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Advances in polishing of internal structures on parts made by laser-based powder bed fusion

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0724-0

摘要： The internal structures of metallic products are important in realizing functional applications. Considering the manufacturing of inner structures, laser-based powder bed fusion (L-PBF) is an attractive approach because its layering principle enables the fabrication of parts with customized interior structures. However, the inferior surface quality of L-PBF components hinders its productization progress seriously. In this article, process, basic forms, and applications relevant to L-PBF internal structures are reviewed comprehensively. The causes of poor surface quality and differences in the microstructure and property of the surface features of L-PBF inner structures are presented to provide a perspective of their surface characteristics. Various polishing technologies for L-PBF components with inner structures are presented, whereas their strengths and weaknesses are summarized along with a discussion on the challenges and prospects for improving the interior surface quality of L-PBF parts.

关键词： laser-based powder bed fusion     polishing     internal structures     surface quality     surface features     post process     additive manufacturing    

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Review of materials used in laser-aided additive manufacturing processes to produce metallic products

Xiaodong NIU, Surinder SINGH, Akhil GARG, Harpreet SINGH, Biranchi PANDA, Xiongbin PENG, Qiujuan ZHANG

《机械工程前沿（英文）》 2019年 第14卷 第3期   页码 282-298 doi: 10.1007/s11465-019-0526-1

摘要： Rapid prototyping (RP) or layered manufacturing (LM) technologies have been extensively used to manufacture prototypes composed mainly of plastics, polymers, paper, and wax due to the short product development time and low costs of these technologies. However, such technologies, with the exception of selective laser melting and sintering, are not used to fabricate metallic products because of the resulting poor life, short cycle, poor surface finish, and low structural integrity of the fabricated parts. The properties endowed by these parts do not match those of functional parts. Therefore, extensive research has been conducted to develop new additive manufacturing (AM) technologies by extending existing RP technologies. Several AM technologies have been developed for the fabrication of metallic objects. These technologies utilize materials, such as Ni-, Al-, and Ti-based alloys and stainless steel powders, to fabricate high-quality functional components. The present work reviews the type of materials used in laser-based AM processes for the manufacture of metallic products. The advantages and disadvantages of processes and different materials are summarized, and future research directions are discussed in the final section. This review can help experts select the ideal type of process or technology for the manufacturing of elements composed of a given alloy or material (Ni, Ti, Al, Pb, and stainless steel).

关键词： direct metal deposition     laser-based manufacturing     rapid manufacturing     selective laser melting     additive manufacturing    

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A zone-layered trimming method for ceramic core of aero-engine blade based on an advanced reconfigurablelaser processing system

《机械工程前沿（英文）》 2022年 第17卷 第2期 doi: 10.1007/s11465-022-0675-5

摘要： Ceramic structural parts are one of the most widely utilized structural parts in the industry. However, they usually contain defects following the pressing process, such as burrs. Therefore, additional trimming is usually required, despite the deformation challenges and difficulty in positioning. This paper proposes an ultrafast laser processing system for trimming complex ceramic structural parts. Opto-electromechanical cooperative control software is developed to control the laser processing system. The trimming problem of the ceramic cores used in aero engines is studied. The regional registration method is introduced based on the iterative closest point algorithm to register the path extracted from the computer-aided design model with the deformed ceramic core. A zonal and layering processing method for three-dimensional contours on complex surfaces is proposed to generate the working data of high-speed scanning galvanometer and the computer numerical control machine tool, respectively. The results show that the laser system and the method proposed in this paper are suitable for trimming complex non-datum parts such as ceramic cores. Compared with the results of manual trimming, the method proposed in this paper has higher accuracy, efficiency, and yield. The method mentioned above has been used in practical application with satisfactory results.

