基于小功率激光烧结的金属零件模具快速制造工艺研究

华中科技大学硕士学位论文基于小功率激光烧结的金属零件/模具快速制造工艺研究姓名：王成申请学位级别：硕士专业：材料加工工程指导教师：史玉升20050428ISLSE-20E-12E-03316L4514W2000mm/s0.1mm0.1mmIIAbstractSelectiveLaserSintering(SLS)isakindofmatureRapidprototyping(RP).AtpresentitishotissueanddifficultproblemthatSLSisappliedtomanufacturemetalpartandmouldrapidly.Therapidmanufactureofmetalpartandmouldhaswideapplicationinmechanicalindustry.AcoatedmetalpowderhasbeenusedtofabricatemetalpartandappliedtomouldindustrysuccessfullythroughindirectSLSintheforeigncountry.Butthetechnologyandmaterialarekeptsecrettoourcountry.Thepurposeofthispaperisfocusonindirectselectivelasersinteringmetalpartandmould.Themainresearchcontentsandresultsareasfollows:EpoxyresinandmetalpowderareaveragelymixedasSLSmaterialwhichisveryeasytoproducewithlowcostandgoodformingproperty.ThreekindsofEpoxyresin,E-20E-12E-03,areinvestigatedasbinderaccordingtocombinationwithmetalandmetalof316L,steel45,ironareselectedasstructurematerial.Theproportionofthebinderisalsodetermined.TheprincipleoflasersinteringforSLSmaterialhasbeendiscussed.Theeffectofsinteringparametersonstrengthandaccuracyofgreenpartisanalysedtheoretically.Sinteringparameterswhichincludelaserpower,scanningspeed,scanningspaceandlayerthicknessareoptimizedasfollows:P=14w,v2000mm/s,d0.1mm,h0.1mm.Post-processingofgreenparthasbeeninvestigatedtoo.Debindingtemperature,keepingtimeandprotectionatmosphereareanalysedforremovalofbinder.Hightemperaturesinteringstudyfocusonmechanismandprocessofsintering,effectofsinteringparameteronpropertyofsinter,sumofshrinkageduringsintering.Thewaystoreducingandcompensationofshrinkagearealsodiscussed.Threekindsofinfiltrationmaterialswhicharecopper,bronzeandepoxyresinarepresentedforinfiltrationforporouspartsandtheirprocessingparametersareinvestigatedaccordingly.Tensilestrengthofsinteringpartsarecomparedwiththoseareinfiltratedwithepoxyresinandcopper.Basedonstudyofindirectselectivelasersinteringmetalpartsandmoulds,metalpartsIIIwithcomplexstructureandmouldswithconformalcoolingchannelshavebeenmanufacturedsuccessfully.Keywords:SelectivelasersinteringParameteroptimizationGreenpartPostprocessingDebindingHightemperaturesinteringInfiltration111.11.1.1RapidPrototypingRP80SelectiveLaserSinteringSLS[1]CADSTLSLS1-1SLSCADCAMCNC[2,3]SLSSLSSLSSLSSLS[4]1-1SLS21.1.21990TexasBeamanDeckardSLS[5]1992DTMSLS[6]CADSLSSLS[7]SLS[8-11]1RP2SLSSLSRP3SLSSLSXCTMRI4SLS5CADCADCTMRISLS6SLSSLS3SLS[12]SLSDTMSLSSLS1.2,1-2[13],+41.2.1SLSSLSSLS[14-16]1.2.2,,SLSSnZnPb[17]SLSHotIsostaticPressingHIP,[18,19]5SLSLiquidPhaseSinteringLPSSLSManchesterSLS5050[20]PrabhuandBourellSLS89Cu11Sn[21]Cu1083Sn231SLSSnCuCuCu-Solder(70Pb-30Sn)Ni-SnSnSolder1000Bronze-NiStainlessSteel-CuSteel-CuSteel-Bronze316LStainlessSteelM2HighSpeedSteel[22-29]LeuvenWC-Co,WC-Cu[30]EOSEOSBronze-NiDirectMetal100DirectMetal50DirectMetal20161Mpa[31]DirectSteel150VI[32]DirectSteel120VI[33]20m20mN2491Mpa414MpaEOSDirectTool95%[34]61.2.3SLSPCnylonSLSDTMDTMDTMDTMSLSRapidSteel1.0108055m5m0.85[35]RapidSteel2.0RapidSteel1.07316L0.075mm4509Mpa10/AlMgZn200500/[36]LaserFormST-10042023-34mRapidSteel2.0587Mpa1[37]LaserFormST-200420LaserFormST-100LaserFormST-10056%44%6.73g/cm,435Mpa277Mpa6%4[38]CopperPolyamidePASLS2203204002.5m1.2mPEPPPSABSPC/ABSPolypropylene100-400/[6]3DSystems2003LaserFormA6LaserFormA655LaserFormA64598Fe2Ni[39][40]8SLS1.312001A107B022SLS”ZX200301005SLSSLSSLSSLSSLSSLSRPSLSSLS91.4300Mpa0.3mm123102SLSSLSSLSSLSDTM[41]2-12.1SLS11123316L316L0Cr17Ni12Mo2[42]2-12-1316LCrNiCMnSiPSMoFe316161810240.082.01.00.0450.0302.03.0316L45452.22.2.131613162-2HRPS-IIIA122-235512512357102-2SLS2-3[43]2-3()34410105STYRONATECH122051221235129913536E-207108132-3[44-46]110101.05200300SLS2PS1.05150180300SLS32123SLS4PUNHCOOSLS5E-2064760.050.10SLS80.3MpaSLS14SLSE-202.2.2AE-20CHCH2OCH2CCH3CH3OCH2CHCH2OHOCCH3CH3OCH2CHCH2OOnE-202-42-4E-20E-20(601)/64760.180.22450525/0.02/0.0585010501103h1.0E-20[47]1OH15OSLS20.20.4SLS30.050.1042002405AASLSAE-20E-20E-12E-032-52-5E-20E-12E-03OCHCH216E-20E-12E-032.2.32-336710E-2061102-22-2SLS1SLS26789100100200300400500600(KPa)2-217345SLS2mm8%2mm4%2.3316L45E-20E-12E-0392%8%96%4%HSJSLS18SLS1SLSSLS316L452OsakaTi5084%70Mpa25150Mpa93%[48]2-32-4316LSEM2-32-445mE-20E-12E-03316L452-33162-419SLS1SLS2SLS20034SLS2.41316L45E-20E-12E-0328%4%34203SLSSLSCAD[49-53]SLSCAD[54-55]3.1TgTm3-1213.2SLS50WHRPS-IIIACO210.6mP=50WSLS[54]DvqW3-1qJ/cm2WDv3-1223.2.1I(r)=I0exp(-2r2/02)(3-2)I00rI(z)=I0(1-R)exp(-z)(3-4)RzI0z0(3-2)3-2dxId03-2(3-3)I0=022P233.2.23-33-1BHBHB3.2.3d3-43-3243.2.4h(3-4)Fn3-5Ft[52]3-6YX3-7[55]Ix0d3-4FtFnVV3-53-6V253-7903.3SLS[56]SLS316LE-203.3.110mm10mm3-13-7263-1(Mpa)(w)(mm/s)(mm)(mm)1231121170010.0710.0810.780.710.820.7702121180020.1020.1020.540.480.550.5233121190030.1330.1230.420.460.420.4334121200040.1640.1440.360.300.330.3305132170010.1020.1230.720.760.810.7636132180020.0710.1440.690.850.760.7877132190030.1640.0810.550.580.600.5778132200040.1330.1020.680.700.650.6779143170010.1330.1440.640.690.780.70310143180020.1640.1230.650.670.610.64311143190030.0710.1021.011.010.981.00012143200040.1020.0811.091.111.041.08013154170010.1640.1020