A gold-porcelain heterostructure laser directional energy deposition additive manufacturing device and method

Abstract

The application belongs to the technical field of advanced manufacturing, and discloses a gold-ceramic heterogeneous component laser directional energy deposition additive manufacturing device and method. The device comprises: a sealed box body for providing a sealed forming environment; a first multi-axis motion mechanism for driving a main laser head to move in multiple degrees of freedom; a second multi-axis motion mechanism for driving an auxiliary laser head to move in multiple degrees of freedom; a powder feeding system for conveying raw material powder; the auxiliary laser head is used for selectively in-situ heat treatment of the deposited component during the manufacturing process; and an in-situ oxygen supply system is used for selectively spraying oxygen to the deposited component to form an oxidation phase in-situ to improve the bonding performance. The application realizes metal / ceramic powder melting and deposition through the main laser, flexibly in-situ heat treatment of the deposited layer through the auxiliary laser, and high-quality composite additive manufacturing of IN718 high-temperature alloy and SiC ceramic and other heterogeneous materials by combining the in-situ oxidation technology, thereby providing an effective means for preparing gold-ceramic heterogeneous components.

Description

Technical Field

[0001] This invention belongs to the field of advanced manufacturing technology, and more specifically, relates to a laser-directed energy deposition additive manufacturing apparatus and method for metal-ceramic heterogeneous components. Background Technology

[0002] In the field of additive manufacturing, laser-directed energy deposition (LDED) technology, with its advantage of using a high-energy laser beam to achieve rapid and precise localized heating control, has become an important technology for the direct manufacturing and repair of metal parts. This technology uses metal powder as raw material and precisely controls a high-speed laser beam as a heat source, directly acting on the powder and substrate surfaces. This efficiently converts laser energy into heat energy, causing the metal powder to rapidly melt and form a stable molten pool. As the heat source moves continuously along a preset path, the molten pool cools and solidifies, stacking layer by layer to ultimately achieve the precise construction of complex three-dimensional metal structures.

[0003] However, with the increasing demands on component performance in high-end equipment fields such as aerospace and nuclear industry, single materials are no longer sufficient to meet the multifunctional requirements under complex service conditions. Metal-ceramic heterogeneous composite components have become a research hotspot due to their combination of the toughness of metals and the high-temperature strength and wear resistance of ceramics. However, the thermophysical properties of metals and ceramics differ significantly, posing the following technical challenges during additive manufacturing: firstly, the interface bonding problem, as the poor wettability between metals and ceramics easily leads to the formation of unfused or brittle interface reaction layers; secondly, the thermal stress problem, where the mismatch in thermal expansion coefficients during cooling can easily cause component cracking.

[0004] To overcome the aforementioned technical bottlenecks, subsequent heat treatment is typically used to improve microstructure and properties. However, this method prolongs the production cycle, increases process complexity, and fails to achieve precise control over interfacial reactions. Therefore, exploring and developing novel multi-material laser-directed energy deposition devices to achieve integrated molding and microstructure and property control of metal-ceramic heterostructures has become a key technical problem urgently needing to be solved in the current additive manufacturing field. Summary of the Invention

[0005] To address the aforementioned deficiencies or improvement needs of existing technologies, this invention provides a laser-directed energy deposition additive manufacturing apparatus and method for metal-ceramic heterogeneous components. This addresses the challenge of additive manufacturing of existing metal-ceramic heterogeneous composite components due to the significant differences in the thermophysical properties of the metal and ceramic. By introducing an auxiliary laser head driven by an independent multi-axis motion mechanism, flexible in-situ heat treatment can be achieved. Combined with in-situ oxygen supply technology, this solves the problems of interface control and thermal stress control in the integrated direct forming of metal-ceramic heterogeneous components, providing strong support for the application of additive manufacturing technology in the field of metal-ceramic composite component manufacturing.

[0006] To achieve the above objectives, according to one aspect of the present invention, a laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components is provided, comprising a sealed housing, a first multi-axis motion mechanism, a second multi-axis motion mechanism, a main laser emitting system, an auxiliary laser emitting system, a powder feeding system, an in-situ oxygen supply system, and a substrate; the sealed housing provides a sealed molding environment; the main laser emitting system includes a main laser head, and the auxiliary laser emitting system includes an auxiliary laser head; the first multi-axis motion mechanism is disposed inside the sealed housing and is used to drive the main laser head to perform multi-degree-of-freedom motion; the second multi-axis motion mechanism is disposed inside the sealed housing and is used to drive the auxiliary laser head to perform multi-degree-of-freedom motion; The powder feeding system is used to transport raw material powder, and the substrate is used to carry the raw material powder for deposition molding. The powder feeding system and the in-situ oxygen supply system are respectively connected to the first multi-axis motion mechanism or the second multi-axis motion mechanism. The auxiliary laser head is used to selectively perform in-situ heat treatment on the deposition component during the manufacturing process. The in-situ oxygen supply system is used to selectively spray oxygen into the deposition component during the manufacturing process to oxidize it in-situ to form an oxide phase and improve the bonding performance.

