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CN110508809B - 一种增材制造与表面涂覆复合成形系统及方法 - Google Patents

一种增材制造与表面涂覆复合成形系统及方法 Download PDF

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CN110508809B
CN110508809B CN201910809421.1A CN201910809421A CN110508809B CN 110508809 B CN110508809 B CN 110508809B CN 201910809421 A CN201910809421 A CN 201910809421A CN 110508809 B CN110508809 B CN 110508809B
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forming
additive
coating
composite
laser
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CN110508809A (zh
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张海鸥
胡晓圻
戴福生
王桂兰
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Huazhong University of Science and Technology
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Priority to US17/005,865 priority patent/US11247392B2/en
Priority to AU2020223753A priority patent/AU2020223753B2/en
Priority to EP20193392.6A priority patent/EP3785827B1/en
Priority to CA3091665A priority patent/CA3091665A1/en
Priority to JP2020144045A priority patent/JP7089662B2/ja
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Abstract

本发明属于多材料复合增材制造领域，并具体公开了一种增材制造与表面涂覆复合成形系统及方法，其包括增材成形装置、激光辅助冷喷涂装置和工作台，增材成形装置和激光辅助冷喷涂装置位于工作台上方，加工时，增材成形装置在工作台上逐层成形待成形零件，激光辅助冷喷涂装置在此成形过程中对待成形零件内外表面进行涂覆增强处理，从而共同完成待成形零件的复合加工制造；本发明在充分利用短流程增材制造快速成形零件优势的基础上，将表面涂覆增强工艺集成到此系统中，提高了零件复合增材制造和表面强化的效率，克服对结构复杂且表面强化要求较高零部件进行直接增材制造与表面涂覆复合成形的技术瓶颈。

Description

一种增材制造与表面涂覆复合成形系统及方法
技术领域
本发明属于多材料复合增材制造领域，更具体地，涉及一种增材制造与表面涂覆复合成形系统及方法。
背景技术
复杂结构零件的增材制造方法主要有大功率激光沉积成形、电子束自由成形、等离子电弧沉积等成形方法。
