An additive manufacturing support structure and an additive manufacturing method

Abstract

The application relates to an additive manufacturing support structure and an additive manufacturing method, the additive manufacturing support structure comprising a support feature unit, the support feature unit comprising a top, side support parts, a middle support part, an oblique support part and an arch-shaped support part, the two sides of the top being respectively provided with the side support parts, the two ends of the arch-shaped support part being respectively connected to the ends of the two side support parts away from the top, the vault being connected to the top, the first end of the middle support part being connected to the vault, the second end being flush with the end of the side support part away from the top, the first end of the oblique support part being connected to the second end of the middle support part, and the second end being connected to the side support part and / or the top through the arch-shaped support part, the middle support part, the oblique support part and the arch-shaped support part dividing the internal space into multiple hollow structures. The support structure has good support effect, avoids support collapse, the hollow structure increases the heat dissipation area, avoids part deformation and cracking caused by thermal stress, and inhibits uneven organization performance caused by heat distribution difference.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing technology, and in particular to an additive manufacturing support structure and an additive manufacturing method. Background Technology

[0002] Additive manufacturing is an advanced manufacturing technology based on the discrete-stacking principle, which creates three-dimensional solid parts by adding materials layer by layer. Additive manufacturing overcomes many limitations of traditional subtractive manufacturing processes, directly converting digital models into solid parts. Laser additive manufacturing, as a mainstream process within additive manufacturing, utilizes a high-energy laser beam to scan layers of metal powder along a pre-set path. The powder rapidly melts and solidifies under the influence of laser energy, layer by layer, forming a dense metal part.

[0003] In the laser selective melting process, the support structure plays a crucial role. First, the support structure can fix the part on the forming substrate, preventing displacement or deformation of the part due to thermal stress or its own weight during manufacturing. Second, the support structure can conduct heat generated by the part during forming, helping to dissipate heat and thus reducing the accumulation of thermal stress inside the part, improving the dimensional accuracy and microstructure of the part.

[0004] Traditional support structures typically employ simple geometric shapes, resulting in insufficient strength and susceptibility to collapse under the weight of heavy components. This leads to loss of fixation and support, causing deformation, displacement, or even collapse of the components, severely impacting the effectiveness and reliability of laser selective melting technology in the manufacturing of large-size parts.

[0005] Furthermore, the existing support structure has poor heat dissipation performance. During the manufacturing of large-sized parts, the large volume and long forming time, coupled with continuous laser energy input, lead to significant heat accumulation inside the part. This increases internal thermal stress, making the part prone to cracking and reducing its integrity and reliability. In addition, uneven heat distribution can cause uneven microstructure and properties, affecting the part's mechanical properties and service life. For example, localized areas of the part may exhibit coarse grains and uneven hardness, severely impacting its quality and performance. Summary of the Invention

[0006] The first objective of this invention is to provide an additive manufacturing support structure that improves its support strength and heat dissipation performance.

[0007] The second objective of this invention is to provide an additive manufacturing method employing the above-described additive manufacturing support structure.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] In a first aspect of this application, an additive manufacturing support structure is provided. The additive manufacturing support structure includes at least one support feature unit along and / or perpendicular to the additive deposition direction. The support feature unit includes a top, side support portions, a middle support portion, an oblique support portion, and an arched support portion. The side support portions are respectively provided on both sides of the top. The two ends of the arched support portion are respectively connected to the ends of the two side support portions away from the top. The arch of the arched support portion is connected to the top. The first end of the middle support portion is connected to the arch of the arched support portion. The second end of the middle support portion extends along the additive deposition direction to be flush with the end of the side support portion away from the top. The two oblique support portions are symmetrically arranged about the middle support portion. The first end of the oblique support portion is connected to the second end of the middle support portion. The second end of the oblique support portion is connected to the side support portion and / or the top through the arched support portion. The middle support portion, the oblique support portion, and the arched support portion divide the space enclosed by the top and the two side support portions into multiple hollow structures.

[0010] In one possible implementation, the additive manufacturing support structure includes a plurality of support structure layers along the additive deposition direction, each of the support structure layers including at least one of the support feature units.

[0011] In one possible implementation, one of the two adjacent support structure layers rotates by a predetermined angle relative to the other of the two adjacent support structure layers about an axis parallel to the additive deposition direction.

[0012] In one possible implementation, the preset angle is 90°.