[0007] According to the laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components provided by the present invention, the powder feeding system includes a powder feeding nozzle and a multi-bin powder feeder. The multiple powder feeding nozzles are connected to the first multi-axis motion mechanism, uniformly arranged around the main laser head, and respectively connected to the multi-bin powder feeder. The powder feeding nozzles face the irradiation direction of the main laser head to accurately deliver the raw material powder to the main laser action area. The multi-bin powder feeder is used to realize the real-time switching or mixed delivery of multiple raw material powders.

[0008] According to the laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components provided by the present invention, the in-situ oxygen supply system includes an oxygen cylinder, a flow controller, and an oxygen nozzle; multiple oxygen nozzles are respectively connected to the oxygen cylinder and the flow controller is provided on the connection path; multiple oxygen nozzles are connected to the first multi-axis motion mechanism and are evenly arranged around the main laser head; the oxygen nozzles face the irradiation direction of the main laser head and are used to spray oxygen into the main laser action area.

[0009] According to the laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components provided by the present invention, the main laser head is connected to the first multi-axis motion mechanism via a mounting base, the powder feeding nozzle and the oxygen nozzle are respectively connected to the mounting base, a plurality of oxygen nozzles are arranged around the powder feeding nozzle, and the bottoms of the main laser head, the powder feeding nozzle and the oxygen nozzle are arranged sequentially at a lower position.

[0010] According to the laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterostructures provided by the present invention, the outlet of the oxygen nozzle is a micro-pore array or a continuous annular slit uniformly distributed along the circumference, used to spray oxygen toward the molten pool region to participate in the molten pool reaction to generate an oxide-reinforced phase.

[0011] The laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterostructures provided by the present invention further includes a substrate rotary table and a control system. The substrate rotary table is rotatably installed inside the sealed housing and is used to support the substrate. The control system is connected to the first multi-axis motion mechanism, the second multi-axis motion mechanism, the main laser head, the auxiliary laser head, the powder feeding system, the in-situ oxygen supply system, and the substrate rotary table respectively, and is used to control the coordinated operation of each component. And / or, it also includes a protective gas cylinder, an oxygen sensor, and a pressure sensor, wherein the protective gas cylinder is connected to the sealed housing and is used to fill the sealed housing with inert gas; the oxygen sensor and the pressure sensor are located inside the sealed housing.

[0012] According to another aspect of the present invention, a method for laser-directed energy deposition additive manufacturing of gold-ceramic heterostructures is provided, based on the laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterostructures described in any one of the preceding claims, the method comprising: A model of a heterogeneous metal-ceramic component is obtained and layered. The model is divided into a metal region, a transition region, and a ceramic region. The transition region is located between the metal region and the ceramic region and is a mixed region of metal and ceramic materials. In an inert atmosphere, deposition is carried out layer by layer according to the layering results of the gold-ceramic heterogeneous component model; in the manufacturing of the metal region, an auxiliary laser head is used for in-situ following heat treatment; in the manufacturing of the metal region and the transition region, an in-situ oxygen supply system is used for in-situ oxidation treatment respectively.

[0013] According to the laser-directed energy deposition additive manufacturing method for gold-ceramic heterogeneous components provided by the present invention, the transition region is set as a gradient transition region, in which the proportion of metal material decreases layer by layer from the side closer to the metal region to the side closer to the ceramic region, and the proportion of ceramic material increases accordingly.

[0014] According to the laser-directed energy deposition additive manufacturing method for metal-ceramic heterostructures provided by the present invention, the main laser power of the metal region, the transition region and the ceramic region increases sequentially during the manufacturing process; The in-situ following heat treatment specifically involves controlling the auxiliary laser emitted by the auxiliary laser head to maintain a 3-8mm gap with the main laser emitted by the main laser head and moving synchronously.

[0015] According to the laser-directed energy deposition additive manufacturing method for gold-ceramic heterogeneous components provided by the present invention, an in-situ oxygen supply system is activated when manufacturing the metal region and the transition region, and the oxygen flow rate in the metal region is greater than that in the transition region.

