Forming system and method of hybrid additive manufacturing and surface coating

Patent metadata

Field	Value
Publication number	US-11247392-B2
Application number	US-202017005865-A
Country	US
Kind code	B2
Filing date	Aug 28, 2020
Priority date	Aug 29, 2019
Publication date	Feb 15, 2022
Grant date	Feb 15, 2022

Abstract

The present invention belongs to the field of multi-material additive manufacturing (AM), and in particular discloses a forming system and method of hybrid AM and surface coating. The hybrid forming system includes an additive forming device, a laser-assisted cold spraying (LACS) device and a workbench. The additive forming device and the LACS device are located above the workbench. During manufacturing, the additive forming device forms a part to be formed on the workbench layer by layer, and the LACS device performs coating peening treatment on inner and outer surfaces of the part to be formed during the forming process, thereby jointly completing the composite manufacturing of the part to be formed. The present invention makes full use of the rapid prototyping advantage of the short-flow AM process, and integrates the surface coating peening process into the hybrid forming system.

First claim

What is claimed is:

1. A forming system of hybrid additive manufacturing (AM) and surface coating, comprising an additive forming device, a laser-assisted cold spraying (LACS) device and a workbench, wherein the additive forming device and the LACS device are located above the workbench; during manufacturing, the additive forming device forms a part to be formed on the workbench layer by layer, and the LACS device performs coating peening treatment on inner and outer surfaces of the part to be formed during the forming process, thereby jointly completing the composite manufacturing of the part to be formed;
wherein, the LACS device comprises a gas compression and drying unit, a powder storage and feeding unit and a ring-shaped laser unit that are sequentially connected; during manufacturing, a coating powder material in the powder storage and feeding unit is compressed and dried by the gas compression and drying unit, sent to the ring-shaped laser unit, then heated by the ring-shaped laser unit, and coated on the inner and outer surfaces of the part to be formed.

2. The forming system of hybrid AM and surface coating according to claim 1 , wherein the powder storage and feeding unit comprises two or more powder storage and feeding tanks.

3. The forming system of hybrid AM and surface coating according to claim 1 , wherein a feeding rate of the coating powder material of the powder storage and feeding unit is 40-70 g/min, a powder particle size is 5-60 μm, and a preheating temperature of the coating powder material is 400-800° C.

4. The forming system of hybrid AM and surface coating according to claim 1 , further comprising a micro-rolling device and a milling and grinding compound device, wherein the micro-rolling device and the milling and grinding compound device are located above the workbench; the micro-rolling device and the milling and grinding compound device perform finish machining on the part to be formed during the process of forming the part to be formed layer by layer by the additive forming device.

5. A forming method of hybrid AM and surface coating, which is implemented by
using a forming system of hybrid additive manufacturing (AM) and surface coating, the forming system comprising an additive forming device, a laser-assisted cold spraying (LACS) device and a workbench, wherein the additive forming device and the LACS device are located above the workbench; during manufacturing, the additive forming device forms a part to be formed on the workbench layer by layer, and the LACS device performs coating peening treatment on inner and outer surfaces of the part to be formed during the forming process, thereby jointly completing the composite manufacturing of the part to be formed;
wherein, the LACS device comprises a gas compression and drying unit, a powder storage and feeding unit and a ring-shaped laser unit that are sequentially connected; during manufacturing, a coating powder material in the powder storage and feeding unit is compressed and dried by the gas compression and drying unit, sent to the ring-shaped laser unit, then heated by the ring-shaped laser unit, and coated on the inner and outer surfaces of the part to be formed;

the forming method comprising the following steps:
S1: presetting an additive forming trajectory and a coating peening trajectory according to a three-dimensional (3D) model of a part to be formed;
S2: enabling an additive forming device to form a multi-layer part to be formed on a workbench layer by layer according to the preset additive forming trajectory, and enabling an LACS device to perform coating peening treatment on inner and outer surfaces of the part to be formed according to the preset coating peening trajectory; and,
S3: repeating S2 several times until the manufacturing of the part is completed.

6. The forming method of hybrid AM and surface coating according to claim 5 ; wherein, the method includes
compressing and drying a coating powder material in the powder storage and feeding unit using the gas compression and drying unit;
sending the coating powder material to the ring-shaped laser unit;
heating the coating powder material with the ring-shaped laser unit; and,
coating the coating powder material on the inner and outer surfaces of the part to be formed.

7. The forming method of hybrid AM and surface coating of claim 6 , wherein the compressing and the drying are performed in two or more powder storage and feeding tanks in the powder storage and feeding unit.

8. The forming method of hybrid AM and surface coating of claim 6 , wherein the method further comprises:
configuring the powder storage and feeding unit to have a powder feeding rate ranging from 40-70 g/min;
selecting the coating powder material to have a particle size ranging from 5-60 μm; and,
preheating the coating powder material at a temperature ranging from 400-800° C.

9. The forming method of hybrid AM and surface coating according to claim 5 , the method further comprising
using a micro-rolling device and a milling and grinding compound device; and,
performing finish machining on the part to be formed with the micro-rolling device and the milling and grinding compound device, wherein the finish machining is performed during the process of forming the part to be formed, the forming occurring layer by layer using the additive forming device.

Assignees

• Univ Huazhong Science Tech

Inventors

• Zhang Haiou
• Hu Xiaoqi
• Dai Fusheng
• Wang Guilan

Classifications

• B22F3/115 Primary

  by spraying molten metal, i.e. spray sintering, spray casting · CPC title

• B22F12/55

  Two or more means for feeding material · CPC title

• B22F12/52

  Hoppers · CPC title

• B22F10/66

  by mechanical means · CPC title

• B22F10/50

  Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up · CPC title