[0013] In one possible implementation, along the additive deposition direction, the number of support feature units in the uppermost support structure layer is greater than the number of support feature units in the other support structure layers, and the dimensions of the top, side support, middle support, oblique support, and arched support of the support feature units in the uppermost support structure layer are proportionally smaller than the dimensions of the top, side support, middle support, oblique support, and arched support of the support feature units in the other support structure layers.

[0014] In one possible implementation, along the additive deposition direction from top to bottom, the number of support feature units in each of the support structure layers decreases sequentially, and the dimensions of the top, side support, middle support, oblique support, and arched support of each of the support feature units in the support structure layers increase proportionally in sequence.

[0015] In one possible implementation, the shape and area of ​​the projections of each of the support structure layers onto a projection plane perpendicular to the additive deposition direction are the same.

[0016] In one possible implementation, the top, the side support, the middle support, the oblique support, and the arched support are all plate-shaped, with the top perpendicular to the additive deposition direction and the side support and the middle support parallel to the additive deposition direction.

[0017] As can be seen from the above technical solution, the present invention discloses an additive manufacturing support structure for additive manufacturing. The additive manufacturing support structure includes at least one support feature unit along the additive deposition direction and / or perpendicular to the additive deposition direction. The support feature unit includes a top, a side support, a middle support, an oblique support, and an arched support. Side support is provided on both sides of the top. The two ends of the arched support are respectively connected to the ends of the two side support away from the top. The arch of the arched support is connected to the top. The first end of the middle support is connected to the arch of the arched support. The second end of the middle support extends along the additive deposition direction to be flush with the ends of the side support away from the top. The two oblique support are symmetrically arranged about the middle support. The first end of the oblique support is connected to the second end of the middle support. The second end of the oblique support is connected to the side support and / or the top through the arched support. The middle support, the oblique support, and the arched support divide the space enclosed by the top and the two side support into multiple hollow structures.

[0018] In application, based on the size, shape, and weight of the part, multiple additive manufacturing support structures are first additively manufactured at the bottom of the part. The top of the top support feature unit of the additive manufacturing support structure contacts the part, distributing the weight of the part to the side support, middle support, oblique support, and arched support through the top. At the same time, the arched support with good support performance connects to the side support on both sides, increasing the side support's resistance to lateral deformation and improving the overall stability of the additive manufacturing support structure while supporting the top. The oblique support connects the arched support, the side support, and / or the top, which can further improve the support performance and stability of the additive manufacturing support structure.

[0019] In summary, the central support, the oblique support, and the arched support divide the space enclosed by the top and side support sections into multiple hollow structures. This not only reduces material usage, lowering costs and improving production efficiency, but also increases the heat dissipation area, thereby improving the heat dissipation effect of the additive manufacturing support structure. It can mitigate heat accumulation during manufacturing, effectively controlling the uniform distribution of the temperature field, preventing part deformation and cracking caused by thermal stress, and suppressing uneven microstructure and properties due to differences in heat distribution. The central support, oblique support, and arched support effectively improve the overall strength of the additive manufacturing support structure, compensate for the structural strength reduction caused by the hollow structure, prevent support collapse, and provide excellent auxiliary forming effects.

[0020] In a second aspect of this application, an additive manufacturing method is provided, comprising the steps of:

[0021] A digital model of the part is established, and a digital model of the additive manufacturing support structure as described in the first aspect and its possible implementations is established at the bottom of the digital model of the part.

[0022] The digital models of the parts and additive manufacturing support structures are sliced ​​along a direction perpendicular to the additive deposition direction, and the sliced ​​digital models of the parts and additive manufacturing support structures are imported into the additive manufacturing equipment.

[0023] In the additive manufacturing equipment, the forming process parameters of the parts and the additive manufacturing support structure are set respectively, and the parts with the additive manufacturing support structure are manufactured on the substrate.

[0024] One possible implementation also includes the following steps:

[0025] Heat treatment is performed on the substrate and the parts of the additive manufacturing support structure.

[0026] Separate the part with the additive manufacturing support structure from the substrate and remove the additive manufacturing support structure from the part;

[0027] The surface treatment of the parts completes the manufacturing process.