[0016] In summary, compared with the prior art, the laser-directed energy deposition additive manufacturing apparatus and method for gold-ceramic heterogeneous components provided by the present invention offer the following advantages: 1. This invention achieves integrated "deposition-heat treatment" manufacturing of metal-ceramic heterogeneous components through a dual-laser system consisting of a main laser and an independently moving auxiliary laser. The auxiliary laser is driven by an independent multi-axis motion mechanism, which can flexibly adjust the heat treatment position and angle according to the component's geometric characteristics and thermal history, without being limited by the main processing head's movement trajectory. This allows for effective control of the interface reaction layer thickness, reducing thermal stress and preventing cracking. Introducing in-situ oxygen supply technology into traditional LDED devices allows for the direct injection of the required oxygen onto the deposited component to form an oxide-reinforced phase. This not only enhances the strength and high-temperature performance of the metal layer but also forms a transition layer at the metal-ceramic interface, improving wettability and bonding strength. Furthermore, it enables interface control and thermal stress management during the deposition and manufacturing process of metal-ceramic heterogeneous components, facilitating integrated molding manufacturing. 2. This invention integrates the main laser emission system, powder feeding system, and in-situ oxygen supply system into a single main processing head. Combined with the first multi-axis motion mechanism, it achieves continuous and seamless connection from powder conveying to melting and deposition, thereby improving manufacturing efficiency and reducing process complexity. The substrate rotary table and the multi-axis motion mechanism in this invention work together to facilitate the additive manufacturing of complex rotating components. 3. The auxiliary laser independent motion system in this invention has high flexibility and adaptability. It can move flexibly inside the sealed box without interfering with the main laser head, which makes it easy to dynamically adjust the heat treatment strategy according to the state of the deposited layer. For example, it can perform synchronous heat treatment with the main laser, or perform fixed-point or scanning heat treatment on the deposited area independently, providing strong support for the precise manufacturing of complex curved surfaces, multi-material gradient components and large components. The model for gold-ceramic heterogeneous components designed for laser deposition additive manufacturing includes a metal region, a transition region, and a ceramic region. By setting a transition region that mixes metal and ceramic materials, it is beneficial to improve the gold-ceramic bonding performance of the gold-ceramic heterogeneous components through material mixing and transition, thereby increasing the success rate of integrated molding manufacturing. 4. This invention achieves metal / ceramic powder melting and deposition through a main laser, and performs flexible in-situ heat treatment on the deposited layer through an independently moving auxiliary laser. Combined with in-situ oxidation technology, it can realize high-quality composite additive manufacturing of heterogeneous materials such as IN718 high-temperature alloy and SiC ceramics, providing an effective means for preparing metal-ceramic heterogeneous components. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components according to an embodiment of the present invention.

[0018] Figure 2 for Figure 1 A schematic diagram of the top of the sealed housing shows the layout relationship between the first multi-axis motion mechanism and the second multi-axis motion mechanism.

[0019] Figure 3 for Figure 1 An enlarged schematic diagram of the main machining head shows the internal structure and airflow path of the coaxial powder feeding nozzle and the annular gas nozzle.

[0020] Figure 4 This is a schematic diagram illustrating the in-situ oxidation-assisted laser forming principle of heterogeneous gold-ceramic components according to an embodiment of the present invention.

[0021] Figure 5 This is a schematic diagram of the turbine blade component prepared in an embodiment of the present invention.

[0022] Figure 6 This is a schematic diagram of the turbine disk component prepared in an embodiment of the present invention.

[0023] In all the accompanying drawings, the same reference numerals are used to denote the same elements or structures, wherein: 100-Sealed housing; 110-Protective gas cylinder; 120-Oxygen sensor; 130-Gas pressure sensor; 210-Main laser head; 260-Auxiliary laser head; 310-Powder feeding nozzle; 320-Multi-hopper powder feeder; 410-Oxygen cylinder; 420-Flow controller; 430-Oxygen nozzle; 510-X1 axis guide rail; 520-Y1 axis guide rail; 530-Z1 axis guide rail; 600-Control system; 710-X2 axis guide rail; 720-Y2 axis guide rail; 730-Z2 axis guide rail; 800-Baseboard rotary table. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0025] Please see Figure 1This embodiment provides a laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components. The apparatus includes a sealed enclosure 100, a first multi-axis motion mechanism, a second multi-axis motion mechanism, a main laser emission system, an auxiliary laser emission system, a powder feeding system, an in-situ oxygen supply system, and a substrate. The sealed enclosure 100 provides a sealed molding environment. The main laser emission system includes a main laser head 210, and the auxiliary laser emission system includes an auxiliary laser head 260. The first multi-axis motion mechanism is located inside the sealed enclosure 100 and drives the main laser head 210 to perform multi-degree-of-freedom motion. The second multi-axis motion mechanism is located inside the sealed enclosure 100 and drives the auxiliary laser head 260 to perform multi-degree-of-freedom motion. The powder feeding system is used to transport raw material powder, and the substrate is used to carry the raw material powder for deposition molding. The powder feeding system and the in-situ oxygen supply system are respectively connected to the first multi-axis motion mechanism or the second multi-axis motion mechanism. The auxiliary laser head 260 is used to selectively perform in-situ heat treatment on the deposition component during the manufacturing process. The in-situ oxygen supply system is used to selectively spray oxygen into the deposition component during the manufacturing process to oxidize it in-situ to form an oxide phase and improve the interfacial bonding performance.

[0026] In this embodiment, the main laser emitting system emits a main laser through the main laser head 210 for component deposition and forming, while the auxiliary laser emitting system emits an auxiliary laser through the auxiliary laser head 260 for in-situ heat treatment to improve the thermal stress of the deposited component. The first multi-axis motion mechanism and the second multi-axis motion mechanism can be controlled independently, allowing the main laser head 210 and the auxiliary laser head 260 to move independently of each other, which is beneficial to improving process flexibility. The powder feeding system is used to transport the raw material powder required for preparation to the substrate. After the main laser irradiates and deposits the raw material powder, the deposited component can be subjected to in-situ heat treatment using the auxiliary laser head 260 as needed. For example, the metal material part of the gold-ceramic heterogeneous component can be subjected to in-situ heat treatment, which is beneficial to improve the thermal stress problem in the deposited component and reduce the risk of component cracking, thereby improving the success rate of integral molding of gold-ceramic heterogeneous components.

