A non-traditional beam laser additive manufacturing apparatus and method

Abstract

This invention relates to a non-traditional beam laser additive manufacturing apparatus and method, belonging to the field of additive manufacturing technology. The apparatus includes a deposition head, a water-cooling system, a motion actuator, a feeding system, and a worktable. The deposition head integrates a dustproof cavity, a beam expander, a beam shaping device, a protective lens, a focusing lens, and a nozzle. The beam shaping device has a rotatable turntable with multiple independent beam shaping lenses, connected to the turntable via a drive mechanism, allowing for rapid and precise switching of the beam shaping lenses. This invention enables rapid online conversion of various non-traditional beams without disassembling lenses or repeated calibration, improving the stability and flexibility of beam shaping and avoiding optical component contamination. By controlling the light field energy distribution through beam shaping, the solidification behavior of the molten pool can be precisely managed, achieving customized microstructure and optimized mechanical properties. Online dynamic switching of beam morphology can meet the needs of rapid component fabrication, significantly enhancing the flexibility and material adaptability of additive manufacturing.

Description

Technical Field

[0001] This invention belongs to the field of additive manufacturing technology and relates to a non-traditional beam laser additive manufacturing device and method. Background Technology

[0002] Laser additive manufacturing technology, with its advantages of high precision, high flexibility and rapid prototyping, is widely used in the direct fabrication of complex metal components, ceramic matrix composites and high-performance parts. This technology uses a high-energy laser beam to completely melt high-purity raw materials, and can achieve the direct forming of near-net-shape structures by layer-by-layer localized deposition of the melt, which has extremely high freedom of material and structural design.

[0003] However, the energy distribution of a traditional Gaussian beam is extremely uneven, easily causing overheating at the center of the molten pool and low temperatures at the edges. This extreme temperature gradient often induces high thermal and residual stresses, ultimately leading to solidification defects such as porosity and cracks, and a reduction in mechanical properties. Non-traditional beams such as flat-top beams, ring beams, and anti-Gaussian beams can optimize the energy distribution of the light field, control key parameters affecting the solidification behavior of the molten pool such as temperature gradient and cooling rate, reduce the temperature gradient during manufacturing, and alleviate the thermal and residual stresses on the components. These are effective means to suppress solidification defects and improve the mechanical properties of components.

[0004] Patent CN202610054740.6 discloses a dynamic beam shaping system and method based on a spatial light modulator and the SPGD algorithm. It accelerates the convergence correction of flat-top beams through a composite performance index and a multi-stage order enhancement strategy, and achieves adaptive optimization of algorithm parameters based on noise estimation, significantly improving beam uniformity and system anti-interference capability. However, this scheme has high system complexity and cost, and the output beam mode is a fixed flat-top beam, unable to dynamically adjust the beam shape according to material properties.

[0005] Patent CN202610043623.X discloses a beam shaping and homogenization system and method for LD arrays based on microlens arrays. It achieves beam segmentation and superposition through a fast-axis pre-correction unit and a two-stage microlens array, resulting in an output beam uniformity of over 90%. However, this method suffers from serrated or wavy edges on the shaped beam, a fixed and unadjustable beam shape, and system sensitivity to assembly tolerances, making assembly and adjustment difficult.

[0006] Patent CN202511990611.X discloses a beam shaping system based on orthogonal cascaded prism pairs and a parallel plate. By using two sets of prism pairs to independently expand / compress the beam in the X and Y directions, and utilizing the parallel plate to compensate for offset, a traditional Gaussian beam can be shaped into a collimated stripe with an aspect ratio of 4:1 to 20:1 and a maximum major axis of 30mm, while maintaining the beam center position unchanged. However, this shaping system outputs a fixed beam pattern and cannot achieve non-traditional beam outputs such as flat-top beams or ring beams.

[0007] Patent CN202511678054.8 discloses a programmable 3D beam shaping device based on sub-beam printing technology. It utilizes polarization beam splitting, Damman grating beam splitting, focus shift introduced by a phase plate, and spatial light modulator offset control to achieve controllable energy deposition of the three-dimensional light field and depth, thereby improving the quality and consistency of laser processing. However, the device employs a reciprocating folding structure in its optical path, making assembly and adjustment difficult and resulting in poor stability. Furthermore, the beam undergoes multiple diffractions, splitting, and phase modulations, leading to significant energy loss.

[0008] Patent CN202511619376.5 discloses a laser beam shaping device and method that utilizes a liquid mirror and photothermal capillary effect. It achieves dynamic phase modulation by inducing controllable deformation of the liquid surface using laser, enabling dynamically adjustable multi-shaped beam output. However, due to the poor stability of the liquid surface, it is easily affected by vibration and environmental factors, making it difficult to guarantee the beam shaping effect. Summary of the Invention

[0009] To address the numerous problems inherent in existing non-traditional beam laser additive manufacturing, such as fixed beam shape and unstable beam shaping effects, this invention proposes a non-traditional beam laser additive manufacturing apparatus and method. This apparatus integrates multiple beam shaping lenses through a rotatable turntable, enabling rapid and precise switching between various beams, including Gaussian, flat-top, ring, and anti-Gaussian beams, according to fabrication requirements. This provides a new approach for the rapid response manufacturing of high-performance, low-defect components. Simultaneously, a dustproof mechanism protects optical components when not in operation. Combined with a water-cooling system, protective gas, and motion actuators working in tandem, this effectively ensures the long-term stability and reliability of the laser optical path system and the entire machine.

