Powder shaping method and apparatus thereof

Patent metadata

Field	Value
Publication number	US-9457517-B2
Application number	US-201314136555-A
Country	US
Kind code	B2
Filing date	Dec 20, 2013
Priority date	Nov 8, 2013
Publication date	Oct 4, 2016
Grant date	Oct 4, 2016

Abstract

A powder shaping method comprises: providing a powder on a target surface; providing a laser beam to illuminate the powder so as to form a pre-treated powder; and providing an energy beam to illuminate the pre-treated powder for enabling a shaping process. In addition, a powder shaping apparatus comprises a base, a target surface, a powder supply unit and an energy beam source system. The target surface is disposed on the base and can be fixed or moved on the base. The powder supply unit provides a powder on the target surface. The energy beam source system has a laser source and an energy source, the laser source provides a laser beam to illuminate the powder to form a pre-treated powder, and the energy source provides an energy beam to further illuminate the pre-treated powder to make a shaping process.

First claim

What is claimed is:

1. A powder shaping method, comprises the following steps:
providing a powder on a target surface;
illuminating a laser beam to the powder to form a pre-treated powder;
illuminating an energy beam to the pre-treated powder to perform a shaping process; and
wherein the laser beam is from substantially an ultra-fast laser source and the threshold fluence of the laser beam working on the powder is smaller than 6 J/cm 2 .

2. The powder shaping method of claim 1 , further comprises a step of:
providing an energy beam source system, while enabling the energy beam source system to comprise: a laser source, for providing the laser beam to illuminate the powder; and an energy source, for providing the energy beam to illuminate the pre-treated powder.

3. The powder shaping method of claim 1 , wherein the shaping process is substantially a sintering process.

4. The powder shaping method of claim 1 , wherein the shaping process is substantially a melting process.

5. The powder shaping method of claim 1 , further comprises a step of:
inducing the surfaced of the pre-treated powder to generate a micro- and nano-structure; or enabling the internal temperature of the electron inside the powder to be raised instantly for enabling the collision rate between electron and phonon to increase so as to cause the reflectivity of the powder to drop, and thereby, enabling the absorptivity of the powder that is to be sintered to be raised and also reducing the reflectivity of the pre-treated powder.

6. The powder shaping method of claim 2 , wherein the energy source is a source selected from the group consisting of: a continuous wave laser source, a long-pulse laser source, an electron beam source, and a plasma source.

7. The powder shaping method of claim 2 , wherein the energy beam source system further comprises: a beam expander, a beam splitter, a machine vision system and a first scan head.

8. The powder shaping method of claim 7 , wherein the first scan head is enabled to illuminate the laser beam onto the powder and then to illuminate the energy beam onto the pre-treated powder.

9. The powder shaping method of claim 2 , wherein the energy beam source system further comprises: a beam expander, a beam splitter, a machine vision system, a second scan head and a third scan head.

10. The powder shaping method of claim 9 , wherein the second scan head is enabled to illuminate the laser beam onto the powder before the third scan head is enabled to illuminate the energy beam onto the pre-treated powder.

11. A powder shaping apparatus, comprising:
a base;
a target, disposed on the base; and
a powder supply unit, for providing a powder on the target surface; and
an energy beam source system, further comprising:
a laser source, for providing a laser beam to illuminate the powder to form a pre-treated powder; and
an energy source, for providing an energy beam to further illuminate the pre-treated powder to perform a shaping process;

wherein, the laser source is substantially an ultra-fast laser source and the threshold fluence of the laser beam working on the powder is smaller than 6 J/cm 2 .

12. The powder shaping apparatus of claim 11 , wherein the energy beam source system illuminates the pre-treated powder to perform a sintering process.

13. The powder shaping apparatus of claim 11 , wherein the energy beam source system illuminates the pre-treated powder to perform a melting process.

14. The powder shaping apparatus of claim 11 , wherein the condition of the target surface is selected from the group consisting of: fixed condition, continuous moving condition, and non-continuous moving condition.

15. The powder shaping apparatus of claim 11 , wherein the wavelength of the ultra-fast laser source is ranged between 250 nm and 3000 nm.

16. The powder shaping apparatus of claim 11 , wherein the pulse width of the ultra-fast laser source is smaller than 1 ns.

17. The powder shaping apparatus of claim 11 , wherein the ultra-fast laser source has a repetition rate ranged between 1 Hz and 1 GHz.

18. The powder shaping apparatus of claim 11 , wherein the energy source is a source selected from the group consisting of: a continuous wave laser source, a long-pulse laser source, an electron beam source, and a plasma source, which the power of the energy beam from the energy source working on the powder is larger than 200 W.

19. The powder shaping apparatus of claim 11 , wherein the energy beam source system further comprises: a beam expander, a beam splitter, a machine vision system and a first scan head.

20. The powder shaping apparatus of claim 19 , wherein the first scan head is enabled to project the laser beam onto the powder and then to project the energy beam onto the pre-treated powder.

21. The powder shaping apparatus of claim 11 , wherein the energy beam source system further comprises: a beam expander, a beam splitter, a machine vision system, a second scan head and a third scan head.

22. The powder shaping apparatus of claim 21 , wherein the second scan head is enabled to project the laser beam onto the powder before the third scan head is enabled to project the energy beam onto the pre-treated powder.

23. The powder shaping apparatus of claim 11 , wherein the target is a plate, a platform, a stage, a work piece, or a powder bed.

24. A powder shaping method by employing a powder shaping apparatus which includes a base, a target disposed on the base, a powder supply unit for providing the powder on the target surface, and an energy beam source system that further comprises a laser source which provides a laser beam to illuminate the powder to form a pre-treated powder; and an energy beam to further illuminate the pre-treated powder; the powder shaping method comprises the following steps:
providing the powder on the target surface; and
illuminating the laser beam to the powder to form the pre-treated powder;
illuminating the energy beam to the pre-treated powder to perform the shaping process; and
wherein the laser source is substantially an ultra-fast laser source and the threshold fluence of the laser beam working on the powder is smaller than 6 J/cm2.

25. The powder shaping method of claim 24 , further comprises a step of:
inducing the surfaced of the pre-treated powder to generate a micro- and nano-structure; or enabling the internal temperature of the electron inside the powder to be raised instantly for enabling the collision rate between electron and phonon to increase so as to cause the reflectivity of the powder to drop, and thereby, enabling the absorptivity of the powder that is to be sintered to be raised and also reducing the reflectivity of the pre-treated powder.

26. The powder shaping method of claim 24 , wherein the energy source is a source selected from the group consisting of: a continuous wave laser source, a long-pulse laser source, an electron beam source, and a plasma source.

27. The powder shaping method of claim 24 , wherein the energy beam source system further comprises: a beam expander, a beam splitter, a machine vision system and a first scan head.

28. The powder shaping method of claim 27 , wherein the first scan head is enabled to illuminate the laser beam onto the powder and then to illuminate the energy beam onto the pre-treated powder.

29. The powder shaping method of claim 24 , wherein the e

Assignees

• Ind Tech Res Inst

Inventors

• Cheng Chung-Wei
• Chang Kuang-Po
• Lin Cen-Ying
• Wang shu-yi

Classifications

• B22F12/63

  Rollers · CPC title

• B22F12/44

  characterised by the configuration of the radiation means · CPC title

• B22F12/43

  pulsed; frequency modulated · CPC title

• B22F10/36

  of energy beam parameters · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title