[0028] The additive manufacturing method provided in this application uses an additive manufacturing support structure, and therefore should have the same beneficial effects as the additive manufacturing support structure, which will not be elaborated here. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of the structure of the support feature unit of the additive manufacturing support structure provided in an embodiment of the present invention;

[0031] Figure 2 This is a front view of the additive manufacturing support structure provided in an embodiment of the present invention;

[0032] Figure 3 for Figure 2 Sectional view along line A;

[0033] Figure 4 This is a side view of the additive manufacturing support structure provided in an embodiment of the present invention;

[0034] Figure 5 for Figure 4 Sectional view along line B;

[0035] Figure 6 This is a top view of the additive manufacturing support structure provided in an embodiment of the present invention;

[0036] Figure 7 This is a schematic diagram of the structure of a part with an additive manufacturing support structure after it has been formed on a substrate in the additive manufacturing method provided in this embodiment of the invention.

[0037] In the picture:

[0038] 100 is the supporting feature unit; 110 is the top; 120 is the side support; 130 is the middle support; 140 is the diagonal support; 150 is the arched support.

[0039] 200 is the additive manufacturing support structure; 210 is the first support structure layer; 220 is the second support structure layer; 230 is the third support structure layer;

[0040] 300 is a component;

[0041] 400 is the substrate. Detailed Implementation

[0042] One of the core aspects of this invention is to provide an additive manufacturing support structure whose structural design can improve its support strength and heat dissipation performance.

[0043] Another core aspect of this invention is to provide an additive manufacturing method employing the above-described additive manufacturing support structure.

[0044] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0045] This application provides an additive manufacturing support structure 200, which includes at least one support feature unit 100 along the additive deposition direction and / or perpendicular to the additive deposition direction. That is, multiple stacked support feature units 100 can be arranged along the additive deposition direction, multiple side-by-side support feature units 100 can be arranged perpendicular to the additive deposition direction, or multiple support feature units 100 can be arranged both along the additive deposition direction and perpendicular to the additive deposition direction. (See also...) Figure 1 and Figure 2 The support feature unit 100 includes a top 110, a side support 120, a middle support 130, an oblique support 140, and an arched support 150.

[0046] The top surface of the top 110 is used to contact the part 300. Therefore, the shape of the top surface of the top 110 should be designed according to the shape of the part 300. It can be a flat surface, a curved surface, or an irregularly shaped surface. Side support portions 120 are provided on both sides of the top 110. It should be noted that the two side support portions 120 can be completely identical, or they can be different shapes or sizes depending on the position of the additive manufacturing support structure 200 and the shape of the part 300. The two ends of the arched support portion 150 are respectively connected to the ends of the two side support portions 120 away from the top 110. The arch of the arched support portion 150 is connected to the top 110. The first end of the middle support portion 130 is connected to the arch of the arched support portion 150. The second end of the middle support portion 130 extends along the additive deposition direction to be flush with the ends of the side support portions 120 away from the top 110. That is, the second end of the middle support portion 130 and the ends of the two side support portions 120 away from the top 110 serve as the bottom ends of the support feature unit 100 that contact the substrate 400.

[0047] Two oblique support portions 140 are symmetrically arranged about the middle support portion 130. The first end of the oblique support portion 140 is connected to the second end of the middle support portion 130. The second end of the oblique support portion 140 is connected to the side support portion 120 and / or the top 110 via the arched support portion 150. The second end of the oblique support portion 140 may be connected only to the side support portion 120, or only to the top 110, or simultaneously connected to both the side support portion 120 and the top 110 at the position where the side support portion 120 and the top 110 are connected.

[0048] The intermediate support 130, the oblique support 140, and the arched support 150 divide the space enclosed by the top 110 and the two side support 120 into multiple hollow structures. In addition to forming hollow structures by the top 110, the side support 120, the intermediate support 130, the oblique support 140, and the arched support 150, these components themselves can also have hollow structures if the strength allows, in order to further improve the heat dissipation effect.

[0049] In application, based on the size, shape, and weight of the part, multiple additive manufacturing support structures 200 are first additively manufactured at the bottom of the part. The top 110 of the topmost support feature unit 100 of the additive manufacturing support structure 200 contacts the part 300 and distributes the weight of the part 300 to the side support 120, the middle support 130, the oblique support 140, and the arched support 150 through the top 110. At the same time, the arched support 150, which has good support performance, connects the side support 120 on both sides, increasing the lateral deformation resistance of the side support 120 and improving the overall stability of the additive manufacturing support structure 200 while supporting the top 110. The oblique support 140 connects the arched support 150, the side support 120, and / or the top 110, which can further improve the support performance and stability of the additive manufacturing support structure 200.

