Process parameter dependencies of continuous and pulsed laser modes on surface polishing of additive manufactured aluminium AlSi10Mg parts

Laser powder bed fusion is a well-established 3D printing technique for metal alloys, but exhibits a poor surface quality. Laser polishing provides the possibility of a fast contact-free and fully-automatable surface treatment. This paper deals with the experimental investigation of laser polishing of laser powder bed fusion parts made of aluminium AlSi10Mg. Laser polishing is done with a 4 kW solid state disc laser in combination with a multi-axis system and a one dimensional scanner optic. The laser is operated at continuous and pulsed operation mode. The parameter study reveals a high dependency of the achievable roughness on the laser beam intensity, the track and pulse overlap, the energy density and the number of polishing passes and polishing directions. Pulsed laser polishing mode with up to four passes from different directions revealed the lowest surface roughness of 0.14 μm Ra. With respect to the initial average surface roughness of Ra = 8.03 μm a reduction of the surface roughness of greater than 98 % could be achieved. Polishing with continuous laser radiation at one polishing pass resulted in Ra = 0.23 μm at an area rate of 20 cm²/min. Laser polishing using four passes achieved a further improvement up to Ra = 0.14 μm.     

载荷对PTFE/AlSi10Mg复合材料摩擦磨损行为的影响

采用选区激光熔化(SLM)、浸渗和真空烧结工艺制备了以AlSi10Mg为基体的多孔骨架填充聚四氟乙烯(PTFE)的自润滑复合材料。采用往复式Bruker UMT-3摩擦试验机研究了速度为5mm/s、不同载荷下复合材料的摩擦磨损性能,并采用SEM、EDS等对其成分、结构以及摩擦学行为进行了研究。结果表明,复合材料的平均摩擦因数和磨损率随着载荷的增加呈现先增大后减小的趋势;复合材料的摩擦稳定性主要由存储在骨架中的PTFE决定。其摩擦机制主要是在载荷的作用下,当磨擦表面发生磨损时,骨架中的PTFE将磨屑捕获,形成完整的PTFE润滑层,并且发生膜的转移,从而增加了复合材料的摩擦学稳定性。     

Evaluation of surface/interface quality,microstructure and mechanical properties of hybrid additive-subtractive aluminium parts

A disadvantage of selective laser melting (SLM) processes for the manufacture of large parts is their slow build time per unit volume. A hybrid route is to generate core simple shapes traditionally, for example by machining, followed by adding final features by SLM. Here the mechanical integrity of such hybrid parts is studied, choosing the building of AlSi10Mg by SLM on a machined AA6082 base, in the shape of a tensile test piece, as a simple example. These materials are chosen for their relevance to lightweight parts. As-built parts fail at the SLM/machined interface but standard heat treatments transfer failures to the machined material. Optimised SLM processing conditions and microstructures of the SLM and interfacial regions are reported.     

Selective Laser Melting process optimization of Ti–Mo–TiC metal matrix composites

Selective Laser Melting (SLM) was used to process a powder mixture of CP Ti, 6.5 wt% Mo and 3.5 wt% Mo₂C. The process parameters were optimized to obtain full-density, crack free parts. After the in situ decomposition of Mo₂C in favor of the formation of TiC, the material consisted of a homogeneous dispersion of submicrometer sized TiC platelets in a β-(Ti,Mo) matrix exhibiting a high hardness up to 550 HV and compressive yield stress of 1164 ± 37 MPa. The microstructure and mechanical properties could be tailored by variation of the process parameters within the high-density processing window, as well as through post-process heat treatments.     

一种降低OFDM系统峰均比的改进算法

选择映射（SLM）技术是一种无失真降低正交频分复用（OFDM）系统信号峰均比的方法,为更好地降低正交频分复用系统的峰均比,文中提出了一种基于SLM级联抵消技术降低PAPR的优化算法。该算法首先利用改进的SLM算法,对系统PAPR特性进行优化,然后利用抽样信号作为参考函数,实现对系统峰均比的有效降低。通过分析SLM级联峰...     

多孔件TC4选区激光熔化成形及力学性能分析

采用选区激光熔化成形技术制备了两种钛合金体心立方多孔结构(BCC和BCC-Z)制件,验证了其成形复杂孔制件的可行性;进行了静态压缩试验,结果表明制件沿近45°方向断裂;压缩试验应力应变曲线表明多孔件使材料抗拉强度大大减小,且随着边径比和孔隙率的增大,峰值应力减小。同时,在边径比和孔隙率相差不大的情况下,BCC-Z结构承受载荷的能力明显高于BCC结构;通过有限元模拟分析了BCC制件在压缩过程中的应力分布情况,针对单元体节点处的应力集中现象,提出了节点加固方法。同时预测了多孔制件的弹性模量和屈服强度,模拟与试验结果基本吻合。     

Experimental investigation of melt pool behaviour during selective laser melting by high speed imaging

Melt pool behaviour and the characteristics of the surrounding metal powder during selective laser melting (SLM) are captured using high-speed imaging, and the influence of the substrate temperature and the line building sequence on the formation of the built structure and the generation of spatter particles is experimentally investigated. The results indicate that the substrate temperature has a measurable effect on the formation of droplets and the generation of spatter particles, while the volume specific energy density of the process was the principal factor affecting the built structure.     

一种全封闭蒙皮点阵支撑结构的优化设计与试验验证

随着人类航天活动范围的不断扩大,复杂航天任务对于结构轻量化技术提出了更高的要求。在传统的结构形式基础上,单纯通过应用高性能材料等手段已经无法满足后续航天任务对于航天器载荷支撑结构轻量化的要求。提出一种封闭蒙皮包裹三维点阵层级结构的设备支撑结构形式,建立设备支撑结构的拓扑优化设计模型,并对优化后的结构进行封闭蒙皮包裹三维点阵化设计。运用激光选区熔化方法制备了支撑结构实物,并进行了振动力学试验验证,试验结果表明设备支撑结构比采用传统设计及制造方法的结构减重46.4%,实物已应用于某型号卫星载荷支撑任务。提出的封闭蒙皮包裹三维点阵的结构形式可以有效提高支架类结构的设计效率,在航天器结构轻量化方面具有推广应用前景。     

流道截面与增材制造加工工艺参数对液压集成块成型质量的影响

液压系统广泛应用于工程领域,提高功率密度是其重要发展方向,其中液压集成块轻量化设计是提高功率密度的有效手段。通过增材制造(AM)灵活的加工特性能使集成块重量降低,是高功率密度液压驱动的一种有效的设计方法,但目前增材制造加工的流道存在塌陷形变、尺寸精度低、内部流道粗糙度高等问题。以提升增材制造流道成型质量为研究目标,选区激光熔融(SLM)为加工方法,探讨流道横截面及打印模型中有无支撑添加对成型质量的影响,并通过非接触测量对打印模型内部流道尺寸进行测量得到定量分析。结果表明,对于圆形流道,有支撑结构有较好的打印结果,菱形流道形变量小于圆形流道。进一步通过改变打印参数对内流道表面质量进行研究,结果显示适当选择工艺参数可以提高表面质量。