[0027] Furthermore, this embodiment proposes to set up an in-situ oxygen supply system for selectively injecting oxygen during the component forming process. For example, during the forming of the metal material portion of the gold-ceramic heterogeneous component, oxygen can be simultaneously injected for in-situ oxidation, forming an oxide-reinforcing phase. This oxide-reinforcing phase is beneficial for improving the bonding performance between the metal and ceramic materials, thereby facilitating the integrated molding manufacturing of the gold-ceramic heterogeneous component. The main laser emission system and the auxiliary laser emission system also include other conventional components for realizing laser emission, which will not be described in detail here.

[0028] In some embodiments, the powder feeding system includes powder feeding nozzles 310 and multi-bin powder feeders 320. Multiple powder feeding nozzles 310 are connected to the first multi-axis motion mechanism, uniformly arranged around the main laser head 210, and respectively connected to the multi-bin powder feeders 320. The powder feeding nozzles 310 face the irradiation direction of the main laser head 210 to accurately deliver the raw material powder to the main laser action area. The multi-bin powder feeder 320 is used to realize real-time switching or mixed delivery of multiple raw material powders. For example, a gold-ceramic heterogeneous component is prepared from IN718 alloy powder and SiC ceramic powder. The multi-bin powder feeder 320 can realize real-time switching or mixed delivery of multiple materials such as IN718 high-temperature alloy powder and SiC ceramic powder. The raw material powder is sprayed into the main laser irradiation area through the powder feeding nozzles 310 for deposition and molding.

[0029] In some embodiments, the in-situ oxygen supply system includes an oxygen cylinder 410, a flow controller 420, and oxygen nozzles 430. Multiple oxygen nozzles 430 are respectively connected to the oxygen cylinder 410, and the flow controller 420 is provided along the connection path. The oxygen cylinder 410 can be connected to an outlet pipeline, on which the flow controller 420 is provided to control the total oxygen flow. The outlet pipeline can pass through a sealed housing 100 and connect to a first multi-axis motion mechanism, and multiple oxygen nozzles 430 are provided at the outlet to achieve uniform oxygen injection. Multiple oxygen nozzles 430 are connected to the first multi-axis motion mechanism and are evenly distributed around the main laser head 210. The oxygen nozzles 430 face the irradiation direction of the main laser head 210 and are used to inject oxygen into the main laser's active area.

[0030] In some embodiments, reference Figure 3 The main laser head 210 is connected to the first multi-axis motion mechanism via a mounting base. The powder feeding nozzle 310 and the oxygen nozzle 430 are respectively connected to the mounting base. Multiple oxygen nozzles 430 are arranged around the powder feeding nozzle 310, with the bottoms of the main laser head 210, the powder feeding nozzle 310, and the oxygen nozzles 430 arranged sequentially towards the bottom. That is, the bottoms of the main laser head 210, the powder feeding nozzle 310, and the oxygen nozzles 430 are arranged sequentially away from the mounting base, which helps to avoid mutual interference.

[0031] In some embodiments, the outlet of the oxygen nozzle 430 is an array of micropores uniformly distributed along the circumference or a continuous annular slit, used to inject oxygen toward the molten pool region to participate in the molten pool reaction to generate an oxide-reinforced phase. This configuration facilitates uniform oxygen injection, thereby enabling better contact and reaction with the deposited metal material to generate the oxide-reinforced phase; it also facilitates oxygen dispersion to avoid interfering with the raw material powder ejected from the powder feeding nozzle 310.

[0032] In some embodiments, reference Figure 2The first multi-axis motion mechanism includes an X1-axis guide rail 510, a Y1-axis guide rail 520, a Z1-axis guide rail 530, and corresponding drive motors; it adopts a gantry or cantilever structure and is used to drive the main machining head to perform high-precision three-dimensional motion. The first multi-axis motion mechanism uses an XYZ three-axis guide rail structure to drive the integrated main machining head to perform three-dimensional linear motion; the main machining head is mounted on the slider of the Z1-axis guide rail 530 of the first multi-axis motion mechanism and integrates a main laser emission system, a coaxial powder feeding system, and an in-situ oxygen supply system. The main laser emission system includes a main laser nozzle, i.e., a main laser head 210, used to generate a high-energy laser beam to melt metal or ceramic powder. That is, the main machining head integrates a main laser head 210, a powder feeding nozzle 310, and an oxygen nozzle 430. The main machining head may include a mounting base for mounting the main laser head 210, the powder feeding nozzle 310, and the oxygen nozzle 430.

[0033] The second multi-axis motion mechanism is installed inside the sealed housing 100 and is independent of the first multi-axis motion mechanism. The second multi-axis motion mechanism includes an X2-axis guide rail 710, a Y2-axis guide rail 720, a Z2-axis guide rail 730, and corresponding drive motors. The second multi-axis motion mechanism adopts an independent XYZ three-axis guide rail structure, driving the auxiliary laser head 260 to perform independent three-dimensional linear motion, enabling flexible adjustment of the heat treatment position. The auxiliary laser emission system includes an auxiliary laser head 260, which is mounted on the slider of the Z2-axis guide rail 730 of the second multi-axis motion mechanism. Driven by the independent second multi-axis motion mechanism, its spatial position can be arbitrarily adjusted. It is used for in-situ laser heat treatment of the deposited layer, controlling interface reactions and releasing thermal stress. The irradiation position and angle of the auxiliary laser are arbitrarily adjusted in space by the independent second multi-axis motion mechanism.