关键词： ceramic parts trimming     computer-aided laser manufacturing     3D vision     reconfigurable laser processing system    

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基于飞秒激光的用于捕获肿瘤细胞的聚合物芯片实验室的智能程序 Article

Annalisa Volpe, Udith Krishnan, Maria Serena Chiriacò, Elisabetta Primiceri, Antonio Ancona, Francesco Ferrara

《工程（英文）》 2021年 第7卷 第10期   页码 1436-1442 doi: 10.1016/j.eng.2020.10.012

摘要：

由于聚合物芯片实验室具有高度的精准性和灵活性，将其用于设计和制造的快速原型制作方法正在兴起。例如，一个微流控平台可能需要优化阶段，而在此阶段需要不断修改结构和几何形状；然而，这只有在具有简易可控的制造方法和低成本材料的情况下才可能实现。本文描述了一个微流控工具的实现过程，从计算机辅助设计（CAD）到作为循环肿瘤细胞（CTC）捕获工具应用的概念验证。整个平台通过使用聚甲基丙烯酸甲酯（PMMA）及结合飞秒（fs）激光和微铣制造技术实现。该多层设备通过一种简便、低成本的溶剂辅助方法组装。然后通过固定能够在没有标记的情况下区分癌细胞与非癌细胞的捕获探针，实现蛇形微通道的直接生物功能化。由于低材料成本、可定制的方法以及可生物应用，已实现的平台成为即时医疗工业开发与应用的合适模型。

关键词： 芯片实验室     飞秒激光     循环肿瘤细胞     即时医疗     热键合     聚合物    

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Development of lunar regolith composite and structure via laser-assisted sintering

《机械工程前沿（英文）》 doi: 10.1007/s11465-021-0662-2

摘要： Aiming at the exploration and resource utilization activities on the Moon, in situ resource utilization and in situ manufacturing are proposed to minimize the dependence on the ground transportation supplies. In this paper, a laser-assisted additive manufacturing process is developed to fabricate lunar regolith composites with PA12/SiO2 mixing powders. The process parameters and composite material compositions are optimized in an appropriate range through orthogonal experiments to establish the relationship of process–structure–property for lunar regolith composites. The optimal combination of composite material compositions and process parameters are mixing ratio of 50/50 in volume, laser power of 30 W, scanning speed of 3500 mm/s, and scanning hatch space of 0.2 mm. The maximum tensile strength of lunar regolith composites reaches 9.248 MPa, and the maximum depth of surface variation is 120.79 μm, which indicates poor powder fusion and sintering quality. Thereafter, the mechanical properties of laser-sintered lunar regolith composites are implemented to the topology optimization design of complex structures. The effectiveness and the feasibility of this laser-assisted process are potentially developed for future lightweight design and manufacturing of the solar panel installed on the lunar rover.

关键词： in situ manufacturing     laser-assisted powder fusion process     mechanical properties     topological structure design    

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Differences in microstructure and properties between selective laser melting and traditional manufacturing

Bo SONG,Xiao ZHAO,Shuai LI,Changjun HAN,Qingsong WEI,Shifeng WEN,Jie LIU,Yusheng SHI

《机械工程前沿（英文）》 2015年 第10卷 第2期   页码 111-125 doi: 10.1007/s11465-015-0341-2

摘要：

Selective laser melting (SLM), as one of the additive manufacturing technologies, is widely investigated to fabricate metal parts. In SLM, parts are manufactured directly from powders in a layer-by-layer fashion; SLM also provides several advantages, such as production of complex parts with high three-dimensional accuracy, compared with other additive manufacturing technologies. Therefore, SLM can be applied in aeronautics, astronautics, medicine, and die and mould industry. However, this technique differs from traditional methods, such as casting and forging; for instance, the former greatly differs in terms of microstructure and properties of products. This paper summarizes relevant studies on metal material fabrication through SLM. Based on a work completed in Huazhong Univ. Sci Tech., Rapid Manuf. Center (HUST-RMC) and compared with characteristics described in other reported studies, microstructure, properties, dimensional accuracy, and application of SLM are presented.

关键词： selective laser melting     microstructure     performance     application    

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我国激光技术与应用2035 发展战略研究

“我国激光技术与应用2035 发展战略研究”项目综合组

《中国工程科学》 2020年 第22卷 第3期   页码 1-6 doi: 10.15302/J-SSCAE-2020.03.001

摘要：

为促进激光技术及应用的发展，中国工程院于2018 年启动了“我国激光技术与应用2035 发展战略研究”重点咨询项目，本文是项目研究综合报告，文章简要分析了激光技术及在科研与产业中的工具性、引领性和颠覆性作用，分析了我国激光技术在前沿激光、制造加工、信息通信、医疗诊治等领域的科研和应用的发展现状，梳理了多个制约加速发展的问题，提出了我国激光技术及应用2035 年发展目标设想：强化顶层统筹谋划，引领我国激光技术与应用产业快速发展；加强基础研究，聚力突破产业化发展中的重大基础问题、共性技术基础和基础材料、器件；设立应用研发专项，打造多个新激光产业链；创新产业协同机制，完善激光产业创新生态；强化激光基础教育，加大对激光及光学学科人才培养力度等政策措施建议。

