CN111922655B - Continuous wire feeding induction heating composite rolling semi-solid additive manufacturing system and method - Google Patents
Continuous wire feeding induction heating composite rolling semi-solid additive manufacturing system and method Download PDFInfo
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- CN111922655B CN111922655B CN202010757960.8A CN202010757960A CN111922655B CN 111922655 B CN111922655 B CN 111922655B CN 202010757960 A CN202010757960 A CN 202010757960A CN 111922655 B CN111922655 B CN 111922655B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P17/00—Metal-working operations, not covered by a single other subclass or another group in this subclass
- B23P17/04—Metal-working operations, not covered by a single other subclass or another group in this subclass characterised by the nature of the material involved or the kind of product independently of its shape
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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Abstract
The invention provides a continuous wire feeding induction heating composite rolling semi-solid additive manufacturing system and a method, comprising the following steps: the device comprises a continuous wire feeding device, a straightening device, an induction heating device, a substrate, an X-direction linear motion mechanism, a first supporting mechanism and a second supporting mechanism; the first supporting mechanism is provided with a first base, a first fixed block and a roller fixed below the first fixed block, and the roller moves in the Y-Z direction; the induction heating device is arranged below the second fixed block of the second supporting mechanism and moves in the Y-Z direction. The power of the induction heating device is controlled through the control system to control the wire to be maintained in a semi-solid state, the wire falls into the substrate to be deposited to form a deposited layer under the propelling of the self gravity and the wire above, then the substrate is driven to move to the lower side of the roller along the X direction, the substrate is controlled to move along the X direction and the roller moves along the Z direction to perform composite rolling on the deposited layer, the grain refining effect inside the printed part is improved, and the mechanical property is improved.
Description
Technical Field
The invention relates to the technical field of additive manufacturing, in particular to a continuous wire feeding induction heating composite rolling semi-solid additive manufacturing method and device.
Background
As a rapid forming technology developed at present, a metal additive manufacturing technology can save a large amount of metal raw materials compared with a traditional material reducing processing and manufacturing method, and can easily prepare metal parts with complex shapes, thereby having great application advantages in shortening the design and development period of parts and reducing the production and preparation costs of the parts, and being concerned more and more widely at present.
The heat sources adopted by the additive manufacturing technology of metals at the present stage mainly comprise the following three types: laser, electron beam, and arc. Laser is a common means as a heat source, and chinese patent CN201811627384.4 proposes a laser-based internal coaxial wire feeding additive manufacturing system and a forming method, and although laser itself has the characteristic of high energy density, it is considered that alloys such as aluminum and copper have high reflectivity (generally over 80%) to laser, and the thermal conductivity of alloys such as aluminum and copper is good, so that the laser energy is insufficiently absorbed in the additive manufacturing process of the alloy wire, and the cost and efficiency requirements are difficult to be met.
For example, chinese patent 2015108143949 proposes an additive manufacturing apparatus capable of realizing wide scanning of an electron beam, which can effectively avoid reflection of metals such as aluminum and copper on the energy of the electron beam, thereby increasing the forming rate, but the electron beam as a heat source requires a harsh vacuum environment, has high requirements on equipment and process conditions, is difficult to prepare and complete specific large-sized structural members, and results in high raw material cost and time cost. For example, chinese patent CN201710129920.7 proposes an additive manufacturing method for an aluminum-magnesium alloy structural member, which has the characteristics of simple forming equipment and high forming efficiency, but due to the disadvantage of poor stability of the arc itself, the difficulty in controlling the arc during the forming process will cause the problem that the fused deposition layer often collapses, and the like, resulting in poor quality and precision of the metal formed part, and difficult to meet the forming requirements of high-quality metal parts.
At present, the metal parts formed by additive manufacturing generally have the unfavorable characteristics of low density, poor comprehensive mechanical property and the like, and the practical comprehensive property is ensured by carrying out secondary processing treatment such as heat treatment or hot isostatic pressing and the like in the follow-up process, but the preparation and forming cost is invisibly increased. Therefore, how to manufacture high-quality metal parts by efficient and low-cost molding has become a critical technical problem to be solved at present.