[0010] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A non-traditional beam laser additive manufacturing apparatus includes a deposition head (1), a water cooler inlet pipe (2), a water cooler outlet pipe (3), a water cooler (4), a beam shaping device (5), a forming component (6), a substrate (7), a worktable (8), a feed pipe (9), a feed mechanism (10), a protective gas cylinder (11), a gas supply pipe (12), a motion actuator (13), a laser (14), and an optical fiber (15). The water cooler (4) forms a circulating cooling loop with the water cooler outlet pipe (3) and the deposition head (1) through the water cooler inlet pipe (2). The deposition head (1) is fixedly connected to the beam shaping device (5). It is mounted on the motion actuator (13), and the protective gas cylinder (11) is diverted through the gas supply pipe (12) and connected to the deposition head (1) and the feeding mechanism (10); the deposition head (1) includes a dustproof cavity (1.1), a beam expander (1.2), an upper protective lens (1.3), a focusing lens (1.4), a middle protective lens (1.5), a lower protective lens (1.6) and a nozzle (1.7); the beam shaping device (5) is located between the beam expander (1.2) and the focusing lens (1.4), and includes a drive mechanism (5.1), a dustproof component (5.2), a turntable (5.4) and a beam shaping lens (5.3); The turntable (5.4) has multiple circumferentially distributed mounting stations, each station fixing a beam shaping lens (5.3). The beam shaping lens (5.3) is a monolithic optical element, including a plane transmission mirror, a flat-top beam shaping lens, a ring beam shaping lens, and an anti-Gaussian beam shaping lens. Each lens can independently shape the incident Gaussian beam into the corresponding target beam. The beam shaping lens is not limited to the above four types; any optical element that can achieve laser beam shape conversion monolithically falls within the scope of protection of this patent.

[0011] The drive mechanism (5.1) is connected to the turntable (5.4) and drives the turntable (5.4) to rotate around the axis, so as to accurately switch any beam shaping lens (5.3) to the laser optical path and complete the real-time dynamic switching of the beam shape.

[0012] The dustproof component (5.2) is used to block pollutants such as dust and smoke, and to protect the beam shaping lens (5.3) when it is not in operation.

[0013] Furthermore, the dustproof component (5.2) is an independent dustproof cover assembly, including a dustproof cover (5.2.1), a dustproof cover elastic element (5.2.2), a ejector pin elastic element (5.2.3), and an ejector pin (5.2.4); each dustproof cover (5.2.1) corresponds to an installation station, and the dustproof cover elastic element (5.2.2) keeps the dustproof cover (5.2.1) normally closed, covering the element; the ejector pin (5.2.4) has an ejector pin elastic element (5.2.3) at its rear and is fixed directly above the optical path of the housing. When the target element is rotated to the optical path, the ejector pin (5.2.4) pushes open the dustproof cover (5.2.1), and after it is removed, the dustproof cover (5.2.1) automatically resets and closes.

[0014] Furthermore, the dustproof component (5.2) is an integral dust cover (5.2.5), which is fixed to the housing and fully covers the turntable (5.4) and the components; the dust cover (5.2.5) has only one optical path through hole (5.2.6), and the turntable (5.4) and the dust cover (5.2.5) can slide relative to each other, so that non-target optical components are fully covered and protected.

[0015] Furthermore, the drive mechanism (5.1) is a manual rotation mechanism or an electric rotation mechanism.

[0016] Furthermore, the electric rotating mechanism is equipped with a central controller, which receives instructions to control the turntable (5.4) to rotate to a specified angle, thereby realizing the automatic switching of optical elements.

[0017] Furthermore, the laser (14) is a fiber laser, a semiconductor laser, or a CO2 laser; the motion actuator (13) can drive the deposition head (1) to complete multi-degree-of-freedom deposition motion, and the feeding mechanism (10) delivers the raw material to below the nozzle (1.7) under a protective gas atmosphere.

