exceed the target angle 22 and perform corresponding angle compensation on the first angle 220, and so on. As long as the first angle 220 and the second angle 221 cooperate to form the target angle 22 of the included angle between the first layer family 20 and the second layer family 21, the first angle 220 and the second angle 221 can be set arbitrarily according to the needs of the designer.

[0059] Exemplarily, the energy beam 150 and the forming platform 13 are set to rotate in combination, and a first angle 220 is assigned to the energy beam 150, a second angle 221 is assigned to the forming platform 13, the target angle 22 is set to the included angle of 90° between the first layer family 20 and the second layer family 21, and the rotation angle of each scanning round remains unchanged. Among them, the first angle 220 is rotated clockwise by 45° based on the initial angle, and the second angle 221 is rotated counterclockwise by 45° based on the initial angle. Thus, in this example, after the material is laid by the powder laying device 12, according to the number of scanning paths required for the designed first layer family 20, one or more energy beam 150 scans are performed on the layer-by-layer stacked material to form the first layer family 20. After the scanning, the energy beam 150 is rotated clockwise by the first angle 220: 45°, and at the same time, the forming platform 13 is rotated counterclockwise by the second angle 221: 45°, so as to rotate the formed first layer family 20 counterclockwise by 45°. Then, according to the number of scanning paths required for the designed second layer family 21, one or more energy beam 150 scans are performed on the layer-by-layer stacked material to form the second layer family 21. At this time, the second layer family 21 and the first layer family 20 meet the requirement of an included angle of 90°. After the scanning, the forming platform 13 and the energy beam 150 are adjusted to the initial angle of each scanning round, and the forming of the first layer family 20 and the second layer family 21 in each scanning round is cycled until the porous material member 2 is completed.

[0060] By adopting the above technical solution, different angle strategies can be set according to design requirements, the printing accuracy can be improved, and by setting different angle strategies, the mechanical properties can be optimized and the scanning error of the energy beam 150 can be reduced, thereby improving the pore uniformity of the porous material member 2.

[0061] Reference Figure 5 and Figure 6 as shown, Figure 5 shows a scanning schematic diagram of an exemplary adjustment of the energy beam to the first angle to form the first layer family and the adjustment of the energy beam to the second angle to form the second layer family in some embodiments of the present application. Figure 6Shown is a schematic scanning diagram of some embodiments of the present application for adjusting the forming platform to a first angle to form a first layer family and adjusting the forming platform to a second angle to form a second layer family. In some examples of the present application, based on the above example, after dividing the target angle 22 into a first angle 220 and a second angle 221, when the energy beam 150 scans to form the first layer family 20, the energy beam 150 and / or the forming platform 13 can be adjusted to the first angle 220 based on the initial angle, and then one or more energy beam 150 scans are performed on the layer-by-layer stacked material according to the scanning parameters to form the first layer family 20, and after scanning, the energy beam 150 and / or the forming platform 13 are adjusted to the second angle 221. Then, the energy beam 150 scans the layer-by-layer stacked material to form the second layer family 21, and after scanning, the energy beam 150 and / or the second layer family 21 are adjusted to the initial angle of the next scanning round; the alternating scanning and forming of the first layer family 20 and the second layer family 21 are cycled until the porous material member 2 is completed. That is, when the first layer family 20 is scanned and formed, the energy beam 150 and / or the forming platform 13 are first adjusted to the position of the first angle 220, and when the second layer family 21 is scanned and formed, the energy beam 150 and / or the second layer family 21 are adjusted to the position of the second angle 221. Thus, it is convenient to set multiple initial angles.

[0062] Reference Figure 7 shown Figure 7 Shown is a schematic scanning diagram of some embodiments of the present application for adjusting the energy beam to a first adjustment angle and adjusting the forming platform to a second adjustment angle to form a first layer family, and then adjusting the energy beam to a third adjustment angle and adjusting the forming platform to a fourth adjustment angle to form a second layer family. In some examples of the present application, based on the above example, the first angle 220 can be further divided into a first adjustment angle 220-1 for adjusting the energy beam 150 and / or a second adjustment angle 220-2 for adjusting the forming platform 13, and the second angle 221 includes a third adjustment angle 221-1 for adjusting the energy beam 150 and / or a fourth adjustment angle 221-2 for adjusting the first layer family 20.