Disclosure of Invention
The invention aims to provide a continuous wire feeding induction heating composite rolling semi-solid additive manufacturing method and device, the energy utilization rate of an induction heating source of the manufacturing method and device is high, the automatic production of metal parts can be efficiently realized, the problems of low production efficiency and high cost in the prior art are solved, and the advantages of high forming precision, excellent comprehensive mechanical property and the like of the formed metal parts can be ensured.
According to a first aspect of the present invention, there is provided a continuous wire feeding induction heating combined rolling semi-solid additive manufacturing system, comprising:
a continuous wire feeder configured to feed a wire along a set path;
the straightening device is arranged on the path and is used for straightening the conveyed wire;
the induction heating device comprises a low-power induction coil mechanism for preheating the straightened wire and a high-power induction coil mechanism for heating the preheated wire;
a substrate located below the induction heating device;
the X-direction linear motion mechanism is used for driving the substrate to move along the X direction;
a first support mechanism and a second support mechanism arranged along the X direction;
the first supporting mechanism is provided with a first base, a first fixed block and a roller fixed below the first fixed block, the first base is arranged to be movable along the Y direction, the first fixed block is arranged to be movable along the Z direction, and therefore the roller is driven to move in the Y-Z direction;
the second support mechanism is provided with a second base and a second fixed block, the straightening device is arranged above the second fixed block, the induction heating device is arranged below the second fixed block, the second base is arranged to move along the Y direction, and the second fixed block is arranged to move along the Z direction, so that the induction heating device is driven to move in the Y-Z direction;
and in the process of inductively heating, material-increasing, manufacturing and printing the metal wire or the metal alloy wire, controlling the power of the induction heating device through a control system to control the metal wire or the metal alloy wire to be maintained in a semi-solid state, falling into the substrate to deposit and form a deposit layer under the action of self gravity and the propelling of the upper wire, then driving the substrate to move to the lower part of the roller along the X direction, and controlling the substrate to move along the X direction and the roller to perform composite rolling on the deposit layer in the movement of the Z direction.
Preferably, a heating mechanism is provided within the substrate, configured to heat the substrate to a predetermined temperature.
Preferably, the X-direction linear motion mechanism includes a first motor and a conveyor belt mechanism driven by the first motor and moving along the X direction, and the substrate is fixed on the conveyor belt mechanism.
Preferably, the roller includes a roller disposed lengthwise and squarely in the Y direction and a bracket supporting the roller, the bracket being fixed to the bottom of the first fixing block and moving in synchronization therewith.
Preferably, the first support mechanism is provided with a first cross beam transversely arranged above the X-direction linear motion mechanism, and the first base is arranged on the first cross beam and can move along the first cross beam under the driving of the second motor.
Preferably, the first fixing block is configured to be driven by a third motor and to move along a first guide groove in a vertical direction of the first base.
Preferably, the second supporting mechanism is provided with a second cross beam transversely arranged above the X-direction linear motion mechanism, and the second base is arranged on the second cross beam and can move along the second cross beam under the driving of the fourth motor.
Preferably, the second fixing block is configured to be driven by a fifth motor and to move in a second guide groove in a vertical direction of the second base.
According to a second aspect of the present invention, there is provided a metal/metal alloy continuous wire feeding induction heating composite rolling semi-solid additive manufacturing method, comprising the steps of:
continuously conveying the metal/metal alloy wire along a set path;
correcting the wire material;
preheating the wire material;
heating the wire material to maintain the wire material in a semi-solid state between a liquid phase and a solid phase;
driving the induction heating device to move in the Y direction and the substrate to move in the X direction according to a layer-by-layer printing mode, and allowing continuous semi-solid wires to fall onto the substrate to deposit to form a layer of accumulation layer under the action of self gravity and the propelling of the wires above the continuous semi-solid wires;
the driving base plate moves to the position below the roller along the X direction, and the roller is driven to perform multi-pass rolling to realize rolling compounding;
and repeating the forming and rolling of the accumulation layer until the printing of the workpiece is finished.
Wherein, each layer of rolling process comprises at least 3 times of rolling treatment, the deformation of single-pass rolling is more than 10%, and the total deformation is more than 40%.