[0050] Compared with the prior art, the additive manufacturing support structure 200 provided in this application, with its central support portion 130, inclined support portion 140, and arched support portion 150, divides the space enclosed by the top 110 and the side support portions 120 into multiple hollow structures. This not only reduces the amount of material used, thereby lowering costs and improving production efficiency, but also increases the heat dissipation area, improving the heat dissipation effect of the additive manufacturing support structure 200. This weakens the heat accumulation during the manufacturing process, achieving a uniform temperature field distribution, preventing deformation and cracking of the part 300 caused by thermal stress, and suppressing uneven microstructure and properties caused by differences in heat distribution. The central support portion 130, inclined support portion 140, and arched support portion 150 can effectively improve the overall strength of the additive manufacturing support structure 200, compensate for the structural strength reduction caused by the hollow structure, prevent support collapse, and achieve a good auxiliary forming effect.

[0051] To further improve heat dissipation, in one embodiment of this application, a hollow structure penetrates the supporting feature unit 100, and / or a heat dissipation fin structure is provided on the surface of the hollow structure to increase heat exchange capacity and further improve heat dissipation.

[0052] The additive manufacturing support structure 200 can be a single-layer structure or a multi-layer structure, such as... Figure 2 and Figure 4 As shown, in one embodiment of this application, the additive manufacturing support structure 200 includes a plurality of support structure layers along the additive deposition direction, and each support structure layer includes at least one support feature unit 100.

[0053] exist Figure 2 and Figure 4 In the illustrated embodiment, the additive manufacturing support structure 200 includes three support structure layers along the additive deposition direction, and the number and size of the support feature units 100 in each support structure layer are different. Of course, in other embodiments, the number or size of the support feature units 100 included in each support structure layer may be the same.

[0054] To further optimize the above technical solution, one of the two adjacent support structure layers rotates at a preset angle relative to the other of the two adjacent support structure layers with the axis parallel to the additive deposition direction as the axis. This allows the pressure of part 300 to be more evenly distributed at different positions of the additive manufacturing support structure 200, so that the pressure of part 300 is transmitted downward more evenly, avoiding deformation and cracking caused by stress concentration, and improving forming quality and product qualification rate.

[0055] Please see Figure 2 and Figure 4 In one embodiment of this application, the preset angle is 90°.

[0056] Preferably, along the additive deposition direction, the number of support feature units 100 in the uppermost support structure layer is greater than the number of support feature units 100 in other support structure layers. Furthermore, the dimensions of the top 110, side support 120, middle support 130, oblique support 140, and arched support 150 of the support feature units 100 in the uppermost support structure layer are proportionally smaller than the dimensions of the top 110, side support 120, middle support 130, oblique support 140, and arched support 150 of the support feature units 100 in other support structure layers. By increasing the number of support feature units 100 in the uppermost support structure layer, the pressure of the part 300 can be transmitted downwards more evenly, and the number of cavity structures and the contact area with air in the uppermost support structure layer can be increased, thereby achieving better heat dissipation.

[0057] like Figures 2 to 5As shown, along the additive deposition direction from top to bottom, the number of support feature units 100 in each support structure layer decreases sequentially. The dimensions of the top 110, side support 120, middle support 130, oblique support 140, and arched support 150 of each support feature unit 100 in each support structure layer increase proportionally. By designing the additive manufacturing support structure 200 as a structure with a gradient change in size and shape along the deposition direction, it is possible to ensure that the additive manufacturing support structure 200 has good overall strength, so that the pressure of the part 300 is evenly applied to all parts of the additive manufacturing support structure 200, avoiding deformation and cracking of the additive manufacturing support structure 200 caused by local stress concentration, and effectively improving the forming quality and product qualification rate.

[0058] Furthermore, in one embodiment of this application, such as Figures 2 to 5 As shown, the shape and area of ​​the projection of each support structure layer on the projection plane perpendicular to the additive deposition direction are the same, in order to reduce manufacturing difficulty.

[0059] Specifically, in one embodiment of this application, such as Figures 2 to 5 As shown, the top 110, side support 120, middle support 130, oblique support 140, and arched support 150 are all plate-shaped. The top 110 is perpendicular to the additive deposition direction, while the side support 120 and middle support 130 are parallel to the additive deposition direction. The upper surface of the arched support 150 is tangent to the lower surface of the top 110. The thicknesses of the top 110, side support 120, middle support 130, oblique support 140, and arched support 150 can be the same or different. Figure 1 As shown, the thickness a of the top 110, the thickness b of the side support 120, the thickness d of the middle support 130, the thickness e of the oblique support 140, and the thickness c of the arched support 150 are all the same.