[0018] A non-traditional beam laser additive manufacturing method, comprising the following steps: First, turn on the water cooler (4) and the protective gas cylinder (11), install the beam shaping device (5) between the beam expander (1.2) and the focusing lens (1.4), and calibrate the optical path coaxiality; The second step is to determine the target beam shape and the corresponding shaping lens according to the preset additive manufacturing process (5.3); In the third step, the drive mechanism (5.1) drives the turntable (5.4) to rotate, switching the target optical element to the laser optical path, and the dustproof component (5.2) automatically exposes the target optical element; In the fourth step, the laser beam is expanded by the beam expander (1.2), passes through the upper protective mirror (1.3), is shaped by the beam shaping device (5), passes through the middle protective mirror (1.5), is focused by the focusing mirror (1.4), and finally passes through the lower protective mirror (1.6) and is ejected from the nozzle (1.7); the motion actuator (13) drives the deposition head (1) to move, and the raw material conveyed by the feed tube (9) acts on the substrate (7) on the worktable (8) to carry out laser additive manufacturing; Fifth, when the beam shape needs to be switched during the additive manufacturing process, repeat steps two through four to complete the dynamic switching of optical elements and beam shape.

[0019] Furthermore, when the independent dust cover assembly is in operation, the ejector pin (5.2.4) automatically pushes open the dust cover (5.2.1) of the target optical element, while the other dust covers (5.2.1) remain closed.

[0020] Furthermore, when the integrated dust cover (5.2.5) is in operation, the target optical element moves to the bottom of the light-transmitting hole (5.2.6) to transmit light, while the remaining optical elements are covered and protected throughout the process.

[0021] Compared with the prior art, the present invention has the following beneficial effects: The rotary multi-optical element integrated design enables rapid and precise switching between unconventional beams such as Gaussian beams, flat-top beams, ring beams, and reverse Gaussian beams, eliminating the need for lens disassembly and repeated calibration, significantly improving manufacturing flexibility and preparation efficiency. Simultaneously, the independent / integrated dustproof structure effectively blocks contaminants, preventing damage to optical elements, ensuring long-term optical path stability, improving beam shaping quality, and reducing equipment maintenance costs. Furthermore, it supports online beam morphology switching during additive manufacturing, allowing for customized temperature fields for different materials, structures, and sizes, thereby optimizing molten pool solidification behavior, reducing temperature gradients and stress levels, and achieving solidification defect suppression and improved mechanical properties. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a non-traditional beam laser additive manufacturing device (powder feeding type).

[0023] Figure 2 This is a schematic diagram of a non-traditional beam laser additive manufacturing device (wire feeding type).

[0024] Figure 3 This is a schematic diagram of the deposition head and beam shaping device.

[0025] Figure 4 This is a schematic diagram of a beam shaping device.

[0026] Figure 5 This is a schematic diagram of the independent dust cover assembly of the beam shaping device.

[0027] Figure 6This is a schematic diagram of the integrated dust cover structure of the beam shaping device.

[0028] In the diagram: 1. Deposition head; 2. Water cooler inlet pipe; 3. Water cooler outlet pipe; 4. Water cooler; 5. Beam shaping device; 6. Forming component; 7. Substrate; 8. Worktable; 9. Feed pipe; 10. Feeding mechanism; 11. Protective gas cylinder; 12. Gas delivery pipe; 13. Motion actuator; 14. Laser; 15. Optical fiber. 1.1 Dustproof chamber; 1.2 Beam expander; 1.3 Upper protective lens; 1.4 Focusing lens; 1.5 Middle protective lens; 1.6 Lower protective lens; 1.7 Nozzle; 5.1 Drive mechanism; 5.2 Dustproof components; 5.3 Beam shaping lens; 5.4 Turntable; 5.2.1 Dust cover; 5.2.2 Dust cover elastic element; 5.2.3 Ejector pin elastic element; 5.2.4 Ejector pin; 5.2.5 Dust cover; 5.2.6 Light transmission hole. Detailed Implementation

[0029] This invention proposes a non-traditional beam laser additive manufacturing apparatus and method, which are described in detail below with reference to the accompanying drawings.

