1390 results about "Selective laser melting" patented technology

An additive manufacturing process (110) wherein a powder (116) including a superalloy material and flux is selectively melted in layers with a laser beam (124) to form a superalloy component (126). The flux performs a cleaning function to react with contaminants to float them to the surface of the melt to form a slag. The flux also provides a shielding function, thereby eliminating the need for an inert cover gas. The powder may be a mixture of alloy and flux particles, or it may be formed of composite alloy/flux particles.

In a method for manufacturing an article (1), particularly a prototype of a product or component, a tool prototype or spare part, by using selected laser melting, for the application onto the article (1) of a layer (13) or portion of a second metallic material, which is different from the material of the first metallic powder (4), a tape (12), sheet (14), foil or three-dimensional pre-form (18) of a second material is applied to the article (1) and is heated by a focused laser or electron beam (6) to a specified temperature such that the tape (12), sheet (14), foil or pre-form, respectively, are made molten by the electron laser beam (6), wherein the focused beam (6) is applied to a given area corresponding to a selected cross-sectional area of the model of the article (1) under formation of a new layer or part made of second material integral with the article (1).

A design method of an easily-removable support structure for SLM-manufactured metal parts is applied to the design of supports for the structures such as suspended planes and surfaces in the process of producing metal parts by SLM (selective laser melting), so that the surfaces can be formed, and stability of the structures on the surfaces and forming quality can meet the technical requirements. A meshed thin-walled structure support is designed by the design method; a saw-toothed structure is designed at the connection of a support and a solid body. The meshed thin-walled structure support has the advantages that weight of the support and even consumption of powder are decreased; forming strength of the support suspended surfaces is met, and the support is easy to remove by mechanical methods; manufacturing time of the support is shortened, and efficiency is improved. The saw-toothed structure has the advantages that strength of the connection of the support with the solid body is decreased, and the influence of many supports upon the surface quality of the formed surfaces after removal is avoided. The support structure is easy to impellent and to produce and is easy to remove during the post-treatment process, the surface roughness of the support faces can be minimized, and the design method is suitable for mass production.

The invention discloses a laser additive manufacturing method and a laser additive manufacturing device of metal parts. In the laser additive manufacturing method, a layered-manufactured profile-followed cylinder is used as a forming cylinder, namely before each metal part layer is manufactured, a layer of closed thin wall is manufactured, the formed cavity is used as the profile-followed cavity, the height of the profile-followed cavity is the same as that of the metal part layer to be manufactured, and the shape of the profile-followed cavity is adapted to that of the metal part layer to be manufactured, so as to provide a plane reference and a cavity for laying powder; the layered-manufactured profile-followed cylinder is used, a scanning galvanometer is used for performing selective laser melting and forming, the metal part layers are manufactured layer by layer, layers of the profile-followed cavities are finally stacked to form the profile-followed cylinder, and the layers of metal parts are stacked to form metal parts. The laser additive manufacturing device comprises a laser galvanometer melting and forming device and a thin wall preparation device which alternatively work, so as to accomplish the selective laser melting and forming process. The method and the device keep the advantages of the selective laser melting (SLM) metal additive manufacturing technology, uses the profile-followed cylinder to break the limit of the conventional SLM device fixed-size forming cylinder, and thus achieving the high-precision manufacture of the large-size even over-sized parts.

The invention provides a method for preparing parts with high-melting point metal powder and the method combines selective laser fusion rapid prototyping technology with powder sintering and forming technology. The method comprises the following steps: firstly, a three-dimensional modeling software is used to design the CAD models of parts, secondly, a slice processing software is used to generate multilayer slice information to be stored as STL files, the data of the STL files are transmitted to a selective laser melting rapid forming system; then in the selective laser melting rapid forming system, a layer of powder to be processed with the thickness of 0.05-0.2mm is laid on a platform by a powder-sending mechanism, a YAG laser or optical fiber laser with the laser power of more than 200W is used to scan the powder to be processed in a scanning speed of 20-300mm/s; and finally the powder is molten to accumulate the parts. The method does not need moulds and is characterized in that the technology has high controllability, does not adopt post-processing, is simple and practical and can be used to prepare parts with complicated shapes.

A technology for manufacturing a part by proximal forming method includes such steps as inputting the 3D model of a part to a fast SLM or SLS machine, vacuumizing the shaping chamber of SLM or SLS machine, using laser to scan the metal powder outside the boundary for smelting it, scan the metal powder inside the boundary to form mesh structure, forming a compact shell sealed part, and HIP processing.

