悬垂结构SLM成形过程中翘曲变形形成机制和控制方法综述

    Review on Formation Mechanisms and Control Methods of Warping Deformation in SLM Forming Process of Overhang Structures

    • 摘要: 激光选区熔化(selective laser melting,SLM)技术凭借其在复杂构件快速成形及优异力学性能方面的显著优势,已在航空航天等高精度制造领域得到广泛应用。然而,在SLM过程中,悬垂区域因下方缺乏足够支撑,常发生翘曲变形现象。这一问题显著降低了零件的尺寸精度、表面质量及力学性能,严重时甚至导致制造失败。聚焦于翘曲变形对成形件的影响、其形成原因、影响因素(包括能量参数、扫描策略、扫描速度、结构参数及支撑设计等)及优化策略,综述了悬垂结构SLM成形过程中翘曲变形的形成机制与控制方法,并总结了智能补偿、数值模拟等先进控制技术的研究进展。进一步展望了基于人工智能的工艺决策、多传感原位监测等前沿研究方向,以期为悬垂结构的高质量SLM成形提供理论参考与技术支撑。

       

      Abstract: Selective laser melting (SLM) has been widely adopted in high-precision manufacturing fields such as aerospace due to its advantages in rapid forming of complex components and excellent mechanical properties. However, during the SLM fabrication process, warping deformation often occurs in overhang regions due to insufficient support beneath them. This issue significantly compromises the dimensional accuracy, surface quality, and mechanical properties of the parts, and in severe cases, it even leads to manufacturing failure. This paper systematically reviewed the formation mechanisms and control methods of warping deformation in SLM-fabricated overhang structures, focusing on its effects on formed parts, underlying causes, influencing factors including energy parameters, scanning strategies, scanning speed, structural parameters, support design and optimization strategies. The recent advances in advanced control techniques such as intelligent compensation and numerical simulation were summarized. Emerging research directions including artificial intelligence-based process decision-making and multi-sensor in-situ monitoring were further prospected to provide theoretical insights and technical support for high-quality SLM fabrication of overhang structures.

       

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