基于粉末成形的激光增材制造陶瓷技术研究进展

陶瓷以其优异的热物理化学性能在航空航天、能源、环保以及生物医疗等领域具有极大的应用潜力。随着这些领域相关技术的快速发展, 其核心零件部件外形结构设计日益复杂、内部组织逐步走向定制化、梯度化。陶瓷具有硬度高、脆性大等特点, 较难通过传统的加工成形方法实现异形结构零件的制造, 最终限制了陶瓷材料的工程应用范围。激光增材制造技术作为一种快速发展的增材制造技术, 在复杂精密陶瓷零部件的制造中具有显著优势: 无模、精度高、响应快以及周期短, 同时能够实现陶瓷零件组织结构灵活调配, 有望解决上述异形结构陶瓷零件成形问题。本文综述了多种基于粉末成形的激光增材制造陶瓷技术: 基于粉末床熔融的激光选区烧结和激光选区熔化; 基于定向能量沉积的激光近净成形技术。主要讨论了各类激光增材陶瓷技术的成形原理与特点, 综述了激光选区烧结技术中陶瓷坯体后处理致密化工艺以及激光选区熔化和激光近净成形技术这两种技术中所打印陶瓷坯体基体裂纹开裂行为分析及其控制方法的研究进展, 对比分析了激光选区烧结、激光选区熔化以及激光近净成形技术在成形陶瓷零件的技术特征, 最后展望了激光增材制造陶瓷技术的未来发展趋势。     

激光选区烧结粉末包覆工艺的研究

激光选区烧结作为快速成型技术的重要组成部分,其成型材料在激光选区烧结工艺中占有至关重要的位置.在考虑激光选区烧结对成型材料性能要求的前提下,研究了SLS粉末包覆工艺.     

金属粉末激光快速成形的工艺及材料成形性

对比了3类金属粉末激光快速成形工艺:选区激光烧结;选区激光重熔,或称选区激光熔覆;以及直接激光沉积,或称激光净成形.提出了其分类依据是金属粉末与激光的作用机制,以及由此导致的金属粉末激光成形机理.综述了上述3类激光快速成形工艺的成形原理、成形材料及工艺优劣,分析了"球化"效应、翘曲变形、以及裂纹等对金属粉末激光成形性的影响规律及相应解决措施.     

不锈钢316L间接选区激光烧结工艺参数优化研究

在不锈钢间接选区激光烧结过程中,由于存在温度梯度场,将产生较大的残余应力和翘曲变形,从而会降低成型件的烧结精度。为了提高不锈钢件的激光烧结成型质量,对316L间接选区激光烧结耦合热应力场进行了数值模拟分析,与烧结实验进行了对比研究。研究表明,模拟结果与烧结实验的实物变形趋势相吻合,验证了模拟的正确性。采用该模拟方案,结合正交试验方法对激光功率、扫描间距、扫描速度和预热温度等4个工艺参数进行了优化,获得了一组最优工艺设计参数。研究结果为间接选区激光烧结成形质量提供了有力的工艺参数判据,具有重要的经济价值和应用前景。     

仿血管聚氨酯基复合材料的激光烧结工艺研究

激光选区烧结(SLS)技术在生物医学领域的应用日渐广泛,但是由于材料的限制,大部分SLS打印的产品都是合成塑料、陶瓷、合金等刚性零件,研究能用于激光选区烧结技术的柔性材料成为当前的迫切需求。本工作采用聚氨酯(TPU)粉末为主料,研究并制备了一种可用于激光选区烧结技术的复合材料,其烧结制件具有较高的强度及成形精度,可用于制作仿血管等柔性医疗模型。首先通过正交试验法对TPU/PS复合粉末进行激光选区烧结实验,并对制件进行测试,获得加工工艺参数对制件强度、成形精度及烧结密度的影响规律。其次对不同配比的TPU/PS复合粉末进行激光选区烧结实验,得到拉伸试件和弯曲试件,通过对制件的尺寸测量、力学强度测试及通过扫描电镜对复合粉末和拉伸试样断口进行显微组织观察,得到了不同组分配比对烧结制件显微组织及拉伸强度、弯曲强度的影响,确定了仿血管柔性材料的理想配比。     

增材制造专用陶瓷材料及其成形技术

陶瓷材料具有高强度、耐磨损、耐腐蚀和耐高温等特点,在航空航天、生物医疗和电子信息等领域具有良好的应用前景。然而,如何制造应用于上述领域的复杂形状陶瓷零件成为了一个重要的问题。目前,增材制造正逐步成为解决复杂形状陶瓷零件制造问题的有效方式。主要介绍了增材制造专用陶瓷材料及其成形技术。根据增材制造专用陶瓷材料的不同形态,可以将陶瓷材料分为粉材、丝材、片材和浆料/膏材4类。基于此,介绍了激光选区烧结(SLS)、激光选区熔化(SLM)、三维喷印(3DP)、熔融沉积制造(FDM)、分层实体制造(LOM)、立体光固化(SL)、数字光处理(DLP)以及直写成形(DIW) 8类主要陶瓷增材制造技术及其应用。最后,根据陶瓷增材制造的最新研究成果,对增材制造专用陶瓷材料及其成形技术发展作出进一步的展望。     

尼龙纳米复合材料的选区激光烧结成型技术研究进展

系统地论述了选区激光烧结原理及尼龙纳米复合材料选区激光烧结的国内外发展概况,总结了目前该领域中所取得的成果,指出了实现选区激光烧结制备尼龙纳米复合零件,不仅要解决其成型收缩,还必需解决无机纳米粒子的分散问题.并展望了尼龙纳米复合材料选区激光烧结快速成型技术的发展前景.     

