大尺寸粉末床激光熔融流场分析及在线监控研究进展

doi:10.3901/JME.2023.19.389

摘要/Abstract

摘要： 多激光束拼接成形的大尺寸粉末床激光熔融(Laser powder bed fusion，LPBF)技术具有成形效率高、成形尺寸大的特点，可满足航空航天、核电动力等领域大型复杂精密关键构件的制造要求，已成为LPBF技术发展的必然趋势。然而如何保证大尺寸LPBF成形过程的稳定性、工艺可重复性以及成形零件的质量可靠性是该技术的关键挑战。近年来，通过分析优化气流场以获得均匀一致的气流是实现大尺寸LPBF长时间稳定、高质量成形的有效途径。同时，引入在线监控技术能实现成形过程的实时监测、反馈和调节，是掌握工艺调控规律和解决工艺过程不稳定的关键技术手段。因此，综述大尺寸LPBF流场分析及在线监控的研究进展。在流场分析方面，从流道结构优化设计、流场参数及多物理场耦合模拟三个方面系统分析了气流场对飞溅及成形性能的影响。在过程监控方面，系统论述LPBF过程在线监测、数据处理与分析和过程控制方法的研究现状。最后探讨了大尺寸LPBF流场分析及在线监控目前存在的问题及发展趋势。通过结合流场分析及在线监控两大关键方向对大尺寸LPBF的研究进展进行阶段性总结，旨在为推进大尺寸LPBF技术的发展提供重要参考。

关键词: 多激光, 大尺寸, 粉末床激光熔融, 流场分析, 在线监控

Abstract: Laser powder bed fusion (LPBF) technology with multi-laser beam splicing has the characteristics of high forming efficiency and large forming size, which can meet the manufacturing requirements of large complex and precise key components in aerospace, nuclear power and other fields, and has become the inevitable trend of LPBF technology development. However, how to ensure the stability, process reproducibility and quality reliability of large-scale LPBF forming process is the key challenge of this technology. In recent years, obtaining uniform and consistent airflow through analysis and optimization of the gas flow field is an effective way to achieve stable and high quality forming of large-scale LPBF for a long time. At the same time, the introduction of in-situ monitoring technology can realize real-time monitoring, feedback and adjustment of the molding process, which is a key technical means to grasp the process regulation rules and solve the process instability. Thus, the research progress in flow field analysis and in-situ monitoring of large-scale LPBF is reviewed: In the analysis of flow field, the influence of flow field on spattering and forming performance is systematically analyzed from three aspects: flow channel structure optimization design, flow field parameters and multi-physical field coupling simulation. In the aspect of in-situ monitoring of forming process, the current research status of in-situ monitoring, data processing and analysis, and process control methods of LPBF process is systematically discussed. Finally, the existing problems and development trend of large-scale LPBF flow field analysis and in-situ monitoring are discussed. A phased summary of the research progress of large-scale LPBF is conducted based on the two key directions of flow field analysis and in-situ monitoring, aiming to provide important references for promoting the development of large-scale LPBF technology.

Key words: multi-laser, large-scale, laser powder bed fusion, flow field analysis, in-situ monitoring

中图分类号:

TG665

杨永强, 蒋仁武, 刘子欣, 周瀚翔, 李阳, 王迪. 大尺寸粉末床激光熔融流场分析及在线监控研究进展[J]. 机械工程学报, 2023, 59(19): 389-410.

YANG Yongqiang, JIANG Renwu, LIU Zixin, ZHOU Hanxiang, LI Yang, WANG Di. Research Progress of Flow Field Analysis and In-situ Monitoring for Large-scale Laser Powder Bed Fusion[J]. Journal of Mechanical Engineering, 2023, 59(19): 389-410.

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