The wire is an aluminum alloy wire, a TC4 titanium alloy wire or a copper alloy wire.
Compared with the traditional metal additive manufacturing method, the method has the remarkable advantages that:
(1) the invention adopts induction heating as a melting heat source of the metal wire, the wire has high absorption and utilization rate of heat source energy, and plays roles of reducing energy consumption and improving the production efficiency of metal parts;
(2) the invention can realize the accurate control of the temperature under the metal semi-solid state, not only ensures the temperature requirement when the semi-solid metal is extruded, but also prevents the excessive burning loss of the low melting point alloy element caused by the over-high temperature, thereby causing the unbalance of the chemical components of the metal forming part;
(3) the invention does not need the condition limitation of vacuum environment, and can work under the inert gas atmosphere such as nitrogen, argon and the like. The three-dimensional coordinated motion of the substrate and the wire can realize the preparation of metal forming parts with complex shapes, and simultaneously can ensure the accurate control of the size and the roughness of the part;
(4) the invention adopts the semi-solid rolling composite forming process, and the prepared metal parts have the advantages of stable alloy chemical components, fine grain structure, excellent comprehensive mechanical properties and the like.
It should be understood that all combinations of the foregoing concepts and additional concepts described in greater detail below can be considered as part of the inventive subject matter of this disclosure unless such concepts are mutually inconsistent. In addition, all combinations of claimed subject matter are considered a part of the presently disclosed subject matter.
The foregoing and other aspects, embodiments and features of the present teachings can be more fully understood from the following description taken in conjunction with the accompanying drawings. Additional aspects of the present invention, such as features and/or advantages of exemplary embodiments, will be apparent from the description which follows, or may be learned by practice of specific embodiments in accordance with the teachings of the present invention.
Drawings
The drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. Embodiments of various aspects of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
fig. 1 is a schematic structural diagram of a continuous wire feeding induction heating composite rolling semi-solid additive manufacturing system according to the present invention.
Fig. 2-3 are schematic structural views of other directions of the continuous wire feed induction heating composite rolling semi-solid additive manufacturing system of the embodiment of fig. 1.
The meaning of the individual reference symbols in the figures is as follows:
a wire feeding motor 1, a wire feeding cylindrical roller 2 and a base 3;
a straightening device 4;
a substrate 5;
a low-power induction coil mechanism 6, a high-power induction coil mechanism 7;
the water cooling system 8, the first water cooling cable 8-1 and the second water cooling cable 8-2;
a first motor 10, a supporting device 11 and a conveyor belt mechanism 12;
the device comprises a first supporting mechanism 20, a first cross beam 21, a first base 22, a second motor 23, a first guide groove 24, a third motor 25 and a first fixing block 26;
a support 27, a roller 28;
a second beam 29, a fourth motor 30, a second base 31, a fifth motor 32 and a second fixing block 33;
a wire 100;
a build-up layer 101;
a control box 200.
Detailed Description
In order to better understand the technical content of the present invention, specific embodiments are described below with reference to the accompanying drawings.
In this disclosure, aspects of the present invention are described with reference to the accompanying drawings, in which a number of illustrative embodiments are shown. Embodiments of the present disclosure are not necessarily intended to include all aspects of the invention. It should be appreciated that the various concepts and embodiments described above, as well as those described in greater detail below, may be implemented in any of numerous ways, and that the concepts and embodiments disclosed herein are not limited to any embodiment. In addition, some aspects of the present disclosure may be used alone, or in any suitable combination with other aspects of the present disclosure.
Induction heating composite rolling semi-solid additive manufacturing system
In combination with the continuous wire feeding induction heating composite rolling semi-solid additive manufacturing system of the illustrated exemplary embodiment, the induction heating composite rolling semi-solid additive manufacturing of metal/metal alloy is realized through the processes of wire feeding, straightening, induction preheating, induction heating, semi-solid wire forming, stacking layer forming, composite multi-pass rolling, repeated stacking and rolling, wherein the preparation of metal forming parts with complex shapes is realized through three-dimensional coordinated movement of a substrate and wires, meanwhile, the precise control of the size and the roughness of the parts is ensured, the excellent grain structure control is realized, and the better comprehensive mechanical property is realized.