激光烧结快速制备自由形状纳米块体材料的试验研究

基于选区激光烧结快速成形技术，以纳米Al2O3粉体材料为研究对象，进行了自由形状纳米块体材料制备的研究。研究结果表明，在适当的工艺参数下，可制备出任意形状的Al2O3块体材料，材料内部组织结构致密，晶粒尺寸保持在40nm以内。与其他烧结方法相比，激光烧结制备的纳米材料晶粒尺寸更为细小，组织结构更为致密。     

选择性激光烧结蒙脱土陶瓷粉末及聚合物纳米复合材料的工艺与性能分析

对蒙脱土陶瓷粉末及聚合物纳米复合材料进行了选择性激光烧结实验，通过改变不同烧结工艺参数，测试并分析了该复合材料的变化规律与影响程度。由于陶瓷材料和复合材料的应用前景广阔，因此这类研究具有很好的应用价值。     

微波烧结工艺制备陶瓷材料的研究现状

微波烧结作为一种陶瓷制备工艺,因其与传统烧结工艺相比体现出快速高效、节能环保等一系列优点而备受关注.主要介绍了采用微波烧结工艺制备陶瓷材料及陶瓷基复合材料的特点；在先驱体裂解、粉末烧结制备陶瓷材料方面对微波烧结工艺与传统烧结工艺进行比较,表明微波烧结工艺是一种极具潜力的技术；最后提出微波烧结工艺在未来发展过程中亟待解决的若干问题.     

金属粉末选择性激光烧结成形机制的研究

分析了纯金属粉末、预合金粉末和多组分金属粉末的选择性激光烧结成形机制;详细讨论了粉末的化学成分和物理性质,激光功率、扫描速率、扫描矢径、扫描间距等激光参数以及粉层厚度、粉床预热温度、保护气氛等工艺参数对成形机制的影响;并简要讨论了金属粉末选择性激光烧结技术的进一步研究方向.     

A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: Processing,microstructure, and properties

Manufacturing businesses aiming to deliver their new customised products more quickly and gain more consumer markets for their products will increasingly employ selective laser sintering/melting (SLS/SLM) for fabricating high quality, low cost, repeatable, and reliable aluminium alloy powdered parts for automotive, aerospace, and aircraft applications. However, aluminium powder is known to be uniquely bedevilled with the tenacious surface oxide film which is difficult to avoid during SLS/SLM processing. The tenacity of the surface oxide film inhibits metallurgical bonding across the layers during SLS/SLM processing and this consequently leads to initiation of spheroidisation by Marangoni convection. Due to the paucity of publications on SLS/SLM processing of aluminium alloy powders, we review the current state of research and progress from different perspectives of the SLS/SLM, powder metallurgy (P/M) sintering, and pulsed electric current sintering (PECS) of ferrous, non-ferrous alloys, and composite powders as well as laser welding of aluminium alloys in order to provide a basis for follow-on-research that leads to the development of high productivity, SLS/SLM processing of aluminium alloy powders. Moreover, both P/M sintering and PECS of aluminium alloys are evaluated and related to the SLS process with a view to gaining useful insights especially in the aspects of liquid phase sintering (LPS) of aluminium alloys; application of LPS to SLS process; alloying effect in disrupting the surface oxide film of aluminium alloys; and designing of aluminium alloy suitable for the SLS/SLM process. Thereafter, SLS/SLM parameters, powder properties, and different types of lasers with their effects on the processing and densification of aluminium alloys are considered. The microstructure and metallurgical defects associated with SLS/SLM processed parts are also elucidated by highlighting the mechanism of their formation, the main influencing factors, and the remedial measures. Mechanical properties such as hardness, tensile, and fatigue strength of SLS/SLM processed parts are reported. The final part of this paper summarises findings from this review and outlines the trend for future research in the SLS/SLM processing of aluminium alloy powders.     