[0030] Figure 1This is a schematic diagram of a non-traditional beam laser additive manufacturing device (powder feeding type). Before preparing powder-formed samples using a non-traditional beam laser additive manufacturing device (powder feeding type), system cooling, gas path protection, and optical path calibration must be completed. Among them, optical path calibration must ensure that the beam shaping device is coaxial with the optical path inside the deposition head. Turn on the water cooler (4), and the cooling medium flows into the cooling chamber inside the deposition head (1) through the water cooler inlet pipe (2). After absorbing the heat generated by the optical components inside the deposition head, it returns to the water cooler (4) through the water cooler outlet pipe (3), forming a closed-loop cooling circuit to ensure that the deposition head (1) is at a stable operating temperature that meets the process requirements. Simultaneously, the protective gas cylinder (11) is opened, and the protective gas is divided into two paths after passing through the gas delivery pipe (12): the first path is directly introduced into the dustproof cavity (1.1) of the deposition head (1) to form an inert protective atmosphere to prevent dust and powder splashes generated during additive manufacturing from contaminating the internal optical lenses; the second path is introduced into the feeding mechanism (10) as a powder carrier gas to fluidize the powder raw material and ensure that the powder is carried and transported uniformly and stably. The beam shaping device (5) is precisely fixed between the beam expander (1.2) and the focusing lens (1.4) of the deposition head (1), and it is confirmed in advance that the beam shaping device (5) is coaxial with the internal optical path of the deposition head (1). The laser (14) is connected to the upper end of the deposition head (1) through the optical fiber (15) to provide the original Gaussian laser beam. The sample preparation process of the non-traditional beam laser additive manufacturing device (powder feeding type) is as follows: The target beam shape required is determined according to the preset additive manufacturing process. The corresponding beam shaping lens (5.3) is switched to the laser beam path through the drive mechanism (5.1) inside the beam shaping device (5). At the same time, the dustproof component (5.2) automatically protects the beam shaping lens (5.3) when it is not in operation. Then the laser (14) is started and the laser beam is transmitted to the deposition head (1) through the optical fiber (15). After beam expansion, shaping and focusing, it is ejected from the nozzle. The motion execution mechanism (13) drives the deposition head (1) to perform multi-degree-of-freedom movement strictly according to the preset forming trajectory. At the same time, the feeding mechanism (10) accurately delivers the powder raw material to the laser focus molten pool area on the surface of the substrate (7) through the feeding pipe (9) under the carrying action of the second protective gas (carrier gas). The substrate (7) is fixedly clamped on the worktable (8). The laser beam melts the powder and deposits it layer by layer, eventually forming a pre-defined shaped component (6) on the surface of the substrate (7). During the manufacturing process, if it is necessary to change the beam energy distribution to optimize the forming quality of different areas of the component, the beam shaping device (5) can be dynamically switched online to shape the beam shaping lens (5.3). The laser path inside the deposition head (1) is adjusted accordingly. The entire process can be completed in real time without interrupting the processing.

[0031] Figure 2This is a schematic diagram of a non-traditional beam laser additive manufacturing device (wire feeding type). Before preparing wire-shaped samples using the non-traditional beam laser additive manufacturing device (wire feeding type), system cooling, gas path protection, and optical path calibration must be completed. Among them, optical path calibration must ensure that the beam shaping device is coaxial with the optical path inside the deposition head. Turn on the water cooler (4), and the cooling medium flows into the cooling chamber inside the deposition head (1) through the water cooler inlet pipe (2). After absorbing the heat generated by the optical components inside the deposition head, it returns to the water cooler (4) through the water cooler outlet pipe (3), forming a closed-loop cooling circuit to ensure that the deposition head (1) is at a stable working temperature that meets the process requirements. At the same time, turn on the protective gas cylinder (11), and the protective gas is introduced into the dustproof chamber (1.1) of the deposition head (1) through the gas delivery pipe (12). An inert protective atmosphere is formed in the outlet area of ​​the internal optical lens and nozzle (1.7) to prevent the smoke and dust generated during the additive manufacturing process from contaminating the optical components and to isolate the atmosphere from the processing area and optical components. Since the raw material is filament, the feeding mechanism (10) is only used to mechanically push the filament without introducing carrier gas, and pushes the filament to the processing area. The beam shaping device (5) is precisely fixed between the beam expander (1.2) and the focusing lens (1.4) of the deposition head (1), and it is confirmed in advance that the beam shaping device (5) and the internal optical path of the deposition head (1) are coaxial. The laser (14) is connected to the upper end of the deposition head (1) through the optical fiber (15) to provide the original Gaussian laser beam. The sample preparation process of the non-traditional beam laser additive manufacturing device (filament feeding type) is as follows: the required target beam shape is determined according to the preset additive manufacturing process, and the corresponding beam shaping lens (5.3) is switched to the laser optical path through the drive mechanism (5.1) inside the beam shaping device (5), while the dustproof component (5.2) automatically protects the beam shaping lens (5.3) in the non-working state. The laser (14) is then activated, and the laser beam is transmitted to the deposition head (1) via the optical fiber (15). After beam expansion, shaping, and focusing, the beam is ejected from the nozzle. The motion actuator (13) drives the deposition head (1) to perform multi-degree-of-freedom motion strictly according to the preset forming trajectory. At the same time, the feeding mechanism (10) steadily pushes the filament through the feeding tube (9) to the laser focal molten pool area on the surface of the substrate (7). The substrate (7) is fixedly clamped on the worktable (8). The filament melts under the action of the laser and is deposited layer by layer, finally forming the preset forming component (6) on the surface of the substrate (7). During the manufacturing process, if it is necessary to change the beam energy distribution to adjust the width or depth of the molten pool, the beam shaping device (5) can be dynamically switched online to adjust the beam shaping lens (5.3). The laser optical path inside the deposition head (1) is adjusted accordingly. The entire process can be carried out without interrupting the processing, and the beam shape can be adjusted online.