The invention discloses a numerical simulation method for a selective laser melting process. The method comprises a first step of establishment of a finite element model of additive manufacturing process simulation; a second step of meshing on the finite element model of the additive manufacturing process, wherein full-hexahedron meshing is adopted; a third step of definition of printing powder material properties and thermal physical performance parameters which must be determined for temperature field analysis in the additive manufacturing process; a fourth step of loading of a control equation of a mobile heat source; and a fifth step of analysis of thermal stress field and total deformation changes in the additive manufacturing process and after sintering is finished. Through the numerical simulation method for the selective laser melting process, printing parameters can be optimized, and warping and deformation of parts can be prevented; and the method provides effective guidancefor supporting structural design and a printing strategy (speed and direction), lowering the rejection rate and realizing ''success at a time''.

A heat sink for cooling a heat generating device comprises a body part with a first surface for contacting the heat generating device, and a second surface contacting a cooling part, and the cooling part including a cooling structure. The structure density of the cooling structure decreases with increasing distance to body part. The cooling structure may be a three dimensional structure e.g. a grid or a lattice, but the cooling structure may also be fins projecting or extending from the second surface of the body part. The heat sink can be manufactured using additive manufacturing e.g. selective laser melting process (SLM). The heat sink can be made of metals e.g. aluminum, copper, ceramics e.g. aluminium nitride (AlN), silicon carbide or a composite containing graphite, graphene or carbon nanotubes.

The invention discloses a method for preparing a composite powder for 3D printing, and belongs to the technical field of material additive manufacturing. The method comprises the following steps: S1, executing mechanical mixing on a metal matrix phase powder and a nano-ceramic strengthening phase powder to obtain a mixed powder; and S2, executing a ball-milling process on the mixed powder to obtain an alloyed powder, wherein a ball-milling medium used in ball-milling is spherical and has a diameter of 6-10mm, a ball-to-powder ratio is 8: 1 to 10: 1, a distance from a ball-milling tank to a rotary centre is 15-30cm, a rotational speed is 150-200rpm, a ball-milling time is 6-8h, and the composite powder is obtained. The invention further provides a method for using the composite powder prepared by the above-mentioned method for 3D printing forming for parts. The composite powder prepared by the method disclosed by the invention is free from micro-cracks and the problem of supersaturated solid solution, and has no high internal stress; and the parts prepared by virtue of the composite powder disclosed by the invention through a selective laser melting forming method have good comprehensive performance.

The invention relates to a method for producing a component through selective laser melting and to a process chamber (11) for carrying out the method. According to the invention, the selective laser melting by way of a laser (17) is also used for producing coating areas (25) of the component (14) being produced, said coating areas having a composition that differs from the composition of the powder. This is accomplished by intermittently introducing a reactive gas (27) that reacts with the powder material or that produces a material on the component (14) from precursors present in the reactive gas. In the process chamber according to the invention, an additional feed line (28a, 28b) is provided for introducing reactive gas, said feed line permitting the feeding of the reactive gas if possible close to the laser (17).

The invention discloses a metal laser melting additive manufacturing method. After each layer is machined by utilizing the laser additive manufacturing method, a single-layer laser photocoagulation area is modified by utilizing a selective friction stir welding, photocoagulation cracks are eliminated and nanocrystalline is formed. Each additive-manufactured layer is subjected to laser melting and friction stir welding and multiple layers are machined by the method repeatedly, so that nanocrystalline complex metal components with high strength and ductility and no cracks are manufactured. The laser melting additive manufacturing method provided by the invention comprises a selective laser melting technique based on powder bed formation and a laser engineering near-net forming technique based on laser coaxial powder feeding, wherein the involved metal materials comprise an aluminum base, a copper base, a titanium base, an iron base, a nickel base and a cobalt base; the selective friction stir welding can eliminate cracks, balling and holes generated during laser additive manufacturing and improves the formation quality; the selective friction stir welding can crush network carbides in a laser photocoagulation structure, so that the crushed network carbides are distributed in a dispersion manner, and the structure is regulated to be the nanocrystalline.

