Additive manufacturing method and device for ceramic and composite thereof

Abstract

Additive manufacturing (AM) methods and devices for high-melting-point materials are disclosed. In an embodiment, an additive manufacturing method includes the following steps. (S1) Slicing a three-dimensional computer-aided design model of a workpiece into multiple layers according to shape, thickness, and size accuracy requirements, and obtaining data of the multiple layers. (S2) Planning a forming path according to the data of the multiple layers and generating computer numerical control (CNC) codes for forming the multiple layers. (S3) Obtaining a formed part by preheating a substrate, performing a layer-by-layer spraying deposition by a cold spraying method, and heating a spray area to a temperature until the spraying deposition of all sliced layers is completed. (S4) Subjecting the formed part to a surface modification treatment by a laser shock peening method.

The disclosure claimed is: 
     
         1 . A device, comprising: a data processing module, a spraying deposition module, a heating module, and a laser shock peening module, wherein:
 the data processing module is configured to:
 slice the three-dimensional computer-aided design model of the workpiece into multiple layers according to the shape, thickness, and size accuracy requirements; 
 obtain data of multiple sliced layers; 
 plan the forming path according to the data of the multiple slice layers; and 
 generate computer numerical control codes for forming the slice layers; 
   the spraying deposition module is configured to perform a layer-by-layer spraying deposition according to the computer numerical control codes of the slice layers obtained by the data processing module;   the heating module is configured to preheat the substrate and heat the spray area to a temperature until the spraying deposition of all slice layers is completed, wherein the temperature is in a range of the melting point of the sprayed powder minus 200° C. to the melting point of the sprayed powder; and   the laser shock peening module is configured to modify a surface of a formed part to generate the predetermined residual compressive stress thereon.   
     
     
         2 . The device according to  claim 1 , further comprising a computer numerical control machine tool, wherein:
 the computer numerical control machine tool comprises a workbench ( 10 ), a gantry machine tool ( 1 ), and a first spindle ( 5 ) provided on the gantry machine tool ( 1 );   the workbench ( 10 ) is provided below the gantry machine tool ( 1 );   the gantry machine tool ( 1 ) is configured to integrate the data processing module, the spraying deposition module, the heating module, and the laser shock peening module;   the spraying deposition module comprises a high-speed cold spraying gun ( 7 ) and a substrate ( 9 );   the high-speed cold spraying gun ( 7 ) is provided at the bottom of the first spindle ( 5 );   the substrate ( 9 ) is provided on the workbench ( 10 );   the heating module comprises a first heating unit and a second heating unit;   the first heating unit is provided above the substrate ( 9 ); and   the second heating unit is provided at the bottom of the first spindle ( 5 ).   
     
     
         3 . The device according to  claim 2 , further comprising a second spindle ( 3 ), a temperature sensor ( 6 ), a milling/grinding device ( 2 ), and a micro-rolling device ( 4 ), wherein:
 the second spindle ( 3 ) is provided on the gantry machine tool ( 1 );   the milling/grinding device ( 2 ) is provided at the bottom of the second spindle ( 3 ); and   the temperature sensor ( 6 ) and the micro-rolling device ( 4 ) are provided at the bottom of the first spindle ( 5 ).   
     
     
         4 . The device according to  claim 2 , wherein:
 the high-speed cold spraying gun ( 7 ) utilizes a laser/cold spraying composite nozzle;   the composite nozzle comprises a composite nozzle outer wall ( 11 ) and a composite nozzle inner wall provided inside the composite nozzle outer wall ( 11 );   a beam splitter ( 14 ) is provided between the composite nozzle outer wall ( 11 ) and the composite nozzle inner wall;   a powder inlet ( 15 ) is provided on the top of the composite nozzle inner wall;   a high-pressure gas inlet ( 16 ) is provided on a side wall of the composite nozzle inner wall; and   a nozzle ( 13 ) is provided at the bottom of the composite nozzle inner wall.