金属面曝光选区激光熔化原理装置及试验研究

与点扫描方式相比,面曝光选区激光熔化因具有成形效率高、残余应力水平低等优势,而成为极具发展前景的新一代选区激光熔化增材制造技术的发展方向。利用波长为915 nm的二极管连续激光器作为光源,结合电寻址反射式纯相位液晶空间光调制器,搭建了新一代面曝光选区激光熔化增材制造原理装置平台。获得了“○”形样式的面光斑曝光,基于光敏纸和低熔点金属粉末材料进行面曝光熔化成形并获得了样品,实现了面曝光选区激光熔化的原理性实验验证。     

激光熔覆中同轴粉末流温度场的数值模拟

在激光同轴送粉熔覆中,由于激光与粉末流相互作用,粉末流整体温度分布直接影响激光熔覆的质量.基于非预混燃烧模型,将激光相处理为连续性介质,粉末颗粒相看作离散相物质,建立了激光作用下粉末流的质量、动量和能量方程.用Fluent软件进行了不同激光功率和粉末流速度条件下粉末流整体温度场数值模拟,讨论了各种参数对温度场分布的影响.为了验证该模型的准确度,利用CCD比色测温方法测量了粉末流整体温度场分布.结果表明,数值模拟与CCD检测结果具有良好的一致性,数值模拟结果对激光熔覆具有指导意义.     

工艺参数对PC光学制品残余应力的影响

先通过光弹实验测量残余应力的分布形态,然后通过应力—光学定律计算出相应的残余应力值,最后把该数值做了数值模拟分析。研究表明:对于同一工艺参数,残余应力的数值从浇口附近至流动末端逐渐减小;对于不同工艺参数,对残余应力的影响程度从大到小的顺序为熔体温度、模具温度、注射压力、冷却时间。     

316L不锈钢粉末光纤激光选区熔化特性

采用自行研制的光纤激光选区熔化快速成型设备,研究了选区激光熔化316L不锈钢粉末工艺参数、能量输入与样件致密度、表面形貌之间的关系以及微观组织特征。结果表明:扫描速度对成型效果影响最为显著;样件致密度随着激光能量密度提高有逐渐增大的趋势;能量密度作为选区激光熔化工艺的技术指标具有可操作性;表面形貌由激光功率与扫描速度比值所决定。深入探讨了能量输入、熔化凝固行为、激光功率与扫描速度比值与样件致密度、表面形貌的关系。结果表明:选区激光熔化凝固组织层内、层间熔合处为弧形,且为冶金结合,金相组织主要由柱状晶与等轴晶组成,层内靠近熔合线周围是柱状晶,而层间靠近熔合线附近主要是细小等轴晶,晶粒直径为1μm左右。     

基于神经网络的叶绿素含量精细测量建模方法研究

活体植物叶片叶绿素含量SPAD值易受叶片厚度、水分等影响,提出了基于多参数神经网络建模的叶绿素含量精细反演方法。通过测量叶片在中心波长分别为650,940和1 450 nm光照射下的透过率,获得叶片的SPAD值和水分指数WI(water index),同时用数字螺旋测微仪测量相应的叶片厚度并用分光光度法测得其叶绿素含量。利用建模集样本分别建立SPAD值与实测叶绿素含量之间的单参数模型和基于BP神经网络的WI、厚度及SPAD值与实测叶绿素含量之间的非线性模型。利用这两种模型分别计算获得验证集样本的叶绿素含量预测值,对预测值和实测值进行了相关分析和相对误差的分析。实验以340个三种不同植物叶片为样本,用以上方法进行了分析。结果表明,利用BP神经网络建模后,每种植物样本的叶绿素含量预测精度都有不同程度的提高,尤其对于叶片厚度值较大的样本,效果更为明显。数据显示所有混合样本平均相对误差绝对值由单参数模型的7.55%降低到5.22%,实测值与预测值的拟合决定系数由0.83提高到0.93。验证了利用多参数BP神经网络模型可以有效地提高活体植物叶绿素含量预测精度的可行性。     

激光烧结石墨烯铜复合材料温度场有限元模拟

在激光烧结石墨烯增强铜基复合材料的过程中,了解瞬时温度场分布对优化工艺参数、控制烧结质量有重要作用。建立了激光烧结预涂在42CrMo基板上的石墨烯铜的混合粉末的有限元模型。研究了激光烧结过程温度场分布,熔池的几何参数以及烧结层与基体的冶金结合宽度。为了验证模拟结果,使用与模拟相同的参数进行了单道激光烧结的实验。研究表明,热传导、热辐射和相变潜热在激光烧结过程的温度场分布中起重要作用。实验结果与模拟结果较为一致。所以可以依据模拟结果预测实验的温度场分布和熔池几何参数,同时也可以据此优化激光烧结参数。     

