面曝光选区激光熔化成形形状精度研究

主要研究面曝光选区激光熔化单层成形时,激光光斑搭接率和电流对形状精度的影响。实验通过控制变量法研究搭接率、曝光时间、电流等工艺参数对激光光斑、熔道、圆环、尖角等成形形状精度的影响。实验结果表明：一定范围内,电流越大,激光光斑更均匀,成形一致性更好;搭接率38.4%能够获得最低的形状误差的熔道;搭接率一定,圆环成形误差随电流的增加而增加;尖角成形误差随着电流增加,呈现先增后减的趋势;搭接率为46.1%、38.4%时,零级衍射带来的形状误差降低。     

基于神经网络的选区激光熔化残余应力预测

当前对选区激光熔化产生的残余应力预测方法主要为数值模拟,但由于设备、环境、粉末等因素差异性较大,且具有较大不确定性,很难建立符合实际情况的数值模拟模型。利用神经网络在预测多变量、复杂线性信息处理方面能力强的特点,建立适用于预测316L不锈钢粉末选区激光熔化残余应力的模型。使用选区激光熔化技术打印相当数量的不同工艺参数的试样,采用超声波检测其内部残余应力作为神经网络的训练样本,并使用这些样本对神经网络模型进行训练,获得具有预测功能的神经网络,将验证样本的工艺参数输入神经网络,计算出预测的残余应力值,与实际检测值进行对比。实验结果表明,预测值与实际测量值偏差较小,验证了所提方法的有效性。采用神经网络预测残余应力的方法,可以快速确定不同选区激光熔化工艺参数对应的残余应力,避免设置残余应力较高的工艺参数,有效缩短制备高质量工件试样的周期,降低成本。     

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1 μm左右。     

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。     

选区激光熔化及热处理工艺对钴铬合金力学性能的影响

系统研究了选区激光熔化（SLM）及热处理工艺对钴铬合金组织与性能的影响。通过设计正交实验,利用EOS M290选区激光熔化设备,优化钴铬合金成型的工艺参数;利用XRD、扫描电镜（SEM）、硬度仪及万能材料试验机对选区激光熔化钴铬合金的显微组织结构、物相组成及力学性能进行观察与测试。研究结果表明,选区激光熔化成型的最佳工艺参数为：扫描间距0.08 mm,扫描速度1110 mm/s,激光功率335 W,能量密度4.8 J/mm2,获得的致密度高达99.18%,且最佳的填充角度为67。SLM成型的钴铬合金的物相主要由相及少量相共存,微观组织由细小均匀的胞状晶及柱状晶构成;其硬度、抗拉强度及延伸率分别为41.0HRC,1032 MPa,10%,断裂机制主要为穿晶脆性断裂。热处理后显微组织发生相变,主要为相及少量相,并产生少量强化相M23C6(M=Cr,Mo,W);其硬度、抗拉强度及延伸率分别提升了6.1%,35.9%和17.6%,断裂机制主要为准解理断裂。     

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。     

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。     

激光脉冲对氢负离子在金属面附近光剥离的影响

利用闭合轨道理论和金属面附近氢负离子的双脉冲光剥离截面的计算公式,计算了氢负离子在金属面附近激光脉冲作用下的光剥离截面.计算结果表明:如果脉冲宽度远大于闭合轨道的回归周期时,它对光剥离截面的影响很小;当脉冲宽度小于闭合轨道的周期或者可以和闭合轨道的周期相比较时,光剥离截面的振荡幅度大大地减弱.光剥离截面除了与脉冲宽度有关外,还与双脉冲之间的时间延迟、相位差有关.对于某些相位差, 双脉冲光剥离截面的取值增大; 而对于另外一些相位差, 光剥离截面的取值减小.因此,可以利用脉冲激光来控制氢负离子在表面附近光剥离 关键词： 激光脉冲 光剥离截面 金属面 闭合轨道理论     

基于空间光调制器的非相干数字全息单次曝光研究

菲涅耳非相干相关全息术(Fresnel incoherent correlation holography,FINCH)利用在空间光调制器(spatial light modulator,SLM)上加载双透镜模式对同一物点光分束自相干,并通过改变加载的相位因子得到不同的相移全息图.本系统利用SLM可分区编码调制特性,将FINCH成像中SLM上分三次加载的0°,120°,240°相位双透镜掩模各提取1/3组成一幅复合相移模式加载,并研究了三种相位分布方式对FINCH成像质量的影响.结果表明:三个相位在SLM上分布间隔越大,再现像越清晰.在此基础上,提出了一种新的掩模加载方式,在SLM加载透镜阵列,每一个相位因子对应一个双透镜,具有一个光轴.实验表明,通过这种加载方式,通过SLM后形成的三个相移图能够一次在电荷耦合器上记录,并且三个相移图不重叠,然后通过MATLAB编程计算将不同相移角度的全息图分别提取出来,通过三步相移计算合成一幅包含有物光波的复值全息图,最后通过数值再现算法重建待测样品.此系统可用于对光源相干性较低的实时成像系统,也为微小形变测量、动态物体的观测提供了新方法,为非相干数字全息术的发展提供了新思路.     

激光光刻中数字微镜器件关键技术研究

在无掩模激光光刻系统中,TI(Texa instrument,德州仪器)公司基于DLP(digital light processing,数字光处理)架构的DMD(digital micromirror device,数字微镜器件)系统已经得到应用,但是存在光刻图像质量和光刻速度无法提高等瓶颈.提出采用单片FPGA控制...     