[0063] Specifically, after the first angle 220 and the second angle 221 cooperate, they form the target angle 22 of the included angle between the first layer family 20 and the second layer family 21; during actual scanning and printing, the first adjustment angle 220-1 can be set to 0, the second adjustment angle 220-2 can be set to the first angle 220, or the first adjustment angle 220-1 can be set to the first angle 220 and the second adjustment angle 220-2 can be set to 0; the first angle 220 can also be divided into two parts, that is, the first adjustment angle 220-1 rotates a part of the first angle 220 based on the initial angle, and the second adjustment angle 220-2 rotates the other part of the first angle 220 based on the initial angle. Among them, after the first adjustment angle 220-1 and the second adjustment angle 220-2 rotate, they are the same as the first angle 220; or there is a progressive angle change, or an over-angle and angle compensation, and so on. By analogy, as long as the first adjustment angle 220-1 and the second adjustment angle 220-2 cooperate to form the first angle 220, the first adjustment angle 220-1 and the second adjustment angle 220-2 can be set arbitrarily according to the needs of the designer.

[0064] Specifically, during actual scanning and printing, the third adjustment angle 221-1 can be set to 0, the fourth adjustment angle 221-2 can be set to the second angle 221, or the third adjustment angle 221-1 can be set to the second angle 221 and the fourth adjustment angle 221-2 can be set to 0; the second angle 221 can also be divided into two parts, that is, the third adjustment angle 221-1 rotates a part of the second angle 221 based on the initial angle, and the fourth adjustment angle 221-2 rotates the other part of the second angle 221 based on the initial angle. Among them, after the third adjustment angle 221-1 and the fourth adjustment angle 221-2 rotate, they need to be the same as the second angle 221; or there is a progressive angle change, or an over-angle and angle compensation, and so on. By analogy, as long as the third adjustment angle 221-1 and the fourth adjustment angle 221-2 cooperate to form the second angle 221, the third adjustment angle 221-1 and the fourth adjustment angle 221-2 can be set arbitrarily according to the needs of the designer.

[0065] Thus, in an example of the present application, based on the above example, the target angle 22 is set to the included angle of 90° between the first layer family 20 and the second layer family 21, and the rotation angle of each scanning round remains unchanged. The first angle 220 is set to rotate counterclockwise by 45° based on the initial angle, and the second angle 221 is set to rotate clockwise by 45° based on the initial angle. Then, in this example, the first adjustment angle 220-1 is set to rotate counterclockwise by 45° based on the initial angle, the second adjustment angle 220-2 is set to 0°, the third adjustment angle 221-1 is set to rotate clockwise by 45° based on the initial angle, the fourth adjustment angle 221-2 is set to 0°, and the first adjustment angle 220-1 is set for the energy beam 150 to rotate, the second adjustment angle 220-2 is set for the forming platform 13 to rotate, the third adjustment angle 221-1 is set for the energy beam 150 to rotate, and the fourth adjustment angle 221-2 is set for the forming platform 13 to rotate. Thus: when scanning the first layer family 20, the energy beam 150 rotates counterclockwise by 45° based on the initial angle, and the forming platform 13 remains unchanged. Then, the energy beam 150 scans the layer-by-layer stacked material to form the first layer family 20. After the scanning, the energy beam 150 is adjusted to the initial angle and then rotates clockwise by 45° based on the initial angle, and the forming platform 13 remains unchanged. Then, the energy beam 150 scans the layer-by-layer stacked material to form the second layer family 21. After the scanning is completed, the energy beam 150 and the forming platform 13 are adjusted to the initial angle. This cycle is repeated for the forming of the first layer family 20 and the second layer family 21 in each scanning round until the porous material component 2 is completed.

