基于DMG MORI LASERTEC 65 3D加工中心的不锈钢粉末激光沉积增/减材复合制造

Laser deposition additive/subtractive hybrid manufacturing process for stainless steel powder based on DMG MORI LASERTEC 65 3D

采用国内首台增/减材复合加工中心——DMG MORI LASERTEC 65 3D,完成不锈钢粉末的增/减材复合制造,通过研究激光直接金属沉积成形的激光功率、扫描速度及送粉速度等増材工艺参数对不锈钢沉积层截面形状尺寸与表面粗糙度的影响,优化沉积工艺参数,测定沉积件的力学性能,并初步探究DMG MORI LASERTEC 653D复合加工中心对于不锈钢异型涡轮增压壳体的增材与减材复合制造的能力水平和应用空间。结果表明:最佳沉积工艺参数为:激光功率为2 400 W,扫描速度为1 000 mm/min,送粉速率为14 g/min,粉末沉积件获得理想的等轴晶组织,其抗拉强度和伸长率分别达到632 MPa和46.9%,与同材料的锻件相当。用DMG MORI LASERTEC65 3D复合加工中心,可完成不锈钢异型涡轮增压壳体的粉末激光直接金属沉积成形和5轴铣削的复合加工制造,在保证工件精度的前提下,能较好地实现如法兰钻孔、接头生产等难加工部件的一次性成形,较传统加工方式效率提高5~8倍。

The rapid preparation of the final quality parts using stainless steel powder was performed on the DMG MORI LASERTEC 65 3D,the first additive/subtractive hybrid manufacturing machine tool in China.The effects of laser power,scanning speed and feeding speed on the section shape,size and surface roughness of stainless steel deposits were studied.Optimizing the deposition parameters and determining the mechanical properties of the integrable parts were also performed.The machining capability level and the application space of the DMG MORI LASERTEC 65 3D for the additive/subtractive hybrid manufacturing of the metal alloy components were also investigated.The results show that the ideal equiaxed grain structure can be obtained by powder deposition and lap joint under the optimized laser forming conditions with the laser power of 2 400 W,the scanning speed of 1 000 mm/min,and the powder feeding rate of 14 g/min.The tensile strength and elongation reach 632 MPa and 46.9%respectively,which are comparable with forgings.Using DMG MORI LASERTEC 65 3D composite machining center,the composite machining of stainless steel special type turbocharged shell by powder laser direct metal deposition and 5 axis milling can be completed.On ensuring the precision of the workpiece,the one-time forming of the difficult parts such as the flange drilling and the joint production can be realized,the efficiency is 5?8 times higher than that of the traditional processing method.