应变效应对金属Cu表面熔化影响的分子动力学模拟

采用Mishin镶嵌原子势，通过分子动力学方法模拟了金属Cu 的(110)表面在不同应变下的熔 化行为，分析了表面熔化过程中系统结构组态和能量的变化以及固液界面迁移情况.金属Cu 的(110)表面在低于热力学熔点的温度下发生预熔化，准液体层的厚度随温度升高而增加.当 温度高于热力学熔点时，固液界面的移动速度与温度成正比，外推得到热力学熔点为1380K ，与实验结果1358K吻合良好.应变效应（包括拉伸和压缩）导致热力学熔点降低，并促进表 面预熔化进程.在相同温度条件下，准液体层的厚度随应变绝对值的增加而增大.应变效应导 致的固相自由能增加是金属Cu(110)表面热稳定性下降的主要因素，且表面应力和应变方向 的异同也会影响表面预熔化的进程. 关键词： 表面预熔化 热力学熔点 表面应力 分子动力学     

Densification behavior of gas and water atomized 316L stainless steel powder during selective laser melting

The densification during selective laser melting (SLM) process is an important factor determining the final application of SLM-part. In the present work, the densifications under different processing conditions were investigated and the densification mechanisms were elucidated. It was found that the higher laser power, lower scan speed, narrower hatch spacing and thinner layer thickness could enable a much smoother melting surface and consequently a higher densification.The gas atomized powder possessed better densification than water atomized powder, due to the lower oxygen content and higher packing density of gas atomized powder. A large number of regular-shaped pores can be generated at a wider hatch spacing, even if the scanning track is continuous and wetted very well. The densification mechanisms were addressed and the methods for building dense metal parts were also proposed as follows: inhibiting the balling phenomenon, increasing the overlap ratio of scanning tracks and reducing the micro-cracks.     

Inhibition of metal dusting of Alloy 800H by laser surface melting

Metal dusting is a catastrophic carburisation phenomenon that occurs at temperatures of 450-850 °C in atmospheres of high carbon activity. The resistance of alloys to corrosion, including metal dusting, relies on the formation of a dense, adherent oxide layer that separates the alloy from the corrosive environment. For such an oxide layer to be protective, it must achieve full surface coverage, be crack-free and be established before significant material degradation has occurred. Formation of a protective oxide scale can be enhanced by increasing the population of rapid diffusion paths for the protective elements (e.g. Cr and Al) to reach the alloy surface.In this work, laser surface melting has been used to improve the metal dusting resistance of Alloy 800H by creating a rapid solidification microstructure and, thereby, increasing the density of rapid diffusion paths. Oxidation during laser processing has been found to be detrimental to metal dusting resistance. However, it has been demonstrated that the resulting oxide can be removed without compromising metal dusting resistance.Results of exposure to a metal dusting atmosphere (20% H₂ and 80% CO at 650 °C) are presented. Samples have been examined in plan and cross-section using optical and scanning electron microscopy (SEM). Selected samples were also examined by electron probe microanalysis (EPMA) and X-ray diffraction (XRD).     

Effect of energy density on defect evolution in 3D printed Zr-based metallic glasses by selective laser melting

In this study, the defects in 3D printed Zr-based bulk metallic glasses(BMGs) fabricated by selective laser melting(SLM) under different energy densities have been investigated via both experimental and simulation approaches. Different defects, including balling, interlayer pores, open pores and metallurgical pores, are detected in the 3D-printed Zr-based MGs depending on the energy inputs. Balling mainly occurs at a relatively low energy density(E<8.33 J/mm^3) due to the incomplete melting of particles, while interlayer pores and open pores are formed at modest energy densities(E=13.89-16.67 J/mm^3) because of incomplete welding and insufficient filling of molten liquid between layers. Fine metallurgical pores appear on the upper surface at relatively high energy densities(E=20.83-27.78 J/mm^3), which originate from gas escaping from molten pools during rapid solidification of the melt. Computational fluid dynamics(CFD) simulations are carried out to verify the experimental observations. The CFD simulations reveal that the various defects formed in the 3D-printed Zr-based BMG are related to the melt flow behaviours in the molten pools under different energy densities. The present work provides in-depth understandings of defect formation in the SLM process and provides methods for eliminating these defects in order to enhance the mechanical performance of 3D printed BMGs.     

Heat transfer modelling and stability analysis of selective laser melting

The process of direct manufacturing by selective laser melting basically consists of laser beam scanning over a thin powder layer deposited on a dense substrate. Complete remelting of the powder in the scanned zone and its good adhesion to the substrate ensure obtaining functional parts with improved mechanical properties. Experiments with single-line scanning indicate, that an interval of scanning velocities exists where the remelted tracks are uniform. The tracks become broken if the scanning velocity is outside this interval. This is extremely undesirable and referred to as the “balling” effect. A numerical model of coupled radiation and heat transfer is proposed to analyse the observed instability. The “balling” effect at high scanning velocities (above ∼20 cm/s for the present conditions) can be explained by the Plateau-Rayleigh capillary instability of the melt pool. Two factors stabilize the process with decreasing the scanning velocity: reducing the length-to-width ratio of the melt pool and increasing the width of its contact with the substrate.