[0066] Thus, in an example of the present application, based on the above example, the target angle 22 is set to the included angle of 90° between the first layer family 20 and the second layer family 21 and the rotation angle of each scanning round remains unchanged. The first angle 220 is set to rotate counterclockwise by 45° based on the initial angle, and the second angle 221 is set to rotate clockwise by 45° based on the initial angle. Then, in this example, the first adjustment angle 220-1 is set to rotate by 0°, the second adjustment angle 220-2 is set to rotate counterclockwise by 45° based on the initial angle, the third adjustment angle 221-1 is set to 0°, the fourth adjustment angle 221-2 is set to rotate clockwise by 45° based on the initial angle, and the first adjustment angle 220-1 is set for the rotation of the energy beam 150, the second adjustment angle 220-2 is set for the rotation of the forming platform 13, the third adjustment angle 221-1 is set for the rotation of the energy beam 150, and the fourth adjustment angle 221-2 is set for the rotation of the forming platform 13. Thus: when scanning the first layer family 20, the forming platform 13 is rotated counterclockwise by 45° based on the initial angle, the energy beam 150 remains unchanged, and then the energy beam 150 scans the layer-by-layer stacked material to form the first layer family 20. After the scanning, the forming platform 13 is adjusted to the initial angle and then rotated clockwise by 45° based on the initial angle, the energy beam 150 remains unchanged, and then the energy beam 150 scans the layer-by-layer stacked material to form the second layer family 21. After the scanning is completed, the energy beam 150 and the forming platform 13 are adjusted to the initial angle, and this cycle is repeated for the forming of the first layer family 20 and the second layer family 21 in each scanning round until the porous material member 2 is completed.

[0067] Thus, in an example of the present application, based on the above example, the target angle 22 is set to the included angle of 90° between the first layer family 20 and the second layer family 21 and the rotation angle of each scanning round remains unchanged. The first angle 220 is set to rotate counterclockwise by 45° based on the initial angle, and the second angle 221 is set to rotate clockwise by 45° based on the initial angle. Then, in this example, the first adjustment angle 220-1 is set to rotate counterclockwise by 25° based on the initial angle, the second adjustment angle 220-2 is set to rotate clockwise by 20° based on the initial angle, the third adjustment angle 221-1 is set to rotate clockwise by 25° based on the initial angle, the fourth adjustment angle 221-2 is set to rotate counterclockwise by 20° based on the initial angle, and the first adjustment angle 220-1 is set to rotate the forming platform 13, the second adjustment angle 220-2 is set to rotate the energy beam 150, the third adjustment angle 221-1 is set to rotate the forming platform 13, and the fourth adjustment angle 221-2 is set to rotate the energy beam 150. Thus: when scanning the first layer family 20, the energy beam 150 rotates counterclockwise by 25° based on the initial angle, the forming platform 13 rotates clockwise by 20° based on the initial angle, and then the energy beam 150 scans the layer-by-layer stacked material to form the first layer family 20. After the scanning, the energy beam 150 is adjusted to the initial angle and then rotates clockwise by 25° based on the initial angle, the forming platform 13 rotates counterclockwise by 20° based on the initial angle, and then the energy beam 150 scans the layer-by-layer stacked material to form the second layer family 21. After the scanning is completed, the energy beam 150 and the forming platform 13 are adjusted to the initial angle, and this cycle is repeated for the forming of the first layer family 20 and the second layer family 21 in each scanning round until the porous material component 2 is completed.

[0068] Specifically, in the present application, the first layer family 20 and the second layer family 21 are only for facilitating the distinction of the layers printed at different angles. The first layer family 20 and the second layer family 21 are not just two layer families, and the first angle 220 and the second angle 221 are not just two angles. Moreover, the target angle 22 of each scanning round can be the same or different, and the initial angle of each scanning round can be the same or different, thereby forming regular or irregular shapes.

[0069] By adopting the above technical solution, since the energy beam 150 scans alternately at different angles, the heat transfer path of the molten pool is optimized, which helps to reduce pores and air gaps and improve the material density; and through multi-angle alternate scanning, the stress concentration phenomenon caused by single-direction scanning is reduced, the warping and cracking problems of the formed part are reduced, and the structural stability is improved; through the alternate scanning method, the grain orientation and grain refinement effect of the material can also be improved, and the strength, ductility and fatigue performance of the material are enhanced.