[0060] Please continue reading. Figures 2 to 5 In one specific embodiment of this application, the additive manufacturing support structure 200 includes three support structure layers, which are, from top to bottom, a first support structure layer 210, a second support structure layer 220 and a third support structure layer 230 along the additive deposition direction. In the additive manufacturing process, the bottommost third support structure layer 230 is additively manufactured first, and then the second support structure layer 220 and the first support structure layer 210 are additively manufactured upwards in sequence.

[0061] like Figure 2 and Figure 6As shown, the first support structure layer 210 is a hollow cuboid with the same length and width. The length and width of the first support structure layer 210 are dimensions perpendicular to the additive deposition direction. The external dimensions of the first support structure layer 210 are (3.5~5) mm × (28~56) mm × (28~56) mm. The above dimensions have been verified to achieve the best effect with the least amount of material, thereby reducing material usage, lowering costs, and shortening the processing cycle.

[0062] The first support structure layer 210 includes four support feature units 100. In the first support structure layer 210, the size (thickness a) of the top 110 of the support feature unit 100 along the additive deposition direction is 0.5 mm to 1 mm. If the size of the top 110 along the additive deposition direction is less than 0.5 mm, the size is too small and the processing is difficult. If the size of the top 110 along the additive deposition direction is greater than 1 mm, more material is used, but it cannot significantly improve the beneficial effect on the manufacturing of part 300 and is easy to cause material waste.

[0063] The second support structure layer 220 is a hollow cuboid with the same length and width. The length and width of the second support structure layer 220 are dimensions perpendicular to the additive deposition direction. The external dimensions of the second support structure layer 220 are (4~8) mm × (28~56) mm × (28~56) mm. It can be seen that the length and width dimensions of the second support structure layer 220 are consistent with those of the first support structure layer 210, but the dimension in the height direction along the additive deposition direction is increased.

[0064] The number of support feature units 100 in the second support structure layer 220 is less than that in the first support structure layer 210. Figures 2 to 5 In the illustrated embodiment, the number of support feature units 100 in the second support structure layer 220 is half the number of support feature units 100 in the first support structure layer 210, that is, the second support structure layer 220 includes two support feature units 100. Therefore, in order to make the length and width of the second support structure layer 220 consistent with the first support structure layer 210, it is necessary to increase the size of the support feature units 100 in the second support structure layer 220. The size (thickness a) of the top 110 of the support feature unit 100 in the additive deposition direction is 1mm to 2mm.

[0065] The third support structure layer 230 is a hollow cuboid with the same length and width. The length and width of the third support structure layer 230 are the dimensions perpendicular to the additive deposition direction. The external dimensions of the third support structure layer 230 are (10~20) mm × (28~56) mm × (28~56) mm. It can be seen that the length and width dimensions of the third support structure layer 230 are consistent with those of the first support structure layer 210 and the second support structure layer 220, but the dimension in the height direction along the additive deposition direction is increased.

[0066] The number of support feature units 100 in the third support structure layer 230 is half the number of support feature units 100 in the second support structure layer 220. That is, the third support structure layer 230 includes one support feature unit 100, and the top 110 of the support feature unit 100 in the third support structure layer 230 has a dimension (thickness a) of 2 mm to 4 mm along the additive deposition direction.

[0067] exist Figures 2 to 5 In the illustrated embodiment, the support feature unit 100 of the second support structure layer 220 is rotated 90° relative to the first support structure layer 210 and the third support structure layer 230 about an axis parallel to the additive deposition direction. This causes the length directions of the side support portion 120, the middle support portion 130, the oblique support portion 140, and the arched support portion 150 of the support feature unit 100 of the second support structure layer 220 to be perpendicular to the length directions of the side support portion 120, the middle support portion 130, the oblique support portion 140, and the arched support portion 150 of the support feature unit 100 of the first support structure layer 210 and the third support structure layer 230.

[0068] It is foreseeable that multiple additive manufacturing support structures 200 need to be set at the bottom of the part. In order to improve stability, in one embodiment of this application, such as... Figure 7 As shown, one of the two adjacent additive manufacturing support structures 200 rotates 90° relative to the other of the two adjacent additive manufacturing support structures 200 about an axis parallel to the additive deposition direction.

[0069] This application also provides an additive manufacturing method, including the following steps:

[0070] A digital model of part 300 is established, and a digital model of additive manufacturing support structure 200, as in the first aspect and its possible implementations, is established at the bottom of the digital model of part 300.