[0032] Figure 3This is a schematic diagram of the deposition head and beam shaping device. The deposition head (1), as the core execution component of laser additive manufacturing, integrates a precision optical lens group, gas path channel, and water path channel. The deposition head (1) includes a dustproof cavity (1.1), a beam expander (1.2), an upper protective lens (1.3), a focusing lens (1.4), a middle protective lens (1.5), a lower protective lens (1.6), and a nozzle (1.7), with each component arranged sequentially according to the laser beam propagation order. The beam shaping device (5) is located inside the deposition head (1), specifically on the laser beam path between the beam expander (1.2) and the focusing lens (1.4), and can independently convert the incident Gaussian beam into non-traditional beam shapes such as flat-top beams, ring beams, and anti-Gaussian beams. The beam expander (1.2) is located upstream of the optical path and is used to expand the beam diameter of the incident laser beam to reduce the beam divergence angle and match the aperture of subsequent optical components. The focusing lens (1.4) is located downstream of the optical path and is responsible for focusing the shaped laser beam onto the processing plane on the substrate (7) to form a high-energy-density micro-spot that meets the requirements of additive manufacturing. In the laser optical path, the upper protective lens (1.3) is located after the beam expander (1.2), the middle protective lens (1.5) is located between the beam shaping device (5) and the focusing lens (1.4), and the lower protective lens (1.6) is close to the inlet end of the nozzle (1.7). The function of the three protective lenses mentioned above—upper protective lens (1.3), middle protective lens (1.5), and lower protective lens (1.6)—is to seal and isolate the internal space of the dustproof cavity (1.1) in layers without hindering laser transmission, preventing high-temperature splashes and dust generated during additive manufacturing from entering upwards along the optical path. This effectively protects expensive and precision optical components such as the beam expander (1.2), focusing lens (1.4), and beam shaping lens (5.3) from contamination and damage. The nozzle (1.7), as the end-acting component of the deposition head (1), guides the focused laser beam to be accurately emitted and act on the processing area. On the other hand, it works with the feed tube (9) and protective gas path to ensure that the raw material is accurately fed into the laser focal molten pool area.

[0033] Figure 4This is a schematic diagram of the beam shaping device. The beam shaping device (5), as the core module for realizing non-traditional beam laser additive manufacturing, is installed on the laser optical path between the beam expander (1.2) and the focusing lens (1.4) inside the deposition head (1). The device mainly consists of a drive mechanism (5.1), a dustproof assembly (5.2), beam shaping lenses (5.3), and a turntable (5.4). The beam shaping lenses (5.3) are installed on the turntable (5.4), the drive mechanism (5.1) is connected to the turntable (5.4), and the dustproof assembly (5.2) is installed above or around the turntable (5.4). The turntable (5.4) has multiple mounting stations evenly distributed along the circumference. The number of mounting stations is consistent with the number of beam shaping lenses (5.3), and each station has one beam shaping lens (5.3) fixed to it. Each beam-shaping lens (5.3) is a monolithic optical element that can independently shape an incident standard Gaussian beam into non-traditional beam shapes with specific energy distributions, such as flat-top beams, ring beams, and anti-Gaussian beams, to meet the needs of different additive manufacturing processes. The drive mechanism (5.1) is connected to the turntable (5.4) and can drive the turntable (5.4) to rotate around its own central axis, thereby precisely switching any target beam-shaping lens (5.3) to the center position of the laser optical path, realizing rapid online switching between different beam shapes without interrupting processing. The dustproof component (5.2) is installed above or around the turntable (5.4) to block the smoke and dust generated during the additive manufacturing process during the operation of the device, protecting the beam-shaping lenses (5.3) in standby mode from contamination except for those currently in working position, thereby ensuring the cleanliness of the lens surface, long-term optical stability, and consistency of beam-shaping effect.

[0034] Figure 5This is a schematic diagram of the independent dust cover assembly of the beam shaping device. The independent dust cover assembly is a turntable (5.4) structure adapted to the beam shaping device (5), providing individual dust protection for each beam shaping lens (5.3). The assembly mainly consists of a dust cover (5.2.1), a dust cover elastic element (5.2.2), a pin elastic element (5.2.3), and a pin (5.2.4). The dust cover (5.2.1) is connected to the turntable (5.4) through the dust cover elastic element (5.2.2), and the pin (5.2.4) is connected to the housing of the beam shaping device (5) through the pin elastic element (5.2.3). Each dust cover (5.2.1) is installed above one station of the turntable (5.4) and connected to the turntable (5.4) via a dust cover elastic element (5.2.2). Under the elastic restoring force of the dust cover elastic element (5.2.2), it remains in an initially closed state, tightly shielding the beam shaping lens (5.3) below to prevent dust and smoke from adhering to the lens surface. The ejector pin (5.2.4) is fixedly installed on the housing of the beam shaping device (5) and corresponds to the position directly above the laser beam path. Its rear end is connected to the housing of the beam shaping device (5) via the ejector pin elastic element (5.2.3). When the turntable (5.4) rotates and a target beam shaping lens (5.3) enters the working optical path, the dust cover (5.2.1) corresponding to the target beam shaping lens (5.3) will come into contact with the fixed ejector pin (5.2.4). Under the elastic force of the ejector pin elastic element (5.2.3), the ejector pin (5.2.4) pushes the dust cover (5.2.1) open, allowing the laser to pass smoothly through the target beam shaping lens (5.3) and complete the beam shaping. When the target beam shaping lens (5.3) completes its working task and rotates out of the optical path with the turntable (5.4), the corresponding dust cover (5.2.1) immediately breaks free from the constraint of the ejector pin (5.2.4) and automatically resets and closes under the elastic restoring force of the dust cover elastic element (5.2.2), restoring the dust protection for the target beam shaping lens (5.3). This structure achieves an automated protection effect where the beam shaping lens (5.3) is automatically exposed when in operation and is dustproof throughout when not in operation.