关键词： 激光技术     激光制造     激光通信     激光诊疗    

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金属激光增材制造技术发展研究

郭绍庆,刘伟,黄帅,向巧

《中国工程科学》 2020年 第22卷 第3期   页码 56-62 doi: 10.15302/J-SSCAE-2020.03.009

摘要：

金属激光增材制造（LAM）技术是支撑航空、航天、医疗等领域智能制造的关键基础技术。本文以问卷与现场调研为主、辅以文献查阅方法，对国内外金属LAM 技术研究和应用的现状与趋势进行系统梳理，总结国外发展经验与启示，分析国内技术发展面临的差距，针对性提出我国LAM 技术发展策略，以期为国家科技与产业发展战略、2035 年领域发展目标的制定提供支持。研究发现，金属LAM 技术的关注点仍为组织性能调控，但形状控制研究相对缺乏；为满足高质量制造的亟需，相关设备的过程监控功能获得高度重视；为提升高价值零件的制造能力与效率，增减材复合加工设备成为新增研发热点；金属LAM 产业的良性发展，需要实施包括材料、工艺、设备、验证、标准、人员培训在内的全产业链整合。研究建议，在夯实研究基础的同时，充分发挥材料基因组技术的作用，加强核心器件自主研发和装备集成的技术研究，稳步推进金属LAM技术的工程化普及应用。

关键词： 激光增材制造     金属材料     设备     产业化     发展建议    

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激光增材制造的热力学和动力学多尺度理解

顾冬冬, 马成龙, 夏木建, 戴冬华, 石齐民

《工程（英文）》 2017年 第3卷 第5期   页码 675-684 doi: 10.1016/J.ENG.2017.05.011

摘要：

选择性激光熔化（SLM）增材制造（AM）技术已成为精密制造高性能复杂形状金属零件的重要选择。SLM AM 工艺涉及复杂的物理化学现象、热力学特性以及高能激光束融化散粉颗粒时产生的相变。本文提出了针对金属材料SLM 工艺的多尺度建模和协调控制，其中，金属材料包括铝（Al）基合金（AlSi10Mg）、镍（Ni）基超合金（Inconel 718）及陶瓷颗粒增强的铝基和镍基复合材料。从微观尺度研究氮化铝（AlN）颗粒在SLM 处理后的铝基纳米复合材料中的迁移和分布机制以及SLM处理后的碳化钨（WC）/Inconel 718 复合材料中增强体和基体之间梯度界面的原位形成。从中尺度研究AlSi10Mg 和Inconel 718 合金粉末的激光吸收和熔化/ 致密化特性。最后，从宏观尺度提出了逐行局部激光扫描过程中的应力发展和SLM 处理后的复合材料变形的参数依赖控制方法。多尺度数值模拟和实验验证方法有利于监测SLM AM 过程中复杂的粉末激光作用、传热传质特性以及微观结构和力学性能的发展。

关键词： 增材制造     选择性激光熔化     多尺度建模     热力学     动力学    

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Effect of process parameters on the density and porosity of laser melted AlSi10Mg/SiC metal matrix composite

Omotoyosi H. FAMODIMU, Mark STANFORD, Chike F. ODUOZA, Lijuan ZHANG

《机械工程前沿（英文）》 2018年 第13卷 第4期   页码 520-527 doi: 10.1007/s11465-018-0521-y

摘要：

Laser melting of aluminium alloy—AlSi10Mg has increasingly been used to create specialised products in various industrial applications, however, research on utilising laser melting of aluminium matrix composites in replacing specialised parts have been slow on the uptake. This has been attributed to the complexity of the laser melting process, metal/ceramic feedstock for the process and the reaction of the feedstock material to the laser. Thus, an understanding of the process, material microstructure and mechanical properties is important for its adoption as a manufacturing route of aluminium metal matrix composites. The effects of several parameters of the laser melting process on the mechanical blended composite were thus investigated in this research. This included single track formations of the matrix alloy and the composite alloyed with 5% and 10% respectively for their reaction to laser melting and the fabrication of density blocks to investigate the relative density and porosity over different scan speeds. The results from these experiments were utilised in determining a process window in fabricating near-fully dense parts.