[0071] The digital model is created in 3D modeling software such as CAD. Based on the shape, size and weight of part 300, an appropriate number of support feature units 100 are set at the bottom to form an additive manufacturing support structure 200 that supports part 300.

[0072] The digital models of part 300 and additive manufacturing support structure 200 are sliced ​​along a direction perpendicular to the additive deposition direction, and the sliced ​​digital models of part 300 and additive manufacturing support structure 200 are imported into the additive manufacturing equipment.

[0073] Additive manufacturing equipment includes, but is not limited to, laser additive manufacturing equipment. In this embodiment, the additive manufacturing equipment used is laser additive manufacturing equipment. The digital models of part 300 and additive manufacturing support structure 200 are sliced ​​according to the power and scanning speed of the laser additive manufacturing equipment.

[0074] In the additive manufacturing equipment, forming process parameters for part 300 and additive manufacturing support structure 200 are set respectively. Part 300, which includes the additive manufacturing support structure 200, is then manufactured on substrate 400. Figure 7 As shown.

[0075] When additively manufacturing the support structure 200, the additive manufacturing equipment can have a lower laser power and a higher laser scanning speed. When additively manufacturing the part 300, the additive manufacturing equipment can have a higher laser power and a lower laser scanning speed. This makes the density of the additive manufacturing support structure 200 lower than that of the part 300. While ensuring that the additive manufacturing support structure 200 provides a support function, the additive manufacturing support structure 200 with lower density is easier to remove, and the use of a higher laser scanning speed can improve manufacturing efficiency.

[0076] Furthermore, in the embodiments of this application, the additive manufacturing method further includes the step of:

[0077] The substrate 400 and the parts 300 of the additive manufacturing support structure 200 are subjected to heat treatment.

[0078] The part 300 with the additive manufacturing support structure 200 is separated from the substrate 400, and the additive manufacturing support structure 200 on the part 300 is removed.

[0079] The surface treatment of part 300 is carried out to complete the manufacturing of part 300. The surface treatment includes chemical treatment and physical treatment. Therefore, according to the needs of part 300, chemical treatment including pickling, electrochemical polishing and electroplating, and physical treatment including sandblasting and grinding can be carried out on part 200.

[0080] The additive manufacturing method of this application will be further described below with reference to specific embodiments.

[0081] Example 1

[0082] Part 300 is a GH3625 high-temperature alloy load-bearing ring for an aero-engine (760mm in diameter, 380mm in height). The additive manufacturing method specifically includes:

[0083] Step 1: Establish a digital model of the load-bearing ring, and set a digital model of the additive manufacturing support structure 200 at the bottom of the load-bearing ring model. The digital model of the additive manufacturing support structure 200 consists of 3 support structure layers and a total of 432 support feature units 100. The external dimensions of the first support structure layer 210 at the top 110 are 3.5 mm × 28 mm × 28 mm, and the thickness 'a' of the top 110 of the support feature unit 100 of the first support structure layer 210 is 0.5 mm.

[0084] The external dimensions of the second support structure layer 220 in the middle are 4mm×28mm×28mm, and the thickness a of the top 110 of the support feature unit 100 of the second support structure layer 220 is 1mm.

[0085] The outer dimensions of the bottom third support structure layer 230 are 10mm × 28mm × 28mm, and the thickness a of the top 110 of the support feature unit 100 of the third support structure layer 230 is 2mm.

[0086] Step 2: After slicing the digital model of the load-bearing ring and the additive manufacturing support structure 200 along the direction perpendicular to the additive deposition direction, import it into the laser additive manufacturing equipment.

[0087] Step 3: Set the forming process parameters for the load-bearing ring and the additive manufacturing support structure 200 respectively, and start the laser additive manufacturing equipment to complete the manufacturing of the load-bearing ring along with the additive manufacturing support structure 200 on the substrate 400. The laser energy density when manufacturing the load-bearing ring is 3.0 J / mm, and the laser energy density when manufacturing the additive manufacturing support structure 200 is 2.6 J / mm.

[0088] Step 4: Heat treat the load-bearing ring, additively manufactured support structure 200, and substrate 400 together. The heat treatment process is: hold at 1050℃ for 2 hours, then air cool.

[0089] Step 5: Separate the additive manufacturing support structure 200 from the substrate 400 by mechanical processing, and remove the additive manufacturing support structure 200 from the surface of the load-bearing ring.

[0090] Step 6: After removing the additive manufacturing support structure 200, the load-bearing ring is sandblasted to complete the manufacturing of the load-bearing ring.