[0034] The first multi-axis motion mechanism may also include turntables in multiple directions for achieving rotational motion. Specifically, the main laser head 210 can be connected to a turntable integrated in multiple directions, and the turntable is correspondingly connected to a linear guide rail (e.g., the slider of the Z1-axis guide rail 530), thereby achieving multi-dimensional linear and rotational motion. The second multi-axis motion mechanism can also include turntables in multiple directions for achieving rotational motion; the specific configuration is similar to the first multi-axis motion mechanism and will not be described again. The specific motion dimensions of the first and second multi-axis motion mechanisms can be flexibly set according to actual needs and are not specifically limited.

[0035] More preferably, the auxiliary laser head 260 achieves spatial multi-degree-of-freedom position adjustment through a second multi-axis motion mechanism, including linear motion along the X2, Y2, and Z2 axes and rotational motion around each axis, with the adjustment range covering the entire forming area. The first and second multi-axis motion mechanisms can move independently or collaboratively under the coordination of the control system 600, achieving precise spatial matching between the main laser deposition and auxiliary laser heat treatment. This enables both follow-up heat treatment during the deposition process and targeted treatment between or after deposition layers.

[0036] More preferably, the outlet angle of the oxygen nozzle 430 is adjustable to adapt to different powder materials and molten pool morphologies. Specifically, the adjustable angle of the oxygen nozzle 430 is connected to the first multi-axis motion mechanism, allowing the angle to be adjusted and fixed before deposition. The coaxial powder feeding nozzle 310 is also connected to a carrier gas source for conveying powder and forming a protective gas curtain around the powder flow to prevent the oxygen ejected from the oxygen nozzle 430 from blowing away the metal powder.

[0037] In some embodiments, the laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components further includes a substrate rotary table 800 and a control system 600. The substrate rotary table 800 is rotatably mounted inside the sealed housing 100, used to support the substrate and to achieve continuous or indexing rotation around a vertical axis. It is controlled by the control system 600 and works in conjunction with a multi-axis motion mechanism. The control system 600 is connected to the first multi-axis motion mechanism, the second multi-axis motion mechanism, the main laser head 210, the auxiliary laser head 260, the powder feeding system, the in-situ oxygen supply system, and the substrate rotary table 800, respectively, and is used to control the coordinated operation of each component. The substrate rotary table 800 is linked with the first multi-axis motion mechanism to achieve all-position machining of complex curved surface components. The control system can be a host computer.

[0038] In some embodiments, the laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components further includes a protective gas cylinder 110, an oxygen sensor 120, and a pressure sensor 130. The protective gas cylinder 110 is connected to the sealed housing 100 and is used to fill the sealed housing 100 with an inert gas such as argon or nitrogen. The oxygen sensor 120 and the pressure sensor 130 are located inside the sealed housing 100 and are used to monitor the atmosphere inside the housing in real time.

[0039] Further, refer to Figure 4 This embodiment also provides a method for laser-directed energy deposition additive manufacturing of gold-ceramic heterogeneous components, based on the laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components described in any of the above embodiments, the method comprising: A model of a heterogeneous metal-ceramic component is obtained and layered. The model is divided into a metal region, a transition region, and a ceramic region. The transition region is located between the metal region and the ceramic region and is a mixed region of metal and ceramic materials. In an inert atmosphere, deposition is carried out layer by layer according to the layering results of the gold-ceramic heterogeneous component model; in the manufacturing of the metal region, an auxiliary laser head 260 is used for in-situ following heat treatment; in the manufacturing of the metal region and the transition region, an in-situ oxygen supply system is used for in-situ oxidation treatment respectively.

[0040] In some embodiments, the transition region is configured as a gradient transition region, wherein the proportion of metal material decreases layer by layer from the side closer to the metal region to the side closer to the ceramic region, and the proportion of ceramic material increases accordingly. The thickness of each layer in the transition region can be 0.3-0.5 mm.

[0041] For example, the gold-ceramic heterogeneous component can be an integral bladed disk of an engine, in which the disk body and disk core are printed using IN718 high-temperature alloy, while the blades and outer edge of the disk are printed using SiC ceramic. The two form a heterogeneous bonding interface in the radial transition region. The transition region can be set as 10 deposition layers, each with a thickness of 0.4 mm; the proportion of IN718 powder and SiC powder in the transition region gradually changes.

[0042] The gold-ceramic heterogeneous component can also be an IN718 / SiC heterogeneous turbine disk component for engines, wherein the hub and disk center (radius 0-50mm) are printed with IN718 high-temperature alloy, and the rim and tenon area (radius greater than 70mm) are printed with SiC ceramic; a radial gradient transition zone (radius 50-70mm, a total of 50 layers are deposited, which is set as 50 deposition layers, each layer with a thickness of 0.4mm) is set between the hub and the rim.