选择性激光烧结成型件密度的支持向量回归预测

根据不同工艺参数（层厚、扫描间距、激光功率、扫描速度、加工环境温度、层与层之间的加工时间间隔和扫描方式）下的选择性激光烧结成型件密度的实测数据集,应用基于粒子群算法寻优的支持向量回归（SVR）方法,建立了加工工艺参数与成型件密度间的预测模型,并与BP神经网络模型进行了比较.结果表明：基于相同的训练样本和检验样本,成型件密度的SVR模型比其BP神经网络模型具有更强的内部拟合能力和更高的预测精度;增加训练样本数有助于提高SVR预测模型的泛化能力;基于留一交叉验证法的SVR模型的预测误差最小.因此,SVR是一种预测选择性激光烧结成型件密度的有效方法. 关键词： 选择性激光烧结 密度 支持向量机 回归分析     

选区激光烧结瞬态温度场模拟与测试方法研究

采用有限元方法,考虑实际的边界条件和热物性参量的变化,对Al2O3覆膜陶瓷粉末的选区激光烧结过程瞬态三维温度场进行动态模拟.通过比色测温法对红外热成像系统的发射系数进行修正后,对选区激光烧结过程瞬态温度场进行测试.数值模拟和实测结果显示,两者吻合较好.     

激光冲击诱导弹簧钢丝残余应力状态分析

利用高功率Nd:YAG激光对不同工艺处理的SWOSC-V弹簧钢丝进行单点冲击处理,用X射线应力分析仪测量弹簧内外侧、侧表面的残余应力并计算出残余主应力,建立了激光冲击SWOSC-V弹簧钢丝表面残余应力的产生模型,并利用该模型分析了弹簧钢丝表面残余应力产生的原因。结果表明:弹簧钢丝在经激光冲击处理的表面强化区产生残余压应力,钢丝退火后直接激光冲击处理与经喷丸强化的钢丝激光冲击处理的表面残余应力变化不同,喷丸强化所引起的材料硬化是激光冲击处理弹簧钢丝残余应力变化不同的原因。     

激光超声检测铝合金材料的残余应力分布

为了有效检测铝合金材料上的残余应力分布,研究了用激光超声技术来检测铝合金材料上的残余应力分布的方法。该方法用Nd:YAG脉冲激光激发声表面波,并用外差激光干涉仪接收。理论分析表明可通过测量表面波在不同位置上声速的相对变化,来确定试样的残余应力分布。并对无残余应力、有压缩残余应力、有拉伸残余应力的三个试样应力分布,进行了实验测定。结果证实了试样的残余应力分布可引发声表面波在不同位置上声速的相对变化,也证实了激光激发声表面波及其接收技术是一种无损检测材料内残余应力分布的有效方法。     

Heat transfer and diffusion-controlled kinetics of liquid–solid phase in titanium matrix composite during selective laser melting

This study describes a self-consistent theoretical model of simulating diffusion-controlled kinetics on the liquid–solid phase boundary during high-speed solidification in the melt pool after the selective laser melting (SLM) process for titanium matrix composite based on Ti–TiC system. The model includes the heat transfer equation to estimate the temperature distribution in the melt pool and during crystallization process for some deposited layers. The temperature field is used in a micro region next to solid–liquid boundary, where solute micro segregation and dendrite growth are calculated by special approach based on transient liquid phase bonding. The effect of the SLM process parameters (laser power, scanning velocity, layer thickness and substrate size) on the microstructure solidification is being discussed.     

Effect of laser energy on the deformation behavior in microscale laser bulge forming

Microscale laser bulge forming is a high strain rate microforming method using high-amplitude shock wave pressure induced by pulsed laser irradiation. The process can serve as a rapidly established and high precision technique to impress microfeatures on thin sheet metals and holds promise of manufacturing complex miniaturized devices. The present paper investigated the forming process using both numerical and experimental methods. The effect of laser energy on microformability of pure copper was discussed in detail. A 3D measuring laser microscope was adopted to measure deformed regions under different laser energy levels. The deformation measurements showed that the experimental and numerical results were in good agreement. With the verified simulation model, the residual stress distribution at different laser energy was predicted and analyzed. The springback was found as a key factor to determine the distribution and magnitude of the compressive residual stress. In addition, the absorbent coating and the surface morphology of the formed samples were observed through the scanning electron microscope. The observation confirmed that the shock forming process was non-thermal attributed to the protection of the absorbent coating.     