其中，大功率激光沉积成形是采用大功率激光，逐层将送到基板上的金属粉末熔化，并快速凝固沉积成形，最终得到近终成形件；该方法成形精度较高，工件的密度远高于选择性激光烧结件，但成形效率、能量和材料的利用率不高、不易达到满密度、设备投资和运行成本高(参见文献A.J.Pinkkerton,L.Li,Effects of Geometry and Composition inCoaxial Laser Deposition Of 316L Steel for Rapid Protyping，Annals Of theCIRP,Vol.52,1(2003)，p181-184)。
电子束自由成形方法采用大功率的电子束熔化粉末材料，根据计算机模型施加电磁场，控制电子束的运动，逐层扫描直至整个零件成形完成；该方法成形精度较高、成形质量较好，然而其工艺条件要求严格，整个成形过程需在真空中进行，致使成形尺寸受到限制，设备投资和运行成本很高，且因采用与选择性烧结相同的层层铺粉方式，难以用于梯度功能材料零件的成形(参见文献：Matz J.E.,Eagar T.W.Carbide formation In Alloy718during electron—beam solid freeform fabrication.Metallurgical andMaterials Transactions A:Physical Metallurgy and Materials Science,2002,v33(8)：p2559-2567)。
等离子熔积成形方法是采用高度压缩、集束性好的等离子束熔化同步供给的金属粉末或丝材，在基板上逐层熔积形成金属零件或模具，该方法比前两种方法成形效率和材料利用率高，易于获得满密度，设备和运行成本低，但因弧柱直径较前两者大，成形的尺寸和表面精度不及前两者，故与大功率激光熔积成形方法相似，大都要在成形完后进行精整加工(参见文献：Haiou Zhang,Jipeng Xu,Guilan Wang,Fundamental Study on PlasmaDeposition Manufacturing,Surface and Coating Technology,v.171(1-3)
2003,pp.112～118；张海鸥，吴红军，王桂兰，陈竞，等离子沉积直接成形高温合金件组织结构研究，华中科技大学学报(自然科学版),v 33，n 11，2005，p54-56)。
然而，直接成形的难加工材料零件因急冷凝固使表面硬度增大，导致加工非常困难：形状复杂的零件还需多次装夹，致使加工时间长，有时甚至要占整个制造周期的60％以上，成为高性能难加工零件低成本短流程生长制造的瓶颈。
现有的成形零件表面强化措施主要有热喷涂、冷喷涂、电火花沉积和气相沉积等。
其中，热喷涂技术是利用等离子弧、电弧、火焰等热源将粉末或丝材加热至熔融、半熔融或者热固态等状态，利用压缩气体裹挟喷涂粒子形成高速射流，与基体碰撞进而沉积形成具有某种特殊功能的涂层(参见文献：Pawlowski L.The science and engineeringof thermal spray coatings,second edition[M].New York:John Wiley&Sons,2008:15)，作为再制造工程的关键支撑技术之一，热喷涂技术具有可喷涂材料范围广、基体不受限、沉积速度快、灵活性高、工件受热温度可控等优点，主要用于实现零部件的表面防护、尺寸恢复和增材制造(参见文献：Baranovski V E,Baranovski AV.Gas dynamic cold spraymethod and apparatus:US,20160047052[P].2016-02-18)，在航空航天、燃气轮机、石油化工、交通运输等领域具有广阔的应用前景。
冷喷涂是一种金属、陶瓷喷涂工艺，但是它不同于传统热喷涂，不需要将喷涂的金属粒子融化。以高压气体作为加速介质，送入喷枪，同时喷涂粉末经送粉气体送入喷枪，经特殊设计的Laval型收缩-扩张喷嘴加速袁形成超音速气固两相流袁喷涂粒子在固态下碰撞基体袁经过剧烈的塑性变形而沉积形成涂层(参见文献：李文亚，张冬冬，黄春杰，郭学平.冷喷涂技术在增材制造和修复再制造领域的应用研究现状[J].焊接,2016,(4):2-8，73)，作为一种新型固态涂层制备方法，冷喷涂技术在制备高性能金属或金属基复合材料涂层方面表现出突出的优点。