[0091] Example 2

[0092] Part 300 is a GH3536 high-temperature alloy adjusting ring for aero engines (diameter 830mm, height 410mm). The additive manufacturing method specifically includes:

[0093] Step 1: Establish a digital model of the adjustment ring, and set a digital model of the additive manufacturing support structure 200 at the bottom of the adjustment ring model. The digital model of the additive manufacturing support structure 200 consists of 3 support structure layers and a total of 628 support feature units 100.

[0094] The external dimensions of the first support structure layer 210 of the top 110 are 4.5mm×42mm×42mm, and the thickness a of the top 110 of the support feature unit 100 of the first support structure layer 210 is 0.75mm.

[0095] The external dimensions of the second support structure layer 220 in the middle are 6.75mm×42mm×42mm, and the thickness a of the top 110 of the support feature unit 100 of the second support structure layer 220 is 1.5mm.

[0096] The outer dimensions of the bottom third support structure layer 230 are 15mm×42mm×42mm, and the thickness a of the top 110 of the support feature unit 100 of the third support structure layer 230 is 3mm.

[0097] Step 2: After slicing the digital model of the adjustment ring and the additive manufacturing support structure 200 along the direction perpendicular to the additive deposition direction, import it into the laser additive manufacturing equipment.

[0098] Step 3: Set the forming process parameters for the adjustment ring and the additive manufacturing support structure 200 respectively, and complete the manufacturing of the adjustment ring along with the additive manufacturing support structure 200. The laser energy density when manufacturing the adjustment ring is 3.0 J / mm, and the laser energy density when manufacturing the additive manufacturing support structure 200 is 2.7 J / mm.

[0099] Step 4: Heat treat the adjusting ring, additive manufacturing support structure 200, and substrate 400 together. The heat treatment process is: hold at 1175℃ for 2 hours, then air cool.

[0100] Step 5: Separate the additive manufacturing support structure 200 from the substrate 400 by mechanical processing, and remove the additive manufacturing support structure 200 from the surface of the adjustment ring.

[0101] Step Six: After removing the additive manufacturing support structure 200, the adjusting ring is sandblasted to complete the manufacturing of the adjusting ring.

[0102] Example 3

[0103] Part 300 is the TA15 titanium alloy cylinder of an aero-engine (960 mm in diameter, 450 mm in height). The additive manufacturing method specifically includes:

[0104] Step 1: Establish a digital model of the cylinder body, and set a digital model of the additive manufacturing support structure 200 at the bottom of the cylinder body model. The digital model of the additive manufacturing support structure 200 consists of 3 support structure layers and a total of 820 support feature units 100.

[0105] The external dimensions of the first support structure layer 210 of the top 110 are 5mm×56mm×56mm, and the thickness a of the top 110 of the support feature unit 100 of the first support structure layer 210 is 1mm.

[0106] The external dimensions of the second support structure layer 220 in the middle are 8mm×56mm×56mm, and the thickness a of the top 110 of the support feature unit 100 of the second support structure layer 220 is 2mm.

[0107] The outer dimensions of the bottom third support structure layer 230 are 20mm×56mm×56mm, and the thickness a of the top 110 of the support feature unit 100 of the third support structure layer 230 is 4mm.

[0108] Step 2: After slicing the digital model of the cylinder and the additive manufacturing support structure 200 along the direction perpendicular to the additive deposition direction, import it into the laser additive manufacturing equipment.

[0109] Step 3: Set the forming process parameters for the cylinder and the additive manufacturing support structure 200 respectively, and complete the manufacturing of the cylinder including the additive manufacturing support structure 200. The laser energy density when manufacturing the cylinder is 2.2 J / mm, and the laser energy density when manufacturing the additive manufacturing support structure 200 is 1.7 J / mm.

[0110] Step 4: Heat treat the cylinder, additively manufactured support structure 200, and substrate 400 together. The heat treatment process is: hold at 850℃ for 4 hours, then air cool.

[0111] Step 5: Separate the additive manufacturing support structure 200 from the substrate 400 and remove the additive manufacturing support structure 200 from the surface of the cylinder.

[0112] Step Six: After removing the additive manufacturing support structure 200, the cylinder body is subjected to sandblasting to complete the manufacturing of the cylinder body.

[0113] As indicated in this application and claims, unless the context clearly indicates otherwise, the words "a," "an," "a," and / or "the" are not specifically singular and may include the plural. Generally, the terms "comprising" and "including" only indicate the inclusion of expressly identified steps and elements, which do not constitute an exclusive list, and the method or apparatus may also include other steps or elements. An element defined by the phrase "comprising an..." does not exclude the presence of other identical elements in the process, method, product, or apparatus that includes the element.