[0070] In some embodiments of the present application, the number of scanning paths for each layer family design is set by the designer according to the number of edges of the porous material member 2, and one or more scanning tracks are set for each scanning path according to the width requirements of each layer family; wherein, the width of each layer family is the sum of the widths of each scanning track and each filling spacing of the layer family.

[0071] Specifically, the designer of the present application designs the number of scanning paths for each layer family according to the number of edges of the porous material member 2, and calculates the filling spacing of each scanning path according to the target porosity and the width of a single-pass molten pool.

[0072] Exemplarily, for example, assuming that the width of a single-pass molten pool is 50 microns and the target porosity is 50%, it can be obtained from the above content that the filling spacing is 100 microns, that is, the filling spacing between each scanning track is set to 100 μm, which can ensure that the porosity of a single layer is 50%; when the width of the first layer family 20 of the porous material member 2 is set to 500 microns, referring to Figure 8 the schematic diagram of the first layer family, on the basis of equal spacing and equal single-pass molten pool width, 4 scanning tracks need to be set, namely T1, T2, T3, T4, to form spacings J1, J2, J3, thus conforming to the width of the first layer family 20: 50*4 + 100*3 = 500. When the width of the second layer family 21 of the porous material member 2 is set to 650 microns, referring to Figure 8 the schematic diagram of the second layer family, on the basis of equal spacing and equal single-pass molten pool width, 5 scanning tracks need to be set, namely D1, D2, D3, D4 and D5, to form spacings U1, U2, U3 and U4, thus conforming to the width of the first layer family 20: 50*5 + 100*4 = 650.

[0073] Exemplarily, for example, assuming that the cross-section of the porous material member 2 is designed as a hexagon, and the designer sets the number of scanning paths for each layer family to 2, referring to Figure 9 as shown, one or more energy beams 150 are scanned on the layer-by-layer stacked material according to 2 scanning paths to form the first layer family 20, and one or more energy beams 150 are scanned on the layer-by-layer stacked material according to 2 scanning paths to form the second layer family 21.

[0074] By adopting the above technical solutions, by adjusting the number of scanning tracks and the filling spacing, the width of the porous material member 2 can be adjusted. By adjusting the number of scanning tracks of the scanning path, regular or irregular polygons can be realized, and further, the pore structure of the porous material member 2 can be accurately controlled and the forming quality can be improved.

[0075] In some embodiments of the present application, based on any of the above embodiments, a matching scanning model 4 can also be designed for the porous material member 2, and the rotation of the energy beam 150 and / or the forming platform 13 is controlled by the scanning model 4.

[0076] Specifically, a parametric scanning model 4 is established according to the scanning parameters, design parameters, and target angle 22 of the porous material member 2, and an optimal scanning path is generated through the scanning model 4. Furthermore, the optimal scanning angle of each layer family is generated through the scanning model 4. During the scanning process, the rotation angle of the energy beam 150 and / or the forming platform 13 is adjusted by using the scanning model 4 to make it precisely match the scanning path. Among them, when adjusting the rotation of the energy beam 150, the incident angle of the energy beam 150 is adjusted to make the energy distribution more uniform.

[0077] Thus, referring to Figure 10 shown, Figure 10 FIG. shows a scanning schematic diagram of an exemplary setting of the scanning model in some embodiments of the present application. In some examples of the present application, the porous material forming method using the scanning model 4 includes:

[0078] S101: Construct the scanning model 4; S102: Use the laying device of the additive manufacturing device 1 to stack the materials layer by layer to the forming area, and then scan the layer-by-layer stacked materials with the energy beam 150 according to the scanning model 4 to form the first layer family 20. After the scanning, adjust the energy beam 150 and / or the forming platform 13 to the target angle 22, and at the same time, use the laying device of the additive manufacturing device 1 to stack the materials of the next layer family layer by layer to the forming area; S103: Scan the layer-by-layer stacked materials with the energy beam 150 again according to the scanning model 4 to form the second layer family 21, and after the scanning, adjust the energy beam 150 and / or the second layer family 21 to the initial angle of the next scanning round; S104: Repeat the alternating scanning and forming steps of S102 and S103 until the porous material member 2 is completed.