[0043] In some embodiments, during the manufacturing process, the main laser power in the metal region, transition region, and ceramic region increases sequentially; the scanning speed decreases sequentially; and the powder feeding rate decreases sequentially. In some optional embodiments, the main laser power in the metal region is 800-1000W, the scanning speed is 7-9mm / s, and the powder feeding rate is 7-9g / min; the main laser power in the ceramic region is 900-1100W, the scanning speed is 5-7mm / s, and the powder feeding rate is 5-7g / min; and the main laser power in the transition region is 850-1050W, the scanning speed is 6-8mm / s, and the powder feeding rate is 6-8g / min (for mixed powder).

[0044] The in-situ following heat treatment specifically involves controlling the auxiliary laser emitted by the auxiliary laser head 260 to maintain a 3-8mm gap with the main laser emitted by the main laser head 210, thus synchronously following each other's movements. In some optional embodiments, the power of the in-situ following heat treatment is 200-400W.

[0045] In some embodiments, an in-situ oxygen supply system is activated during the manufacturing of the metal zone and the transition zone, with the oxygen flow rate in the metal zone being greater than that in the transition zone. Optionally, the in-situ oxygen supply system is activated in the metal zone at an oxygen flow rate of 0.08-0.12 L / min to generate a nanoscale oxide reinforcing phase in the molten pool; the oxygen flow rate in the transition zone is 0.03-0.07 L / min. It is evident that the oxygen introduced by the in-situ oxidation process is trace and does not affect the overall environmental atmosphere inside the sealed enclosure 100.

[0046] The following is a specific application example, Example 1: refer to Figure 5 This embodiment addresses a heterogeneous component of an integral bladed disk for an aero-engine. The disk body and center are printed using IN718 high-temperature alloy, while the blades and outer edge of the disk are printed using SiC ceramic. A heterogeneous bonding interface is formed between the two in the radial transition region. Additive manufacturing using the apparatus of this invention includes the following steps: S1: Fix the integral bladed disk special base plate onto the base plate rotating stage 800 and close the sealed box 100. Fill the box with high-purity argon gas through the protective gas cylinder 110 and control the oxygen content in the box to below 50ppm through the oxygen sensor 120.

[0047] S2: Import the overall bladed disk 3D model into the control system 600, and preset material partitions in the model: the disk body (radius 0-40mm) is the IN718 material area; the blades and outer edge of the disk (radius greater than 40mm) are the SiC material area; a radial gradient transition zone (radius 38-42mm, 10 layers deposited, each layer 0.4mm thick) is set between the two areas. In the transition zone, the proportion of IN718 powder decreases from 100% to 0% layer by layer, and the proportion of SiC powder increases accordingly.

[0048] S3: Set the main laser process parameters: IN718 region main laser power 900W, scanning speed 8mm / s, powder feed rate 8g / min; SiC region main laser power 1000W, scanning speed 6mm / s, powder feed rate 6g / min; gradient transition region main laser power 950W, scanning speed 7mm / s, powder feed rate 7g / min (mixed powder). Set the motion path of the first multi-axis motion mechanism to a layer-by-layer circular scanning trajectory with a layer thickness of 0.4mm.

[0049] S4: Set auxiliary laser process parameters: IN718 region follows the heat treatment power of 300W; SiC region does not follow the heat treatment. Set the motion path of the second multi-axis motion mechanism so that it moves synchronously with the main laser at a 5mm distance when depositing the IN718 region; the auxiliary laser remains in standby state when depositing the transition region and SiC region.

[0050] S5: Based on the material zoning, set the in-situ oxygen supply parameters: In zone IN718, activate the in-situ oxygen supply system with an oxygen flow rate of 0.10 L / min to generate nanoscale oxide reinforcement phases in the molten pool; in the gradient transition zone, activate a low-flow oxygen supply (0.05 L / min); in zone SiC, deactivate the in-situ oxygen supply system. The control system 600 automatically controls the opening and closing of the oxygen valves and adjusts the flow rate according to the current deposition layer region.

[0051] S6: Set the substrate rotary table 800 to rotate continuously and uniformly during the deposition process, and link it with the first multi-axis motion mechanism to realize the rotary deposition of the entire bladed disk.

[0052] S7: The coaxial powder feeding system and main laser emission system are activated. The first multi-axis motion mechanism moves in coordination with the substrate rotary table 800 to begin depositing the IN718 layer of the main body of the deposition wheel. During deposition, the in-situ oxygen supply system remains on (0.10L / min), and the auxiliary laser performs follow-up heat treatment on the newly deposited area at a power of 300W to eliminate residual stress. Deposition continues layer by layer until the initial height of the transition zone is reached.

[0053] S8: Enter the gradient transition zone deposition. The powder feeder mixes IN718 and SiC powders according to a preset ratio. The main laser deposits the transition layer at a power of 950W, and the in-situ oxygen supply system supplies oxygen at a low flow rate of 0.05L / min. During the transition zone deposition process, the auxiliary laser remains on standby and does not undergo heat treatment. This process is repeated until 10 transition layer layers are deposited.

[0054] S9: After the transition layer is completed, the in-situ oxygen supply system is shut down, the powder feeder is switched to pure SiC powder, the main laser power is increased to 1000W, and the scanning speed is reduced to 6mm / s. The blades and outer edge of the disk are deposited layer by layer. During the deposition process, the auxiliary laser remains on standby and is not subjected to heat treatment.