选择性激光烧结峰值温度的三维有限元模拟

选择性激光烧结(SLS)中工艺参数和扫描路径对烧结件性能有较大影响,文中研究了激光烧结工艺参数和扫描路径对峰值温度的影响规律。通过建立SLS的温度场模型并开发C++的有限元模拟软件,分析了激光功率、激光扫描速率及预热温度等工艺参数对SLS峰值温度的影响,对比了不同扫描路径下高分子粉末和金属粉末的SLS峰值温度变化规律。数值算例表明,SLS温度场中峰值温度随激光功率和预热温度的升高而升高,随激光扫描速率的升高而降低;扫描路径对高分子粉末SLS峰值温度的影响较小;开发的温度场模型准确合理,能够为实际生产提供理论依据。     

Laser micro sintering: A new method to generate metal and ceramic parts of high resolution with sub-micrometer powder

Laser micro sintering (LMS) was developed by the research group at University of Applied Sciences Mittweida and the associated Laserinstitut Mittelsachsen e.V. as the result of research started in 2001 with a project on the possibility of generating parts by selective laser sintering (SLS) with improved resolution. For the successful generation of solid bodies from various metal powders the technology uses essentially sub-micrometer powders, a cylindrical coating blade and a q-switched solid state laser. The resolution and the surface roughness are by more than one order of magnitude better than those achieved by previous selective laser sinter technologies. Presently the technology shows advancements in selective laser sintering of highly resolved specimens of densely sintered Al₂O₃ and SiC ceramics too.

This paper reports the process mechanism of LMS and its principal differences compared to other SLS methods. A variety of laser micro sintered parts from different metals and the newest results in laser micro sintering of ceramic parts are presented. Material specific behaviour in laser micro sintering is discussed. Also the ability of the method will be shown to generate parts of layer wise different materials (laminate sintering) in one sintering machine.     

Physical Aspects of Process Control in Selective Laser Sintering of Metals

Direct selective laser sintering (SLS) is a layered manufacturing technique that can produce fully dense, functional components in high performance metals. In this review paper, a first step is taken towards identifying and understanding some of the important physical mechanisms in direct SLS. This study not only provides an insight into phenomena observed during direct SLS processing of a variety of metallic materials but also helps in selecting those materials that are most amenable to direct SLS processing. The physical mechanisms discussed include oxidation, non‐equilibrium wetting, epitaxial solidification, metal vaporization, and oxide purification. Understanding these mechanisms is crucial for the design of direct SLS machines, process development, and process control.     

陶瓷材料增材制造技术研究进展

增材制造技术是20世纪90年代出现的,以高能束为基础通过逐层叠加材料得到终产品的快速成形技术。以选择性激光烧结/熔融为主线,综述了陶瓷材料增材制造技术的发展历程,概述了间接法和直接法的原理、特点以及其局限性,指出要解决陶瓷制品增材制造存在的问题,必须加强相关理论研究,优化粉末质量和后处理工艺,以及探索合适的工艺参数。     

Electrostatically assembled SiC–Al2O3 composite particles for direct selective laser sintering

In the advancement of directed energy deposition, 3D printing technology has been undergoing revolutionary changes, especially in metal and polymer printing technology. On the contrary, the 3D printing of ceramics has not experienced such rapid development due to their requirement for high-temperature sintering and inferior energy adsorption property, limiting their use in application such as direct selective laser sintering (SLS). In this study, a novel controlled fabrication of composite powders consisting of silicon carbide (SiC) and alumina (Al₂O₃) was developed for fundamental investigation in direct SLS using an infrared laser radiation with a wavelength of 915 nm. Improved laser absorbance and a plausible way to reduce volume shrinkage during the sintering process are demonstrated through the control of composite particles formation. The composite particles were designed using a bottom-up approach via an electrostatic nano-assembly method at room temperature. Although further finetuning is still indispensable prior to practical applications, the findings of this work will provide a vital platform for powder modification and advanced powder development for ceramic materials fabrication through directed energy deposition route.     

选择性激光烧结用原材料研究进展

文章阐述了当前快速原型技术中选择性激光烧结材料的国内外研究现状,包括金属材料、聚合物材料、陶瓷材料等。重点提出新型材料木塑复合材料的研究现状,指出基于木塑复合材料的低成本、可降解和可循环使用等优点,它将成为SLS未来发展的趋势。     

Structure and properties of nano-hydroxypatite scaffolds for bone tissue engineering with a selective laser sintering system

In this study, nano-hydroxypatite (n-HAP) bone scaffolds are prepared by a homemade selective laser sintering (SLS) system based on rapid prototyping (RP) technology. The SLS system consists of a precise three-axis motion platform and a laser with its optical focusing device. The implementation of arbitrary complex movements based on the non-uniform rational B-Spline (NURBS) theory is realized in this system. The effects of the sintering processing parameters on the microstructure of n-HAP are tested with x-ray diffraction (XRD), Fourier transform infrared (FTIR) spectroscopy and scanning electron microscopy (SEM). The particles of n-HAP grow gradually and tend to become spherical-like from the initial needle-like shape, but still maintain a nanoscale structure at scanning speeds between 200 and 300 mm min(-1) when the laser power is 50 W, the light spot diameter 4 mm, and the layer thickness 0.3 mm. In addition, these changes do not result in decomposition of the n-HAP during the sintering process. The results suggest that the newly developed n-HAP scaffolds have the potential to serve as an excellent substrate in bone tissue engineering.