Titanium and aluminum nitride synthesis via layer by layer LA-CVD

The possibility of the layer-by-layer synthesis of 3D parts from nitrides of titanium or aluminum by selective laser sintering/melting is discussed. The relationship between laser processing parameters and structure and phase content of sintered/melted samples are studied by means of optical metallography, X-ray diffraction, scanning electron microscopy and energy dispersive X-ray analysis. Optimal parameters of SLM process for AlN and TiN synthesis are determined. Solid 3D parts containing a TiN phase are produced from Ti powder. Distortion of the crystalline lattice of AlN and TiN phases is observed with the laser energy input.     

全密度功能性复杂金属零件的激光直接快速制造

 针对具有复杂结构的全密度功能性金属零件快速制造难题,探讨了该类零件的选区激光熔化直接快速制造方法,并结合实验,重点对同步保证选区激光熔化快速制造金属零件成型密度及精度的工艺进行了研究。结果表明：同步消除球化、飞溅及气孔对成型件致密性及精度的影响是实现选区激光熔化快速制造全密度功能性复杂金属零件的难点及关键;在维持良好的抗氧化气氛条件下,可采用尽可能薄的铺粉厚度及恰当调节其它成型参数的方法,以保证对上一层有足够的重熔量来消除球化及气孔现象;同时,采用合适的扫描策略,可弱化飞溅对成型质量的影响来解决工艺难题。采用该工艺方案可快速制造全密度功能性复杂金属零件,所成型的316L不锈钢叶轮零件相对密度为99.8%,硬度为HB192,表面粗糙度约为40 μm,尺寸精度在±0.1 mm以内,稍经打磨后即可投入使用。     

Direct manufacturing of Cu-based alloy parts by selective laser melting

The frequent defects of the metal parts, such as non-fully melting, thermal strain, and balling, which are produced by selective laser melting (SLM) that is a novel method of one-step manufacturing, are analyzed theoretically and experimentally. The processing parameters significantly affect the quality of the final parts, and simultaneously, the appropriate laser mode and the special scanning strategy assure a satisfying quality of the final parts. The SLM experiment is carried out using Cu-based powder. The metal part is divided into several scanned regions, each of which is scanned twice at the cross direction with different scanning speeds. The microstructure is analyzed on microscope. The results show that the part is metallurgically bonded entity with a relative density of 95%, and the microstructure is composed of equiaxial crystal and dendritic crystal whose distributions are mainly decided by the scanning strategy.     

错位光纤干涉激光谱结合BP神经网络的温度传感研究

在分析不同温度时单模错位光纤干涉光谱对应波长的条件下,搭建三层BP神经网络模型对温度传感进行研究,解决了常规光纤测温系统复杂和精度不高的问题。对建立的网络模型参数进行探讨,将采集的激光波长与对应的温度数据,经BP神经网络训练,对比得到最佳网络结构,达到在训练完成的网络输入层输入激光波长值时,便可在输出层得到对应的温度预测值。结果证明,实验输出的预测温度值与实际温度值之间表现出明显的相关性,即预测值能够逼近实测值。温度校正和预测相关系数分别达到0.999 61和0.979 27,校正标准误差与预测标准误差分别为0.017 5和0.144 0,得到预测集的平均相对误差为0.17%,剩余预测误差RPD可达到5.258 3,RPD大于3.0,说明定标效果良好,所建模型可用于实际的检测。另外,将该算法用于了带校正的双耦合结构单模错位光纤测温系统中,结果表明BP神经网络方法能够较好的处理错位光纤测温系统中激光光谱数据和温度之间的非线性关系,预测温度值与实测温度值之间的相关度为0.996 58,得到预测温度值与实际温度值之间平均相对误差为0.63%,从而提高了光纤测温传感器的精度和稳定性,同时也验证了该算法在光纤传感上的可行性,也为错位光纤的压力、曲率等其他物理量传感的精确测量提供了新思路。     

Effects analysis of ambient conditions on process of laser surface melting

In the process of laser surface melting (LSM), ambient conditions around the workpiece have important influences on the processing results. As an effective and feasible method for ambient changing, water-assisted approach can be expected to gain better results such as desired machining goals and reliable service performances. However, the effects of different water ambient on LSM process are needed to be further clarified. To this end, three 3-D transient process models in ambient dry air, water film and water are developed, respectively, using finite element method (FEM); the thermo-mechanical parameters, which depend on temperature, are taken into account and the complex physical essences are integrated. In experimental verification, these three LSM processes on mild steel Q235 are carried on and the computed results are in good agreement with respective measurements. Based on the proposed models, the transient temperature fields and residual stress distributions on workpieces are investigated. The numerical results suggest that the states of temperature and residual stress fields can be improved to different degrees using water film and water ambient.