[0055] S10: After manufacturing is complete, shut down all systems, fill the chamber with argon gas to accelerate cooling, and remove the workpiece after it has cooled to room temperature.

[0056] Example 2 refer to Figure 6 This embodiment targets an IN718 / SiC heterogeneous turbine disk component for aero-engines. The hub and disk center (radius 0-50mm) are printed using IN718 high-temperature alloy to withstand high centrifugal loads and meet low-cycle fatigue performance requirements. The rim and tenon area (radius greater than 70mm) are printed using SiC ceramic to utilize SiC's high-temperature strength, low density, and high wear resistance to meet the high-temperature durability and wear resistance requirements of the rim. A radial gradient transition zone (radius 50-70mm, 50 layers deposited, each layer 0.4mm thick) is set between the hub and rim. Within the transition zone, the proportion of IN718 powder decreases layer by layer from 100% to 0%, while the proportion of SiC powder increases accordingly to achieve a smooth performance transition. Additive manufacturing using the apparatus of this invention includes the following steps: S1: Fix the IN718 substrate onto the substrate rotation stage 800 and close the sealed enclosure 100. Fill the enclosure with high-purity argon gas through the protective gas cylinder 110 and control the oxygen content in the enclosure to below 50 ppm through the oxygen sensor 120.

[0057] S2: Import the turbine disk 3D model into the control system 600, and preset material partitions in the model: the hub and disk center (radius 0-50mm) is the IN718 material area; the rim and tenon area (radius greater than 70mm) is the SiC material area; a radial gradient transition zone (radius 50-70mm, 50 layers deposited, each layer 0.4mm thick) is set between the two areas. In the transition zone, the proportion of IN718 powder decreases from 100% to 0% layer by layer, and the proportion of SiC powder increases accordingly.

[0058] S3: Set the main laser process parameters: IN718 region main laser power 900W, scanning speed 8mm / s, powder feed rate 8g / min; SiC region main laser power 1000W, scanning speed 6mm / s, powder feed rate 6g / min; gradient transition region main laser power 950W, scanning speed 7mm / s, powder feed rate 7g / min (mixed powder). Set the motion path of the first multi-axis motion mechanism to a layer-by-layer circular scanning trajectory with a layer thickness of 0.4mm.

[0059] S4: Set auxiliary laser process parameters: IN718 region follows the heat treatment power of 300W; SiC region does not follow the heat treatment; transition region does not follow the heat treatment. Set the motion path of the second multi-axis motion mechanism so that it moves synchronously with the main laser at a 5mm distance when depositing the IN718 region; the auxiliary laser remains in standby state when depositing the transition region and SiC region.

[0060] S5: Based on material zoning, set the in-situ oxygen supply parameters: In zone IN718, activate the in-situ oxygen supply system with an oxygen flow rate of 0.10 L / min to generate nanoscale oxide reinforcing phases in the molten pool, improving the high-temperature strength and fatigue resistance of the hub area; in the gradient transition zone, activate a low-flow oxygen supply (0.05 L / min); in zone SiC, deactivate the in-situ oxygen supply system. The control system 600 automatically controls the opening and closing of the oxygen valves and adjusts the flow rate according to the current deposition layer region.

[0061] S6: Set the substrate rotary table 800 to rotate continuously at a constant speed during the deposition process, and link it with the first multi-axis motion mechanism to realize continuous rotary deposition of the turbine disk.

[0062] S7: The coaxial powder feeding system and main laser emission system are activated. The first multi-axis motion mechanism works in tandem with the substrate rotary table 800 to begin depositing the hub and disc center IN718 layers. During deposition, the in-situ oxygen supply system remains on (0.10L / min), and the auxiliary laser performs follow-up heat treatment on the newly deposited area at a power of 300W to eliminate residual stress. Deposition continues layer by layer until the initial radius of the transition zone (50mm) is reached.

[0063] S8: Enter the gradient transition zone deposition. The powder feeder mixes IN718 and SiC powders according to a preset ratio. The main laser deposits the transition layer at a power of 950W, and the in-situ oxygen supply system supplies oxygen at a low flow rate of 0.05L / min. During the transition zone deposition process, the auxiliary laser remains on standby and does not undergo heat treatment. This process is repeated until 50 transition layer layers are deposited, at which point the radius reaches 70mm, the IN718 ratio decreases to 0%, and the SiC ratio increases to 100%.

[0064] S9: After the transition layer is completed, the in-situ oxygen supply system is shut down, the powder feeder is switched to pure SiC powder, the main laser power is increased to 1000W, and the scanning speed is reduced to 6mm / s. The rim and tenon groove areas are deposited layer by layer. During the deposition process, the auxiliary laser remains on standby and no heat treatment is performed.

[0065] S10: After manufacturing is complete, shut down all systems, fill the chamber with argon gas to accelerate cooling, and remove the workpiece after it has cooled to room temperature.

