双紫外臭氧动态掩膜高效制造大尺度零件原型的方法研究

In recent years macro high precision high efficiency surface curing manufacturing methods have become a hot topic. Certain critical strategic Chinese production parts like wind tunnel blade can reach to size up to 1.3 – 1.5 meters. Continuous liquid interface Production technology has accelerated Z-axis manufacturing speed for nearly 100 times faster. However, limitation in optical solidifying components restrained single manufacturing size to within 100mm, which is 1/200 of the required whole single step surface manufacturing size. This project intends to utilize phenomenon like O2 and O3 behavior in absorbs ultra-violet lights, pure O2-O3 transferring mechanism, as well as the immediate solidifying nature in optical-chemical reactions. A closed system of pure O2 will be built, using O3 filled layer mask as amplifier to increase single layer solidifying area, which will dynamically produce large scale prototypes. The project will analyze the speed of O2-O3 transfer, gas temperature, gas distribution under short-wavelength ultra-violet light exposure in room temperature, and the system temperature change speed in O3-O2 transfer under ultra-violet absorption. The process will test O3 filled mask’s amplifying effect. Combining with excimer lamp, based on quantum yield, the experiment will improve energy source with double ultra-violet combination solution. This process will be used to analyze mass and heat transfer mechanism in photothermal field and cooling solution, build a system parameter with mask effect model, and form a computation system for controllable exposure amount. As a result, a double ultra-violet source system will be built based on exposure light spectrum, a suitable initiate solution for resin will be developed, and the process will be analyzed for cooperate mechanism. This study will provide fundamental guidance for future processes.

近年来宏微高精高效制造技术成为研究热点,我国战略装备关键件如风洞压气叶片尺寸达1.3至1.5米。连续液面生长技术将传统面制造速度提升了一百倍,但其曝光平面仅能制造小于一百毫米的原型,单层固化面积是战略需求的两百分之一。根据臭氧在地球外层的循环保护机制,本项目提出构建纯氧封闭体,采用臭氧实现掩膜功能，提高光制造固化面积的新方法。主要研究内容为：常温下不同紫外照度氧气生成臭氧的速度、浓度及温度分布；臭氧吸收紫外线转化为氧气的过程及温度场变化，实验测试臭氧掩膜效果；选择准分子光计算双紫外线量子产额，实验测定臭氧消失条件，优化形成双紫外曝光组合方案；研究二者叠加反应中，光热场传质传热机制及冷却方法；建立封闭体结构的掩膜效应模型，形成可控的恒温循环方法；最后根据实际曝光谱线，构建双紫外光路系统，依据树脂性能建立臭氧掩膜协同固化机制。研究结果对大尺度原型制造有指导意义。

宏微高精高效制造是光固化增材重要发展方向，本项目提出双紫外臭氧动态掩模(dual-ultraviolet ozone dynamic mask,DUOBM)新方法，解决高效增材大面积光固化矛盾。项目在双紫外辐照纯氧气的条件下，完成了紫外光子与氧异构体分子结构转化基础梳理；探索了封闭体臭氧掩模固化准则：基于朗伯比尔定律和树脂曝光特性，提出臭氧临界掩模浓度新概念，通过理论推导给出掩模版高度设计准则，结合树脂光聚合理论给出了光固化方程，形成了掩模版平面设计准则和精度基础，依据树脂聚合机理揭示了臭氧掩膜协同固化机制。项目开发了双紫外臭氧掩模数据采集系统，形成了不同阶段科研基础条件，根据科研需要搭建不同实验台，完成了常温下短紫外照度氧气生成臭氧的速度、浓度实验，测试了中紫外消除臭氧的规律；分析了双紫外臭氧掩模主要误差来源，对掩模版内臭氧扩散和磁约束进行了仿真计算。这些基于规律性的系统化研究探索，为大面积光固化增材方法提供新的途径。.项目结合原理样机需求，开展了LED、无极紫外灯及其匀光系统的研究；根据不同工程场景需求，开展了新光敏树脂配制、金属陶瓷改性材料的性能研究；结合光固化原型特征，开展了快速铸造应用案例研究；根据人才培养要求，开展了增材制造不同材料的组织性能基础研究，这些成果为增材制造技术的推广应用有重要参考价值。

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