电火花沉积技术利用电极材料与金属工件表面间的脉冲火花放电，将作为电极的导电材料熔渗到金属表层，形成硬度高、耐磨性以及理化特性好的沉积层，在模具、刀具和大型机械零件的局部强化与修补等方面具有广阔的应用(参见文献：刘吉延,马世宁,李长青,等.电火花沉积涂层性能及其应用[C],第7届全国表面工程学术会议暨第二届表面工程青年学术论坛论文集,2008:123-126)。
化学气相沉积技术是应用气态物质在固体上产生化学反应并产生固态沉积物的一种工艺。其主要内容包括形成挥发性物质，再将其转移至沉积区域，最后在固体上产生化学反应并产生固态物质的过程，在贵金属薄膜和涂层成形方面有重要作用(参见文献：范保虎，彭波南，张恒超.从专利文献分析化学气相沉积金刚石膜技术进展[J].真空，2016(05)：37～40)。
上述四种表面强化工艺，分别从各自不同的角度解决了零件和模具的表面性能增强问题，但各自也分别存在着难以获得大厚度和高致密涂层、涂层材料易发生氧化和相变等缺点，难以同时满足当下航空航天高端零件对短流程制造和耐高温腐蚀表面的需求。
此外，航空航天、能源动力等行业的零部件结构复杂，且对其组织性能及表面特性的要求很高，现有无模增材制造方法因其急速加热快速凝固和自由生长成形的特点，增材成形过程中的开裂、气孔等难以避免，并且在完成零件增材制造后再进行表面涂覆工艺，对复杂零件来说会存在难以涂覆、涂覆效果差等问题，零件组织性能和表面特性不能满足要求。以上问题己成为制约短流程直接增材成形技术能否进一步发展和实现工业化应用所急需解决的关键技术难点和瓶颈问题，因此，需要开发可有效提高制造效率、改善成形性、组织性能和零件表面性能的新方法。
发明内容
针对现有技术的以上缺陷或改进需求，本发明提供了一种增材制造与表面涂覆复合成形系统及方法，其目的在于，通过激光辅助冷喷涂装置在此增材成形装置逐层成形待成形零件的过程中，对零件完成表面强化处理，提高零件复合增材制造和表面强化效率，克服对结构复杂且表面强化要求较高零部件进行直接增材制造与表面涂覆复合成形的技术瓶颈。
为实现上述目的，按照本发明的一个方面，提出了一种增材制造与表面涂覆复合成形系统，包括增材成形装置、激光辅助冷喷涂装置和工作台，其中，所述增材成形装置和激光辅助冷喷涂装置位于所述工作台上方，加工时，所述增材成形装置在所述工作台上逐层成形待成形零件，所述激光辅助冷喷涂装置在此成形过程中对待成形零件内外表面进行涂覆增强处理，从而共同完成待成形零件的复合加工制造。
作为进一步优选的，所述激光辅助冷喷涂装置包括依次相连的气体压缩干燥单元、储送粉单元和环状激光单元，加工时，储送粉单元中的涂覆材料粉末被由气体压缩干燥单元压缩干燥后的高压气体送入环状激光单元，进而由环状激光单元加热后涂覆到待成形零件内外表面。
作为进一步优选的，所述储送粉单元包括两个及以上的储送粉罐。
作为进一步优选的，所述储送粉单元的送粉速率40-70g/min，粉末颗粒尺寸5-60μm，预热温度400-800℃。
作为进一步优选的，该复合成形系统还包括微轧制装置和铣磨复合装置，所述微轧制装置和铣磨复合装置位于所述工作台上方，所述微轧制装置和铣磨复合装置在所述增材成形装置逐层成形待成形零件过程中，对待成形零件进行精整加工。
按照本发明的另一方面，提出了一种增材制造与表面涂覆复合成形方法，其采用上述系统实现，包括如下步骤：
S1根据待成形零件的三维模型，预设增材成形轨迹和涂覆增强轨迹；
S2增材成形装置按预设的增材成形轨迹在所述工作台上逐层成形数层待成形零件；然后激光辅助冷喷涂装置按预设的涂覆增强轨迹对待成形零件内外表面进行涂覆增强处理；
S3重复S2若干次，直至完成零件制造。
总体而言，通过本发明所构思的以上技术方案与现有技术相比，主要具备以下的技术优点：