[0066] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components, characterized in that, The system includes a sealed enclosure, a first multi-axis motion mechanism, a second multi-axis motion mechanism, a main laser emitting system, an auxiliary laser emitting system, a powder feeding system, an in-situ oxygen supply system, and a substrate. The sealed enclosure provides a sealed molding environment. The main laser emitting system includes a main laser head, and the auxiliary laser emitting system includes an auxiliary laser head. The first multi-axis motion mechanism is located inside the sealed enclosure and is used to drive the main laser head to perform multi-degree-of-freedom motion. The second multi-axis motion mechanism is located inside the sealed enclosure and is used to drive the auxiliary laser head to perform multi-degree-of-freedom motion. The powder feeding system is used to transport raw material powder, and the substrate is used to carry the raw material powder for deposition molding. The powder feeding system and the in-situ oxygen supply system are respectively connected to the first multi-axis motion mechanism or the second multi-axis motion mechanism. The auxiliary laser head is used to selectively perform in-situ heat treatment on the deposition component during the manufacturing process. The in-situ oxygen supply system is used to selectively spray oxygen into the deposition component during the manufacturing process to oxidize it in-situ to form an oxide phase and improve the bonding performance.

2. The laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components as described in claim 1, characterized in that, The powder feeding system includes powder feeding nozzles and a multi-bin powder feeder. Multiple powder feeding nozzles are connected to the first multi-axis motion mechanism, evenly arranged around the main laser head, and respectively connected to the multi-bin powder feeder. The powder feeding nozzles face the irradiation direction of the main laser head to accurately deliver the raw material powder to the main laser action area. The multi-bin powder feeder is used to realize the real-time switching or mixed delivery of multiple raw material powders.

3. The laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components as described in claim 2, characterized in that, The in-situ oxygen supply system includes an oxygen cylinder, a flow controller, and oxygen nozzles; multiple oxygen nozzles are respectively connected to the oxygen cylinder and the flow controller is provided on the connection path; multiple oxygen nozzles are connected to the first multi-axis motion mechanism and are evenly arranged around the main laser head; the oxygen nozzles face the irradiation direction of the main laser head and are used to spray oxygen into the main laser action area.

4. The laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components as described in claim 3, characterized in that, The main laser head is connected to the first multi-axis motion mechanism via a mounting base. The powder feeding nozzle and the oxygen nozzle are respectively connected to the mounting base. Multiple oxygen nozzles are arranged around the powder feeding nozzle, and the bottoms of the main laser head, the powder feeding nozzle, and the oxygen nozzles are arranged sequentially downwards.

5. The laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components as described in claim 3, characterized in that, The outlet of the oxygen nozzle is a uniformly distributed array of micropores or a continuous annular slit, used to spray oxygen toward the molten pool region to participate in the molten pool reaction and generate an oxide-reinforced phase.

6. The laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterogeneous components as described in any one of claims 1-5, characterized in that, It also includes a substrate rotary table and a control system. The substrate rotary table is rotatably installed inside the sealed housing to support the substrate. The control system is connected to the first multi-axis motion mechanism, the second multi-axis motion mechanism, the main laser head, the auxiliary laser head, the powder feeding system, the in-situ oxygen supply system, and the substrate rotary table respectively, and is used to control the coordinated operation of each component. And / or, it also includes a protective gas cylinder, an oxygen sensor, and a pressure sensor, wherein the protective gas cylinder is connected to the sealed housing and is used to fill the sealed housing with inert gas; the oxygen sensor and the pressure sensor are located inside the sealed housing.

7. A method for laser-directed energy deposition additive manufacturing of gold-ceramic heterogeneous components, characterized in that, The laser-directed energy deposition additive manufacturing apparatus for gold-ceramic heterostructures according to any one of claims 1-6, the method comprising: A model of a heterogeneous metal-ceramic component is obtained and layered. The model is divided into a metal region, a transition region, and a ceramic region. The transition region is located between the metal region and the ceramic region and is a mixed region of metal and ceramic materials. In an inert atmosphere, deposition is carried out layer by layer according to the layering results of the gold-ceramic heterogeneous component model; in the manufacturing of the metal region, an auxiliary laser head is used for in-situ following heat treatment; in the manufacturing of the metal region and the transition region, an in-situ oxygen supply system is used for in-situ oxidation treatment respectively.

8. The laser-directed energy deposition additive manufacturing method for gold-ceramic heterogeneous components as described in claim 7, characterized in that, The transition zone is designated as a gradient transition zone, with the proportion of metal material decreasing layer by layer from the side closer to the metal zone to the side closer to the ceramic zone, and the proportion of ceramic material increasing accordingly.

9. The laser-directed energy deposition additive manufacturing method for gold-ceramic heterogeneous components as described in claim 7, characterized in that, During the manufacturing process, the main laser power increases sequentially in the metal region, transition region, and ceramic region. The in-situ following heat treatment specifically involves controlling the auxiliary laser emitted by the auxiliary laser head to maintain a 3-8mm gap with the main laser emitted by the main laser head and moving synchronously.

10. The laser-directed energy deposition additive manufacturing method for gold-ceramic heterogeneous components as described in claim 7, characterized in that, The in-situ oxygen supply system is activated during the manufacturing of the metal zone and the transition zone, with the oxygen flow rate in the metal zone being greater than that in the transition zone.

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