[0079] In some examples of the present application, when the target angle 22 is divided into a first angle 220 and a second angle 221 based on any of the above embodiments, the method further includes:

[0080] S111: Construct a scanning model 4; S112: Use the laying device of the additive manufacturing equipment 1 to stack materials layer by layer onto the forming area, then adjust the energy beam 150 and / or the forming platform 13 to the first angle 220 according to the scanning model 4 and perform an energy beam 150 scan on the layer-by-layer stacked materials to form the first layer family 20. After the scan, adjust the energy beam 150 and / or the forming platform 13 to the second angle 221; S113: Use the laying device of the additive manufacturing equipment 1 to stack the materials of the next layer family layer by layer onto the forming area, then perform an energy beam 150 scan on the layer-by-layer stacked materials again according to the scanning model 4 to form the second layer family 21 and adjust the energy beam 150 and / or the forming platform 13 to the initial angle of the next scan cycle after the scan; S114: Repeat the alternating scanning and forming steps of S112 and S113 until the porous material component 2 is completed.

[0081] By adopting the above technical solution, by constructing a matching scanning model 4, optimizing the scanning path and precisely controlling the rotation of the energy beam 150 and / or the forming platform 13, the forming accuracy of the porous material component 2 and the uniformity of its pore structure can be improved.

[0082] In some embodiments of the present application, based on the above construction of the scanning model 4, multiple models can be constructed for the scanning model 4. Specifically, the number of the scanning models 4 is set by the designer according to actual needs.

[0083] Exemplarily, the number of models included in the scanning model 4 can be set to at least half of the number of design edges of the porous material component 2, and the scanning model 4 includes at least two models.

[0084] Thus, referring to Figure 11 as shown, Figure 11Shows a scanning schematic diagram of an exemplary setting of a first scanning model and a second scanning model in some embodiments of the present application. In some examples of the present application, the scanning model 4 is divided into a first scanning model 40 and a second scanning model 41, and an energy beam 150 scanning at a first angle 220 is set for the first scanning model 40 and an energy beam 150 scanning at a second angle 221 is set for the second scanning model 41. Specifically, it includes: S121: Construct the first scanning model 40 and the second scanning model 41; S122: Use the laying device of the additive manufacturing device 1 to stack materials layer by layer to the forming area, and then adjust the energy beam 150 to the first angle 220 according to the first scanning model 40 and perform energy beam 150 scanning at the first angle 220 on the stacked materials layer by layer to form the first layer family 20; S123: Use the laying device of the additive manufacturing device 1 to stack materials of the next layer family layer by layer to the forming area, and then adjust the energy beam 150 to the second angle 221 according to the second scanning model 41, perform energy beam 150 scanning at the second angle 221 on the stacked materials layer by layer to form the second layer family 21, and adjust the energy beam 150 to the initial angle of the next scanning round after scanning; S124: Cycle the alternating scanning and forming of steps S122 and S123 until the porous material component 2 is completed.

[0085] Further, on the basis of the above embodiments, a forming platform 13 at a first angle 220 can also be set for the first scanning model 40, and a forming platform 13 at a second angle 221 can be set for the second scanning model 41.

[0086] Further, on the basis of the above embodiments, if the first angle 220 is divided into a first adjustment angle 220-1 and a second adjustment angle 220-2, and the second angle 221 is divided into a third adjustment angle 221-1 and a fourth adjustment angle 221-2, then an energy beam 150 scanning at the first adjustment angle 220-1 and a forming platform 13 at the second adjustment angle 220-2 can also be set for the first scanning model 40, and an energy beam 150 scanning at the third adjustment angle 221-1 and a forming platform 13 at the fourth adjustment angle 221-2 can be set for the second scanning model 41; and so on. The specific setting method is set by the designer according to actual needs.