[0035] Figure 6This is a schematic diagram of the integrated dust cover structure of the beam shaping device. The integrated dust cover structure adopts a full-coverage protection scheme, adapted to the turntable (5.4) structure of the beam shaping device (5). Its core components are the dust cover (5.2.5) and the light-transmitting hole (5.2.6) opened on the dust cover (5.2.5). The dust cover (5.2.5) is fixedly installed inside the housing of the beam shaping device (5). Its size is sufficient to completely cover the area below the entire turntable (5.4) and all the beam shaping lenses (5.3) installed on it, ensuring that all beam shaping lenses (5.3) are within the protection range. The dust cover (5.2.5) is an overall closed structure, with only one light-transmitting hole (5.2.6) opened at the position directly above the laser beam path. The size of the light-transmitting hole (5.2.6) matches the diameter of the laser beam, ensuring that the laser passes through smoothly. During operation, the turntable (5.4) and the dust cover (5.2.5) can slide relative to each other along the central axis of the turntable (5.4). When a target beam shaping lens (5.3) rotates with the turntable (5.4) to a position directly below the light-transmitting hole (5.2.6), the laser beam can pass through the light-transmitting hole (5.2.6) and irradiate the target beam shaping lens (5.3), completing the beam shape shaping. Meanwhile, all other beam shaping lenses (5.3) on the turntable (5.4) that are not in operation are always tightly covered by the solid part of the dust cover (5.2.5), completely isolating them from the smoke and dust in the external processing environment. This structure, through the cooperation of a single dust cover (5.2.5) and light-transmitting hole (5.2.6), achieves full protection of the non-operating beam shaping lens (5.3) in a simple and reliable physical isolation method, without affecting laser transmission and beam shaping functions.

[0036] Example 1: Taking Al2O3-ZrO2 composite ceramics deposited by non-traditional beam laser directional energy deposition as an example, such as... Figure 1 , 3 As shown in Figures 4, 5, and 6, the non-traditional beam laser additive manufacturing apparatus of the present invention is used in the following specific steps.

[0037] The lens support platform of the beam shaping device (5) is fixed on the dustproof cavity (1.1), reinforced and sealed with bolts to ensure that the deposition head (1) and the beam shaping device (5) are fixedly connected as one unit, and the optical path is coaxial.

[0038] Install the beam shaping lens (5.3). Place the plane transmission mirror, flat-top beam shaping mirror, ring beam shaping mirror, and anti-Gaussian beam shaping mirror in sequence at the corresponding positions on the turntable (5.4), and use gaskets to protect the lenses; the protective gas output from the protective gas cylinder (11) is continuously introduced throughout the process to prevent dust and avoid contamination of optical components, while creating an inert environment for subsequent additive manufacturing.

[0039] Turn on the water cooler (4) to form a circulating cooling circuit through the water cooler inlet pipe (2) and water cooler outlet pipe (3) to cool the beam expander (1.2), upper protective mirror (1.3), focusing mirror (1.4), middle protective mirror (1.5) and lower protective mirror (1.6) in the deposition head (1) to prevent the optical components from thermal distortion caused by laser irradiation.

[0040] Inspect the beam. The laser beam (14) is transmitted through the optical fiber (15), expanded by the beam expander (1.2), and then modulated by the target shaping lens on the turntable (5.4) to output non-traditional beams of different shapes. The laser power is set to 600W and the exposure time is 0.01s. The beam is projected onto the photographic paper. The marks on the photographic paper are compared with the beam energy distribution map to confirm that the shape of the target beam meets the requirements for component preparation.

[0041] Powder drying. Al2O3 powder and ZrO2 powder with a particle size of 40-106μm were placed in a drying oven at 120℃ for 4 hours to remove moisture from the powder and reduce forming defects.

[0042] Powder mixing. Weigh the dried Al2O3 and ZrO2 powders at a weight ratio of 58.5:41.5 and put them into a planetary ball mill for mixing. Set the rotation speed to 300 r / min and the revolution speed to 3 r / min, and the mixing time to 2 hours to complete the powder mixing and balling simultaneously, thereby improving the powder flowability.

[0043] Powder sieving. The mixed powder is sieved through a combination of 170-mesh and 325-mesh sieves to collect powder with a particle size of 45-90μm for later use, ensuring uniform powder particle size.

[0044] Process parameter settings. Adjust the laser beam to focus on the surface of the Al2O3 substrate (7), adjust the spot diameter to 3mm, set the laser power to 600W, the scanning speed to 10mm / s, and the interlayer lift to 0.4mm; start the feeding mechanism (10), adjust the feeding rate to 15g / min, and ensure that the protective gas, as the carrier gas, carries the powder and is stably transported to the nozzle (1.7) through the feeding pipe (9).

[0045] Forming process. The motion actuator (13) drives the deposition head (1) and the beam shaping device (5) to move along the positive Y direction. The nozzle (1.7) moves relative to the Al2O3 substrate (7) in the positive Y direction, with a moving length of 20mm. The laser beam is expanded, shaped and focused before being emitted to melt the synchronously transported powder. For each layer deposited, the motion actuator (13) rises by 0.4mm and returns to the starting point XY position of the previous layer to carry out the laser directional energy deposition of the next layer until the set number of layers is reached to complete the unidirectional multilayer deposition.

[0046] The forming process is complete. The motion actuator (13) stops moving and sequentially shuts down the laser (14), the feeding mechanism (10), the protective gas cylinder (11), and the water cooler (4). The dustproof chamber (1.1) and the dustproof assembly (5.2) together protect all beam shaping lenses (5.3) to avoid dust contamination.

[0047] Example 2: Taking non-traditional beam laser-directed energy deposition of 7075 aluminum alloy as an example, such as... Figure 2 , 3 As shown in Figures 4, 5, and 6, the non-traditional beam laser additive manufacturing apparatus of the present invention is used in the following specific steps.

[0048] The lens support platform of the beam shaping device (5) is fixed on the dustproof cavity (1.1), reinforced and sealed with bolts to ensure that the deposition head (1) and the beam shaping device (5) are fixedly connected as one unit, and the optical path is coaxial.

[0049] Install the beam shaping lens (5.3). Place the plane transmission mirror, flat-top beam shaping mirror, ring beam shaping mirror, and anti-Gaussian beam shaping mirror in sequence at the corresponding positions on the turntable (5.4), and use gaskets to protect the lenses; the protective gas output from the protective gas cylinder (11) is continuously introduced throughout the process to prevent dust and avoid contamination of optical components, while creating an inert environment for subsequent additive manufacturing.

[0050] Turn on the water cooler (4) to form a circulating cooling circuit through the water cooler inlet pipe (2) and water cooler outlet pipe (3) to cool the beam expander (1.2), upper protective mirror (1.3), focusing mirror (1.4), middle protective mirror (1.5) and lower protective mirror (1.6) in the deposition head (1) to prevent the optical components from thermal distortion caused by laser irradiation.

[0051] Test the beam. The laser beam (14) is transmitted through the optical fiber (15), expanded by the beam expander (1.2), and then modulated by the target shaping lens on the turntable (5.4) to output non-traditional beams of different shapes. The laser power is set to 600W and the exposure time is 0.01s. The beam is projected onto the photographic paper. The marks on the photographic paper are compared with the beam energy distribution map to confirm that the shape of the target beam meets the preparation requirements.

[0052] Wire processing. The 1.2mm diameter 7075 aluminum alloy wire undergoes physical cleaning and polishing followed by chemical cleaning to remove oxide scale and surface oil. After cleaning, the wire is dried using a heating device to completely remove any residual moisture from the surface.

[0053] Process parameter settings. Adjust the laser beam to focus on the surface of the aluminum alloy plate (7), adjust the spot diameter to 2mm, set the laser power to 3000W, the scanning speed to 10mm / s, and the interlayer lifting amount to 0.4mm; start the feeding mechanism (10), adjust the feeding speed to 600mm / min, and ensure that the wire is stably conveyed to the nozzle (1.7) through the feeding tube (9).

[0054] Forming process. The motion actuator (13) drives the deposition head (1) and the beam shaping device (5) to move along the Y direction. The first layer is translated 20mm along the positive Y axis. The laser beam is expanded, shaped and focused and then emitted to melt the synchronously transported filament. For each layer deposited, the motion actuator (13) rises 0.4mm and moves to the starting point XY position of the previous layer, and is translated along the negative Y axis to deposit until the set number of layers is reached to complete the reciprocating multi-layer deposition.

[0055] The forming process is complete. The motion actuator (13) stops moving and sequentially shuts down the laser (14), the feeding mechanism (10), the protective gas cylinder (11), and the water cooler (4). The dustproof chamber (1.1) and the dustproof assembly (5.2) together protect all beam shaping lenses (5.3) to avoid dust contamination.

[0056] The embodiments described above are merely illustrative of implementation methods of the present invention and should not be construed as limiting the scope of patent protection. Modifications and improvements made by those skilled in the art based on the inventive concept are all within the scope of protection of the present invention.