1.本发明进行零件的短流程增材制造和表面强化复合加工时，在增材成形过程中逐层或间隔层对成形件的外表面或内腔进行涂覆增强处理，而传统在完成零件增材制造后再进行表面涂覆工艺，对复杂零件来说会存在难以涂覆、涂覆效果差等问题，本发明可以有效克服现有航空发动机零部件等具有复杂内腔和外壁结构且对表面强化要求较高零部件的直接增材制造与表面涂覆复合成形的技术瓶颈。
2.本发明在充分利用短流程增材制造快速成形零件的优势的基础上，将表面涂覆增强工艺集成到此系统中，同时对成形零件完成表面强化处理过程，提高了零件复合增材制造和表面强化的效率，大大缩短了现有需表面强化复杂金属构件的直接短流程增材制造的周期。
3.本发明系统加工得到的零件组织性能优良，达到了锻件的性能标准，避免了气孔、夹渣、缩孔、未熔合、相变、开裂、流淌等不良特性的产生，且多种增材制造热源的应用可以使得本发明适用于多种直接增材制造的材料；同时，可调整的激光辅助冷喷涂表面强化工艺也使得本发明能适用于多种涂层的涂覆，激光这种高能热源的应用也使得本发明可以获得更大厚度的涂层，达到更好的表面强化性能，同时可以克服冷喷涂后涂层表面呈锥形而导致沉积速率呈线性下降、设备和运营成本较高的问题。
4.本发明系统同时结合了增材成形装置、激光辅助冷喷涂装置、微轧制装置和铣磨复合装置，使制备的零件直接达到使用要求，无需再进行后续的精加工与表面强化过程，达到了形貌与性能的综合特性快速成形。
5.本发明中储送粉单元由多个储送粉罐集合而成，使其可由送粉伺服电机实现对送粉量的精确控制，进而实现梯度或复合材料的涂覆。
附图说明
图1是本发明实施例中增材制造与表面涂覆复合成形方法流程图；
图2是本发明实施例中增材制造与表面涂覆复合成形系统示意图；
图3是本发明实施例中多储送粉器伺服送粉示意图。
在所有附图中，相同的附图标记用来表示相同的元件或结构，其中：1-工作台，2-基板，3-铣磨复合装置，4-微轧制装置，5-待成形零件，6-待成形零件内外表面，7-增材成形装置，8-增材成形表面，9-激光辅助冷喷涂装置。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。此外，下面所描述的本发明各个实施方式中所涉及到的技术特征只要彼此之间未构成冲突就可以相互组合。
本发明实施例提供的一种增材制造与表面涂覆复合成形系统，如图2所示，包括增材成形装置7、激光辅助冷喷涂装置9和工作台1，其中，增材成形装置7和激光辅助冷喷涂装置9位于工作台1上方，工作台1上放置有基板2，加工时，增材成形装置7在基板2上逐层成形待成形零件5，激光辅助冷喷涂装置9在此成形过程中对待成形零件内外表面6进行涂覆增强处理，从而共同完成待成形零件5的复合加工制造。
具体的，如图3所示，激光辅助冷喷涂装置9包括依次相连的气体压缩干燥单元、储送粉单元和环状激光单元，加工时，储送粉单元中的涂覆材料粉末被由气体压缩干燥单元压缩干燥后的高压气体送入环状激光单元，进而由环状激光单元加热后涂覆到待成形零件内外表面6；更具体的，环状激光单元包含有用于表面涂覆的激光辅助冷喷涂枪，在涂覆过程中，根据涂覆材料的不同熔点不同选择是否使用辅助加热激光以及辅助加热激光的功率，进而实现对不同熔点材料的表面涂覆；
优选的，储送粉单元包括两个及以上的储送粉罐；储送粉单元送粉速率40-70g/min，粉末颗粒尺寸5-60μm，预热温度400-800℃。
进一步的，该复合成形装置还包括微轧制装置4和铣磨复合装置3，微轧制装置4和铣磨复合装置3位于工作台1上方，微轧制装置4和铣磨复合装置3在增材成形装置7逐层成形待成形零件5过程中，对待成形零件内外表面6进行精整加工；
具体的，该复合成形装置安装在五轴联动机床上，配合双龙门或机械臂来实现短流程复合增材制造，其中，增材成形装置7、微轧制装置4和铣磨复合装置3安装于一个龙门或机械臂上，同时各自配有升降装置，使每个设备可以单独工作并自由切换所需设备；激光辅助冷喷涂装置9安装于另一个龙门或机械臂上；同时工作台1可按机床C轴旋转和A轴翻转运动，以便在加工时使待成形零件5的加工面与加工设备垂直，达到更好的成形质量和效果。