关键词： selective laser melting     additive manufacturing     mechanical alloying     powder metallurgy     aluminium metal matrix composite    

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Process improvement in laser hot wire cladding for martensitic stainless steel based on the Taguchi method

Zilin HUANG,Gang WANG,Shaopeng WEI,Changhong LI,Yiming RONG

《机械工程前沿（英文）》 2016年 第11卷 第3期   页码 242-249 doi: 10.1007/s11465-016-0397-7

摘要：

Laser hot wire cladding, with the prominent features of low heat input, high energy efficiency, and high precision, is widely used for remanufacturing metal parts. The cladding process, however, needs to be improved by using a quantitative method. In this work, volumetric defect ratio was proposed as the criterion to describe the integrity of forming quality for cladding layers. Laser deposition experiments with FV520B, one of martensitic stainless steels, were designed by using the Taguchi method. Four process variables, namely, laser power (P), scanning speed (Vs), wire feed rate (Vf), and wire current (I), were optimized based on the analysis of signal-to-noise (S/N) ratio. Metallurgic observation of cladding layer was conducted to compare the forming quality and to validate the analysis method. A stable and continuous process with the optimum parameter combination produced uniform microstructure with minimal defects and cracks, which resulted in a good metallurgical bonding interface.

关键词： process optimization     Taguchi method     signal-to-noise (S/N) ratio     volumetric defect ratio     laser hot wire cladding    

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Training for smart manufacturing using a mobile robot-based production line

Shuting WANG, Liquan JIANG, Jie MENG, Yuanlong XIE, Han DING

《机械工程前沿（英文）》 2021年 第16卷 第2期   页码 249-270 doi: 10.1007/s11465-020-0625-z

摘要： Practice experimentation that integrates the manufacturing processes and cutting-edge technologies of smart manufacturing (SM) is essential for future academic and applied engineering personnel. The broadening efficacy of hands-on experience in SM engineering education has been manifested. In this regard, a reference practical system is proposed in this study for hands-on training in SM crucial advancements. The system constructs a mobile robot-based production line (MRPL) to increase participants’ interest in theoretical learning and professional skills. The MRPL-based reference system includes the comprehensive principles and processes involved in modern SM factories from warehousing to logistics, processing, and testing. With key features of modularity, integrability, customizability, and open architecture, this system has a threefold objective. First, it is an interdisciplinary subject that enables students to translate classroom learning into authentic practices, thus facilitating knowledge synthesis and training involvements. Second, it offers effective support to cultivate the attributions and behavioral competencies of SM talents, such as perseverance, adaptability, and cooperation. Third, it promotes students’ capacities for critical thinking and problem solving so that they can deal with the difficulties that physical systems have and motivates them to pursue careers with new syllabi, functions, and process technologies. The received positive evaluations and assessments confirm that this MRPL-based reference system is beneficial for modern SM talent training in higher engineering education.

关键词： smart manufacturing     hands-on experience     engineering education     mobile robot-based production line    

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微观选择性激光熔化技术发展的现状及未来展望 Review

Balasubramanian Nagarajan, Zhiheng Hu, Xu Song, Wei Zhai, Jun Wei

《工程（英文）》 2019年 第5卷 第4期   页码 702-720 doi: 10.1016/j.eng.2019.07.002

摘要：

增材制造（AM）能将各种材料制成形状复杂的部件，因此在制造业中越来越受到青睐。选择性激光熔化（SLM）是一种常见的AM技术，它基于粉床熔融法（PBF）来处理金属，但目前只专注于大中型元件的制作。本文综述了微型金属材料SLM的研究现状。与通常用于微观AM的直接写入技术相比，微观SLM由于许多因素而更加具有吸引力，包括更快的周期时间、流程简单性和材料通用性。此外，本文综合评价了利用SLM和选择性激光烧结（SLS）制造微尺度零件的各种研究工作和商业系统，不仅从微观尺度上找出了SLM存在的问题，包括粉末重涂、激光光学和粉末粒度等， 还详细阐述了SLM未来的发展方向。文章详细回顾了粉床技术中现有的粉末重涂方法，并描述了在AM领域实施干粉分配方法的新进展。对AM部件的一些二次整理技术进行了回顾，重点介绍了细微加工特征的应用以及与微观SLM系统的结合。