[0114] In the description of this application, unless otherwise expressly defined, terms such as "setup," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this application in conjunction with the specific content of the technical solution.

[0115] It should be noted that the various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0116] This article uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the core ideas of the present invention. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. An additive manufacturing support structure, characterized in that, The additive manufacturing support structure (200) includes at least one support feature unit (100) along and / or perpendicular to the additive deposition direction. The support feature unit (100) includes a top (110), side supports (120), a middle support (130), an oblique support (140), and an arched support (150). The side supports (120) are respectively provided on both sides of the top (110). The two ends of the arched support (150) are respectively connected to the ends of the two side supports (120) away from the top (110). The arch of the arched support (150) is connected to the top (110). The first end of the middle support (130) is connected to the arch of the arched support (150). The second end of the intermediate support (130) extends along the additive deposition direction to be flush with the end of the side support (120) away from the top (110). The two oblique support parts (140) are symmetrically arranged about the intermediate support (130). The first end of the oblique support part (140) is connected to the second end of the intermediate support (130). The second end of the oblique support part (140) is connected to the side support (120) and / or the top (110) through the arched support part (150). The intermediate support part (130), the oblique support part (140) and the arched support part (150) divide the space enclosed by the top (110) and the two side support parts (120) into multiple hollow structures.

2. The additive manufacturing support structure according to claim 1, characterized in that, The additive manufacturing support structure (200) includes a plurality of support structure layers along the additive deposition direction, and each of the support structure layers includes at least one of the support feature units (100).

3. The additive manufacturing support structure according to claim 2, characterized in that, One of the two adjacent support structure layers rotates by a predetermined angle relative to the other of the two adjacent support structure layers about an axis parallel to the additive deposition direction.

4. The additive manufacturing support structure according to claim 3, characterized in that, The preset angle is 90°.

5. The additive manufacturing support structure according to any one of claims 2-4, characterized in that, Along the additive deposition direction, the number of support feature units (100) in the uppermost support structure layer is greater than the number of support feature units (100) in other support structure layers, and the dimensions of the top (110), side support (120), middle support (130), oblique support (140) and arched support (150) of the support feature unit (100) in the uppermost support structure layer are proportionally smaller than the dimensions of the top (110), side support (120), middle support (130), oblique support (140) and arched support (150) of the support feature unit (100) in other support structure layers.

6. The additive manufacturing support structure according to claim 5, characterized in that, Along the additive deposition direction from top to bottom, the number of the support feature units (100) of each support structure layer decreases sequentially, and the dimensions of the top (110), the side support (120), the middle support (130), the oblique support (140), and the arched support (150) of each support feature unit (100) of the support structure layer increase proportionally in sequence.

7. The additive manufacturing support structure according to claim 5, characterized in that, The shape and area of ​​the projection of each of the aforementioned support structure layers on the projection plane perpendicular to the additive deposition direction are the same.

8. The additive manufacturing support structure according to any one of claims 1-4, characterized in that, The top (110), the side support (120), the middle support (130), the oblique support (140), and the arched support (150) are all plate-shaped. The top (110) is perpendicular to the additive deposition direction, and the side support (120) and the middle support (130) are parallel to the additive deposition direction.

9. An additive manufacturing method, characterized in that, Including the following steps: A digital model of part (300) is established, and a digital model of additive manufacturing support structure (200) as described in any one of claims 1-8 is established at the bottom of the digital model of part (300); The digital models of the part (300) and the additive manufacturing support structure (200) are sliced ​​along a direction perpendicular to the additive deposition direction, and the sliced ​​digital models of the part (300) and the additive manufacturing support structure (200) are imported into the additive manufacturing equipment. In the additive manufacturing equipment, the forming process parameters of the part (300) and the additive manufacturing support structure (200) are set respectively, and the part (300) with the additive manufacturing support structure (200) is manufactured on the substrate (400).

10. The additive manufacturing method according to claim 9, characterized in that, It also includes the following steps: Heat treatment is performed on the substrate (400) and the parts (300) of the additive manufacturing support structure (200). The part (300) with the additive manufacturing support structure (200) is separated from the substrate (400), and the additive manufacturing support structure (200) on the part (300) is removed. The surface treatment of part (300) is carried out to complete the manufacturing of part (300).

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