The invention discloses an Al-Mg-Sc-Zr series aluminum alloy composition for selective laser melting technology and a preparation method for a molding part. The composition comprises, by mass, 6-15% of Mg, 0.5-4% of Sc, 0.7-3% of Zr, 0.5-2% of Mn and the balance aluminum. An aluminum alloy molding part are prepared by smelting of master alloy, preparation of metal powder, preparation of aluminum alloy molding parts and heat treatment processes. According to the elective laser melting technology, the solubility of Mg, Sc and Zr alloy elements in aluminum matrix is greatly improved, the concentration of solid solution strengthening elements and dispersion strengthening particles in the aluminum alloy is increased, and the mechanical property of the aluminum alloy is improved. According to the aluminum alloy obtained by preparation of the selective laser melting technology, the highest density is 99.8%, the highest extension strength sigma b reaches 550 MPa, the yield strength sigma0.2 reaches 520 MPa, the plastic deformation rate of about 12 % is maintained, and the Al-Mg-Sc-Zr series aluminum alloy composition for the ctive laser melting technology and the preparation method for themolding part is applied to complicated structural parts with higher mechanical properties.

The invention discloses a high-entropy alloy hot-end part manufacturing method of a turbine engine on the basis of selective laser melting and belongs to the technical field of manufacture of hot-end parts of the turbine engine. The high-entropy alloy hot-end part manufacturing method includes firstly selecting five or more of eight kinds of high-melting metal powder of tungsten, titanium, zirconium, hafnium, vanadium, niobium, tantalum and molybdenum, and mixing the powder uniformly according to a certain mole ratio to obtain high-entropy alloy powder; setting up a three-dimensional solid model of a hot-end part of the turbine engine, slicing and layering by software to obtain profile data of various sections, and importing the data into a quick forming device; quickly forming a hot-end part blank of the turbine engine by the SLM technology; thermally treating and finely processing the blank to obtain the high-temperature high-entropy alloy hot-end part of the turbine engine. The formed hot-end part of the turbine engine has high compactness and excellent high temperature performance, has high forming accuracy and surface accuracy and can be quickly and accurately manufactured.

A method for making golf club heads includes using direct metal laser sintering (DMLS), selective laser melting (SLM) and other computer controlled high energy sintering or melting techniques to form club heads with customized user parameters. The powdered metals can be selected by type and quantity to achieve a desired density or weight distribution. Club heads made by these techniques are characterized by having customized parameters chosen for individual golfers. By sintering powdered metal to form areas of different porosity, club heads with desired weight distributions can be achieved.

The invention provides a method for manufacturing a pure titanium porous structure through selective laser melting. The method for manufacturing the pure titanium porous structure through selective laser melting comprises the following steps that firstly, a three-dimensional model of the porous structure to be manufactured is built in a computer; secondly, hierarchical preprocessing is conducted on the built three-dimensional model; thirdly, 3D printing parameters are set, hierarchical processing is conducted on the three-dimensional mode, and a file of a corresponding format is saved and exported; fourthly, the exported file is imported into 3D printing equipment, and 3D printing is conducted. According to the method for manufacturing the pure titanium porous structure through selective laser melting, metal parts with various macro-structure porous structures can be manufactured according to actual requirements, one-time forming is realized, the shortcomings of unstable mechanical properties and a simplex shape caused by a traditional processing method are overcome, and processing efficiency and economic benefit are improved.

The invention discloses equipment and a method for single-cylinder type selective laser melting and milling composite processing. The equipment comprises a selective laser melting forming device, a vertical milling machine device and a central control system, wherein the vertical milling machine device is positioned in a forming chamber and comprises a chain type tool magazine, the chain type tool magazine is positioned at the right side of the exterior of the forming chamber, a laser device is positioned at the right side of the forming chamber of the selective laser melting forming device, a collimating beam expander, an optical lens and a scanning vibration lens are arranged at the top part of the forming chamber, and the optical lens is positioned at the upper part of the forming chamber, is embedded in the outer wall of the forming chamber, and is in sealed combination with the outer wall of the forming chamber. The equipment has the advantages that the size accuracy and surface quality of a forming part are improved, so the organic combination of additive manufacturing and high-accuracy milling processing is realized; by closing an automatic tool switching valve and a tool switching opening, the influence on a milling tool caused by metal powder and residual heat during laser processing is avoided, the quality of the milling tool is guaranteed, and the service life is prolonged.

The invention belongs to the technical field of additive manufacturing and discloses an online detecting and optimizing system for a selective laser melting forming defect. The online detecting and optimizing system comprises a selective laser melting manufacturing platform, an image acquisition module and a processing module; the selective laser melting manufacturing platform comprises a supporting baseplate, a forming device and a laser scanning device; the image acquisition module comprises a three-axis motion platform and a CCD camera; and the processing module comprises an image processing module and an automatic process parameter adjusting module, and the image processing module comprises an image pre-processing module, an image threshold segmentation module, a neural network identifying and counting module and the automatic process parameter adjusting module. By using the online detecting and optimizing system, the surface defect condition of every layer of a part in a selective laser melting manufacturing process can be rapidly detected on line by using a machine vision technology and a digital image processing technology, and no human eye detection limitation exists, so that the accuracy of every defect detection is guaranteed.