[0087] Thus, in some embodiments of the present application, it also relates to a porous material component 2 made by using the porous material forming method of any one of the above embodiments.

[0088] Reference Figure 12 as shown Figure 12A block diagram of a porous material forming system 3 of the present application is shown. In some embodiments of the present application, the porous material forming system 3 includes a processor 310 and a memory 320. The number of the processor 310 and the memory 320 can be one or more. The memory 320 is coupled to the processor 310 and is used to store a computer program or instruction 330 executed by the processor 310. When the computer program or instruction 330 is executed by the processor 310, the terminal device 3 is enabled to execute the forming method described in any of the foregoing items.

[0089] Specifically, the processor 310 communicates with the memory 320. The memory 320 may include a read-only memory 320 and a random access memory 320, providing instructions and data to the processor 310. In addition, a part of the memory 320 may further include a non-volatile random access memory 320 (NVRAM). In the memory 320, operation instructions, executable modules, data structures, or subsets thereof, or even extended sets thereof are stored. These operation instructions cover various operations and are used to implement various operations. The forming method described in the embodiments of the present application can be applied to the processor 310 or implemented by the processor 310. The processor 310 can be any applicable computer processor 310, such as a central processing unit (CPU), a graphics processing unit (GPU), a field-programmable gate array (FPGA), etc. In the embodiments of the present application, the processor 310 is responsible for executing each step of the forming method.

[0090] The computer program or instruction 330 includes a computer program for executing a computer process on a computing device. In some embodiments, the computer program or instruction 330 is provided using a signal-bearing medium. The signal-bearing medium may include one or more program instructions that, when run by one or more processors 310, can provide the functions or partial functions described in the implementation of the above forming method. Therefore, for example, one or more features in the forming method can be borne by one or more instructions associated with the signal-bearing medium.

[0091] In some embodiments, the present application further provides a computer-readable storage medium storing a computer program that, when executed by the processor 310, implements the forming method described in any of the foregoing items.

[0092] Specifically, a computer-readable storage medium refers to a medium that can be read by a computer system, such as a hard disk, a solid-state drive, an optical disc, a flash drive, etc. In some embodiments of the present application, the computer-readable storage medium stores a set of computer programs, and these programs are executed by the processor 310 to implement the various steps and functions described in the forming method. These computer programs may include an operating system, embedded software, application programs, etc., for controlling and managing the process of the forming method. By reading and executing the programs stored on the computer-readable storage medium, the computer system can effectively implement the forming method of the present application.

[0093] In some embodiments, the present application also provides a computer program product, which includes computer-executable instructions that, when executed by the processor 310, cause the computer to implement the forming method described in any one of the foregoing.

[0094] Specifically, a computer program product is a product that stores computer-executable instructions, and its purpose is to implement the various steps and functions described in the forming method when executed by the processor 310 of a computer system. The computer-executable instructions may include an operating system, application programs, embedded software, etc., to control and manage the process of the forming method. By using such a computer program product, a user can execute the forming method of the present application on a computer system.

[0095] Therefore, in some embodiments of the present application, there is also involved a porous material forming method using any one of the foregoing embodiments and an additive manufacturing apparatus 1 including the foregoing system.

[0096] As described above, the above are only the specific embodiments of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art can easily think of changes or substitutions within the technical scope disclosed by the present application, and all should be covered by the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.

Claims

1. A method for forming a porous material, characterized in that, The method includes: Calculating scanning parameters based on the single-pass molten pool size and the designed porosity, and generating a target angle based on the scanning parameters and design parameters, wherein the filling pitch of the scanning parameters is at least greater than the single-pass molten pool size; Performing an energy beam scan on the layer-by-layer stacked material according to the scanning parameters to form a first layer family; Performing an energy beam scan on the layer-by-layer stacked material to form a second layer family, and the included angle between the first layer family and the second layer family is the target angle; Repeatedly performing the alternating scan forming of the first layer family and the second layer family until the porous material component is completed.