关键词： 增材制造     选择性激光熔化     微细加工     混合处理     粉床重涂    

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Novel slack-based robust scheduling rule for a semiconductor manufacturing system with uncertain processing

Juan LIU, Fei QIAO, Yumin MA, Weichang KONG

《工程管理前沿（英文）》 2018年 第5卷 第4期   页码 507-514 doi: 10.15302/J-FEM-2018045

摘要：

The NP-hard scheduling problems of semiconductor manufacturing systems (SMSs) are further complicated by stochastic uncertainties. Reactive scheduling is a common dynamic scheduling approach where the scheduling scheme is refreshed in response to real-time uncertainties. The scheduling scheme is overly sensitive to the emergence of uncertainties because the optimization of performance (such as minimum make-span) and the system robustness cannot be achieved simultaneously by conventional reactive scheduling methods. To improve the robustness of the scheduling scheme, we propose a novel slack-based robust scheduling rule (SR) based on the analysis of robustness measurement for SMS with uncertain processing time. The decision in the SR is made in real time given the robustness. The proposed SR is verified under different scenarios, and the results are compared with the existing heuristic rules. Simulation results show that the proposed SR can effectively improve the robustness of the scheduling scheme with a slight performance loss.

关键词： semiconductor manufacturing system     uncertain processing time     dynamic scheduling     slack-based robust scheduling rule    

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标题 作者 时间 类型 操作

Advances in polishing of internal structures on parts made by laser-based powder bed fusion

期刊论文

Review of materials used in laser-aided additive manufacturing processes to produce metallic products

Xiaodong NIU, Surinder SINGH, Akhil GARG, Harpreet SINGH, Biranchi PANDA, Xiongbin PENG, Qiujuan ZHANG

期刊论文

A zone-layered trimming method for ceramic core of aero-engine blade based on an advanced reconfigurablelaser processing system

期刊论文

Masoud Mahjouri-Samani：Laser-based synthesis and Processing of 2D Quantum Materials（2019年10月10日）

2021年04月23日

会议视频

基于飞秒激光的用于捕获肿瘤细胞的聚合物芯片实验室的智能程序

Annalisa Volpe, Udith Krishnan, Maria Serena Chiriacò, Elisabetta Primiceri, Antonio Ancona, Francesco Ferrara

期刊论文

Development of lunar regolith composite and structure via laser-assisted sintering

期刊论文

Differences in microstructure and properties between selective laser melting and traditional manufacturing

Bo SONG,Xiao ZHAO,Shuai LI,Changjun HAN,Qingsong WEI,Shifeng WEN,Jie LIU,Yusheng SHI

期刊论文

我国激光技术与应用2035 发展战略研究

“我国激光技术与应用2035 发展战略研究”项目综合组

期刊论文

金属激光增材制造技术发展研究

郭绍庆,刘伟,黄帅,向巧

期刊论文

激光增材制造的热力学和动力学多尺度理解

顾冬冬, 马成龙, 夏木建, 戴冬华, 石齐民

期刊论文

Effect of process parameters on the density and porosity of laser melted AlSi10Mg/SiC metal matrix composite

Omotoyosi H. FAMODIMU, Mark STANFORD, Chike F. ODUOZA, Lijuan ZHANG

期刊论文

Process improvement in laser hot wire cladding for martensitic stainless steel based on the Taguchi method

Zilin HUANG,Gang WANG,Shaopeng WEI,Changhong LI,Yiming RONG

期刊论文

Training for smart manufacturing using a mobile robot-based production line

Shuting WANG, Liquan JIANG, Jie MENG, Yuanlong XIE, Han DING

期刊论文

微观选择性激光熔化技术发展的现状及未来展望

Balasubramanian Nagarajan, Zhiheng Hu, Xu Song, Wei Zhai, Jun Wei

期刊论文

Novel slack-based robust scheduling rule for a semiconductor manufacturing system with uncertain processing

Juan LIU, Fei QIAO, Yumin MA, Weichang KONG

期刊论文