The invention discloses a real-time quality monitoring device and method for a selective laser melting processing process. Advantages of non-contact measurement means such as an industrial camera, aninfrared thermal imager, a high-speed camera and a photodiode are comprehensively utilized, and a set of complete monitoring method is formed. Through the on-line monitoring method combining an off-axis on-line monitoring device with a coaxial on-line monitoring device, the working condition of a printing work plane can be captured, and real-time molten pool data can also be collected. The meltingand condensation processes of metal powder can be monitored in a microcosmic manner, and a printer system and a workpiece layer-by-layer quality can also be monitored in a macroscopic manner. The industrial camera is adopted to monitor powder bed defects and printing defects, and the infrared thermal imager tracks the scanning path and captures the thermal stress; and the high-speed camera observes the geometrical morphology of a molten pool, and the photodiode captures the radiation strength of the molten pool. The process marks are made to correspond to printing process parameters, and on-line monitoring of the selective laser melting processing process can be realized more effectively.

A turbine blade having a squealer tip coupled to a radially outer end of the turbine blade that is usable in a gas turbine engine is disclosed. The squealer tip may require less cooling air and may therefore be more efficient than conventional configurations. The squealer tip may be formed from one or more materials such as oxide dispersion strengthened alloys and FeCrAl alloys. The squealer tip may be formed from a plurality of segmented tips extending radially outward and spaced apart from each other. For example, the squealer tip may be formed from two rails extending radially outward and spaced apart from each other. The two rails may be formed from outer and inner rails that each form a continuous ring. The squealer tip may be attached to the tip with a transient liquid phase bond or an additive manufacturing process, such as, a selective laser melting process.

The invention discloses a powder spreading device and a powder spreading method for selective laser melting (SLM) equipment. The device comprises a powder spreading main body, an auxiliary guide rail linear motor and an auxiliary powder spreading guide motor, wherein the auxiliary guide rail linear motor is used for driving the powder spreading main body to slide on an auxiliary powder spreading guide rail; the inside of the powder spreading main body is partitioned into three segments, namely, a cylindrical segment, a circular arc segment and a conical segment from top to bottom respectively; the cylindrical segment is a powder carrying area; a powder feeding hole is formed between the cylindrical segment and the circular arc segment; the circular arc segment is provided with a powder supply roller; a plurality of dovetail grooves are uniformly formed on the powder supply roller; the excircle of the powder supply roller is tangential to a circular arc on the upper part of the circular arc segment; the powder supply roller is driven to rotate by a servo driving motor; the conical segment is provided with a powder scraping device; the bottom of the conical segment is provided with a powder outlet; the upper end of the powder scraping device is tangential to the excircle of the powder supply roller, and the lower end of the powder scraping device extends out of the powder outlet; gaps are reserved between the lower end of the powder scraping device and the two ends of the powder outlet; the powder scraping device comprises a flexible powder scraping brush. By adopting the powder spreading device and the powder spreading method, quantitative powder supply can be realized, waste of powder is reduced, bidirectional powder spreading can be performed, the SLM molding auxiliary process time is shortened, and the SLM molding efficiency is increased.

The invention discloses a reciprocating powder laying device for selective laser melting. The reciprocating powder laying device comprises a powder laying mechanism which can lay powder in a reciprocating manner. The powder laying mechanism comprises powder laying box which can transversely move in a reciprocating manner and a partition, wherein the partition is disposed in the powder laying box, powder laying cavities are formed on two transverse sides of the partition, the lower end of the partition communicates the powder laying cavities and powder outlets below the powder laying box in an openable manner. When the powder laying box moves, the partition can transversely swing to allow the rear powder laying cavity in the advancing direction of the powder laying box to be communicated with the powder outlets. The reciprocating powder laying device has the advantages that twice powder laying is performed by one reciprocation, no idle running exists in the middle, time waste is reduced greatly, work efficiency is increased, pausing during powder laying can be avoided, and the device is suitable for large parts; an upper power feeding manner is used, compactness in structure is achieved, overall structural space is reduced greatly, circulating power feeding can be achieved, sufficient powder can be fed at one step, and powder can be saved effectively.