2. The shaping method according to claim 1, wherein, When calculating the scanning parameters, the method includes: Calculate the filling spacing based on the single-pass molten pool width and the target void fraction: where S is the filling spacing, and W m is the single-pass molten pool width, and P is the target void fraction; Calculate the number of scanning layers required to maintain the current layer printing based on the single-pass molten pool depth and the single-layer printing thickness: N l = D m / T l where N l is the number of scanning layers required to maintain the current layer printing, D m is the single-pass molten pool depth, and T l is the single-layer printing thickness.

3. The shaping method according to claim 1 or 2, characterized in that, The design parameters include the designed number of layers and the designed width of the porous material component, as well as one or more initial angles and the designed rotation angle of the porous material component.

4. The shaping method according to claim 3, characterized in that, The target angle includes a first angle for adjusting the energy beam and a second angle for adjusting the first layer family, or, a first angle for adjusting the first layer family and a second angle for adjusting the energy beam.

5. The shaping method according to claim 1 or 2 or 4, characterized in that, When generating the target angle, the target angle is divided into a first angle and a second angle, wherein, Performing an energy beam scan on the layer-by-layer stacked material according to the scanning parameters to form a first layer family at the first angle; Performing an energy beam scan on the layer-by-layer stacked material to form a second layer family at the second angle, and the included angle between the first angle and the second angle is the target angle; Repeatedly performing the alternating scan forming of the first layer family and the second layer family until the porous material component is completed.

6. The shaping method according to claim 5, characterized in that, The first angle includes a first adjustment angle for adjusting the energy beam and / or a second adjustment angle for adjusting the forming platform, and the second angle includes a third adjustment angle for adjusting the energy beam and / or a fourth adjustment angle for adjusting the first layer family.

7. The shaping method according to claim 1 or 2 or 4, characterized in that, After generating the target angle, the method includes: Constructing a preset scan model according to the scanning parameters, design parameters, and target angle; Performing an energy beam scan on the layer-by-layer stacked material according to the preset scan model to form a first layer family; Performing an energy beam scan on the layer-by-layer stacked material to form a second layer family, and the included angle between the first layer family and the second layer family is the target angle; Repeatedly performing the alternating scan forming of the first layer family and the second layer family until the porous material component is completed.

8. The shaping method according to claim 7, characterized in that, Wherein, The number of models included in the preset scan model is at least half of the number of edges of the designed porous material component.

9. The shaping method according to claim 7 or 8, characterized in that, The preset scan model includes at least two scan models.

10. The shaping method according to claim 9, characterized in that, The method further includes: Constructing a first scan model and a second scan model according to the rotation parameters, filling pitch, and number of scan layers; Performing an energy beam scan on the layer-by-layer stacked material according to the first scan model to form a first layer family; Performing an energy beam scan on the layer-by-layer stacked material according to the second scan model to form a second layer family, and the included angle between the first layer family and the second layer family is the target angle Repeatedly performing the alternating scan forming of the first layer family and the second layer family until the porous material component is completed.

11. The shaping method according to any one of claims 1, 2, 4, 6, 7, 8, and 10, characterized in that, The first layer family and the second layer family use the same or different forming materials.

12. The shaping method according to any one of claims 4, 6, 7, 8, and 10, characterized in that The first angle and the second angle are set based on the initial angle, wherein, The first angle is an angle formed by rotating in a first direction relative to the initial angle; The second angle is an angle formed by rotating in a second direction relative to the initial angle.

13. The shaping method according to claim 13, characterized in that, The initial angle can be adjusted every preset layer family.

14. A component made using the shaping method according to any one of claims 1 - 13.

15. A porous material forming system using the forming method according to any one of claims 1-13, characterized in that, Comprising: One or more processors; One or more memories; The one or more memories are coupled to the one or more processors for storing instructions executed by the one or more processors, and when the instructions are executed by the one or more processors, cause the porous material forming system to perform the porous material shaping method according to any one of claims 1 - 13.

16. An additive manufacturing apparatus using the method according to any one of claims 1 - 13 or comprising the shaping system of claim 15.

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