采用上述系统进行复合成形，如图1所示，具体包括如下步骤：
S1根据待成形零件5的几何形貌和涂覆增强区域的要求，将待成形零件5的三维CAD模型进行分层切片处理，以获得多个分层切片的数据，并根据该分层切片数据预设增材成形轨迹和涂覆增强轨迹；
S2增材成形装置7采用激光、电弧等快速成形方法按预设的增材成形轨迹在基板2上逐层成形数层待成形零件5；
S3激光辅助冷喷涂装置9按预设的涂覆增强轨迹对待成形零件内外表面6进行涂覆增强处理；具体的，涂覆过程中，激光辅助冷喷涂枪需要与涂覆表面法向量成一定夹角，以保证激光辅助冷喷涂枪与待成形零件5不发生干涉；
S4重复S2至S3若干次，直至完成零件加工制造。
进一步的，在上述加工过程中，对待成形零件5的尺寸、表面精度和致密度进行实时检测，当其达不到预设要求时，通过微轧制装置4或铣磨复合装置3对待成形零件5进行精整加工，直至达到零件或模具的尺寸和表面精度要求。
上述复合成形系统和方法适用于各种类型的零件制造，例如：
(1)采用上述系统将铜或铜合金涂覆于高强钢基材零件表面以增强零部件表面润滑、提高零部件耐磨性，该零件满足发动机及航空航天领域对零部件的整体性、轻质化、强度及稳定性的要求；
(2)上述系统特别适合于梯度功能、高熔点材料的熔覆，如陶瓷材料具有熔点高、耐磨、耐腐蚀等优点，但其本身的脆性和难加工性使得其难以应用于高性能材料的制造，同时陶瓷与金属本身性质的不同使其难以产生紧密结合，又如陶瓷金属材料与金属的物理相容性较差，使其难以产生紧密结合，采用上述系统可将陶瓷或陶瓷金属材料涂覆于金属零件表面，制造具有梯度功能陶瓷涂层的金属零件。
本领域的技术人员容易理解，以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。

Claims (6)

1.一种增材制造与表面涂覆复合成形系统，其特征在于，包括增材成形装置(7)、激光辅助冷喷涂装置(9)和工作台(1)，其中，所述增材成形装置(7)和激光辅助冷喷涂装置(9)位于所述工作台(1)上方，加工时，所述增材成形装置(7)在所述工作台(1)上逐层成形待成形零件(5)，所述激光辅助冷喷涂装置(9)在此成形过程中对待成形零件内外表面(6)进行涂覆增强处理，从而共同完成待成形零件(5)的复合加工制造。
2.如权利要求1所述的增材制造与表面涂覆复合成形系统，其特征在于，所述激光辅助冷喷涂装置(9)包括依次相连的气体压缩干燥单元、储送粉单元和环状激光单元，加工时，储送粉单元中的涂覆材料粉末被由气体压缩干燥单元压缩干燥后的高压气体送入环状激光单元，进而由环状激光单元加热后涂覆到待成形零件内外表面(6)。
3.如权利要求2所述的增材制造与表面涂覆复合成形系统，其特征在于，所述储送粉单元包括两个及以上的储送粉罐。
4.如权利要求2所述的增材制造与表面涂覆复合成形系统，其特征在于，所述储送粉单元的送粉速率40-70g/min，涂覆材料粉末颗粒尺寸5-60μm，涂覆材料粉末颗粒预热温度400-800℃。
5.如权利要求1所述的增材制造与表面涂覆复合成形系统，其特征在于，该复合成形系统还包括微轧制装置(4)和铣磨复合装置(3)，所述微轧制装置(4)和铣磨复合装置(3)位于所述工作台(1)上方，所述微轧制装置(4)和铣磨复合装置(3)在所述增材成形装置(7)逐层成形待成形零件(5)过程中，对待成形零件(5)进行精整加工。
6.一种增材制造与表面涂覆复合成形方法，其特征在于，采用如权利要求1-5任一项所述的系统实现，包括如下步骤：
S1根据待成形零件(5)的三维模型，预设增材成形轨迹和涂覆增强轨迹；
S2增材成形装置(7)按预设的增材成形轨迹在所述工作台(1)上逐层成形数层待成形零件(5)；然后激光辅助冷喷涂装置(9)按预设的涂覆增强轨迹对待成形零件内外表面(6)进行涂覆增强处理；
S3重复S2若干次，直至完成待成形零件制造。
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