Claims

1. A non-traditional beam laser additive manufacturing apparatus, characterized in that, The system includes a deposition head (1), a water cooler inlet pipe (2), a water cooler outlet pipe (3), a water cooler (4), a beam shaping device (5), a forming component (6), a substrate (7), a worktable (8), a feed pipe (9), a feed mechanism (10), a protective gas cylinder (11), a gas delivery pipe (12), a motion actuator (13), a laser (14), and an optical fiber (15). The water cooler (4) is connected to the deposition head (1) through the water cooler inlet pipe (2) and the water cooler outlet pipe (3) to form a circulating cooling circuit. The deposition head (1) is fixedly connected to the beam shaping device (5) and installed on the motion actuator (13). The gas from the protective gas cylinder (11) flows into the deposition head (1) or the feed mechanism (10) through the gas delivery pipe (12) as a protective gas or raw material carrier gas. The deposition head (1) includes a dustproof chamber (1.1) and a beam expander (1). 2) Upper protective lens (1.3), focusing lens (1.4), middle protective lens (1.5), lower protective lens (1.6), and nozzle (1.7); The beam shaping device (5) is located between the beam expander (1.2) and the focusing lens (1.4), including a drive mechanism (5.1), a dustproof component (5.2), a beam shaping lens (5.3), and a turntable (5.4); The turntable (5.4) is provided with multiple mounting positions evenly distributed along the circumference, and each mounting position is fixed with a single-piece beam shaping lens (5.3); The drive mechanism (5.1) is connected to the turntable (5.4) and is used to drive the turntable (5.4) to rotate so as to switch any beam shaping lens (5.3) into the laser optical path; The dustproof component (5.2) is an independent dustproof cover component or an integrated dustproof cover, used to prevent dust from contaminating the beam shaping lens (5.3) in the non-working state.

2. The non-traditional beam laser additive manufacturing apparatus according to claim 1, characterized in that, The beam shaping lens (5.3) is a monolithic optical element, including a plane transmission mirror, a flat-top beam shaping mirror, a ring beam shaping mirror and an anti-Gaussian beam shaping mirror. Each lens can independently shape the incident Gaussian beam into the corresponding target beam.

3. The non-traditional beam laser additive manufacturing apparatus according to claim 1, characterized in that, The dustproof assembly (5.2) is an independent dustproof cover assembly, which includes multiple dustproof covers (5.2.1), dustproof cover elastic elements (5.2.2), ejector pin elastic elements (5.2.3), and ejector pins (5.2.4). Each dustproof cover (5.2.1) is installed on the turntable (5.4) through the corresponding dustproof cover elastic element (5.2.2) and covers the corresponding beam shaping lens (5.3). The ejector pin (5.2.4) is located directly above the laser optical path and connected to the ejector pin elastic element (5.2.3). When the turntable (5.4) rotates, the ejector pin (5.2.4) pushes open the dustproof cover (5.2.1) located at the optical path position. When the beam shaping lens moves out of the optical path, the corresponding dustproof cover (5.2.1) resets and closes.

4. The non-traditional beam laser additive manufacturing apparatus according to claim 1, characterized in that, The dustproof component (5.2) is an integral dust cover (5.2.5), which is fixed to the device housing and covers the entire turntable (5.4), and only has a light-transmitting hole (5.2.6) at the corresponding position of the laser light path. The turntable (5.4) and the dust cover (5.2.5) can slide relative to each other.

5. The non-traditional beam laser additive manufacturing apparatus according to claim 1, characterized in that, The drive mechanism (5.1) is a manual rotation mechanism or an electric rotation mechanism; the electric rotation mechanism is equipped with a central controller, which is used to receive switching instructions and control the rotation of the turntable (5.4).

6. The non-traditional beam laser additive manufacturing apparatus according to claim 1, characterized in that, The laser (14) is a fiber laser, a semiconductor laser, or a CO2 laser.

7. A non-traditional beam laser additive manufacturing method using the apparatus described in any one of claims 1-6, characterized in that, The steps are as follows: Step 1: Turn on the water cooler (4) to circulate and cool the deposition head (1), turn on the protective gas cylinder (11) to introduce protective gas, and confirm that the beam shaping device (5) is fixed between the beam expander (1.2) and the focusing lens (1.4); Step 2: Determine the target beam shape and corresponding beam shaping lens based on the additive manufacturing process (5.3); Step 3: Drive the turntable (5.4) to rotate via the drive mechanism (5.1), switch the target beam shaping lens (5.3) to the laser beam path, and the dustproof component (5.2) automatically protects the non-target lens and exposes the target lens to allow light to pass through; Step 4: Start the laser (14), drive the nozzle (1.7) to move along the preset forming trajectory through the motion actuator (13), and cooperate with the feeding mechanism (10) to transport powder or filament to carry out laser additive manufacturing; When it is necessary to switch the beam during additive manufacturing, repeat steps two to three to achieve dynamic beam switching.

8. The non-traditional beam laser additive manufacturing method according to claim 7, characterized in that, The raw material is powder or filament; the powder or filament is metal powder / filament, ceramic powder, metal-ceramic mixture / filament, intermetallic compound powder / filament, etc.

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