The continuous wire feeder is mainly used for conveying wires along a set path.
The continuous wire feeder of the illustrated example includes a wire feed motor 1, a wire feed cylinder roller 2, and a base 3, and the wire feed motor 1 drives the wire feed cylinder roller 2 to move so that the wire 100 is fed from the wire feed cylinder roller 2 along a set path. Particularly preferably, the wire is fed at a constant speed. Wherein, send a base 3 on the silk cylinder roller 2 accessible frame ancient spindle sword.
A straightening device 4 provided on the wire feeding path for straightening the fed wire 100. Optionally, the straightening device can be realized by a plurality of groups of rollers which are oppositely arranged, and the wires passing through the middle of the rollers are straightened.
And the induction heating device is used for preheating the wire and heating the wire to a semi-solid state. The induction heating apparatus of the incorporated example includes a low-power induction coil mechanism 6 that preheats the straightened wire and a high-power induction coil mechanism 7 that heats the preheated wire. The preheating and semi-solid heating of the metal wire materials without materials can be realized by controlling the power of the low-power induction coil mechanism 6 and the high-power induction coil mechanism 7.
And a substrate 5 located below the induction heating device and used for providing a base for forming the stacked layer. Preferably, heating means, such as resistance wires or other heating elements, are provided inside the base plate 5 for heating the base plate to a predetermined temperature, in order to prevent the edges and inside of the shaped part from exhibiting a large temperature gradient, which leads to an increase in internal stresses and reduces the possibility of microcracks.
In conjunction with the figures, the low power induction coil mechanism 6 and the high power induction coil mechanism 7 work in conjunction with a water cooling system 8. The low-power induction coil mechanism 6 is connected to the first water-cooling cable 8-1, the high-power induction coil mechanism 7 is connected to the second water-cooling cable 8-2, the hollow induction coil in each winding and fixing induction coil mechanism is electrified externally to form a magnetic field, and circulating water is electrified internally to cool. In the process of additive manufacturing, printing and forming, the first water-cooling cable and the second water-cooling cable are flexibly designed, so that flexible movement can be realized, and the water-cooling system is in a fixed state.
And an X-direction linear motion mechanism for driving the substrate 5 to move along the X direction.
In conjunction with the illustration, the X-direction linear motion mechanism optionally includes a first motor 10 and a conveyor belt mechanism 12 driven by the first motor and moving along the X-direction, and the conveyor belt mechanism 12 may be disposed and supported in a support device 11. The substrate 5 is fixed to the conveyor mechanism so as to be moved synchronously in the X direction in accordance with the movement of the conveyor mechanism 12.
In conjunction with the illustration, the first support mechanism and the second support mechanism are arranged along the X direction.
The first support mechanism 20 has a first beam 21 disposed transversely above the X-direction linear motion mechanism, and a first base 22 is provided on the first beam and is movable along the first beam 21 by a second motor 23. The first fixing block 26 is provided to be driven by the third motor 25 and moves along the first guide groove 24 in the vertical direction of the first base 22.
A roller is fixed below the first fixing block 26. In connection with the illustration, the roller comprises a roller 28 disposed lengthwise and squarely in the Y direction and a bracket 27 supporting the roller, fixed to the bottom of said first fixed block 26 and moving synchronously therewith.
As such, the first base is provided to be movable in the Y direction. The first fixing block 26 is provided to be movable in the Z direction so as to drive the roller to move in the Y-Z direction, and in conjunction with the movement of the substrate 5 in the X direction, the rolling control of the accumulated layer on the substrate by the roller can be realized.
In conjunction with the drawings, the second support mechanism is provided with a second cross member 29, a second base 31, and a second fixed block 33.
The straightening device 4 is arranged above the second fixed block 33, and the induction heating device is arranged below the second fixed block 33.
In the figure, the second beam 29 is disposed transversely above the X-direction linear motion mechanism, and the second base 21 is disposed on the second beam 29 and can be moved along the second beam by the fourth motor 30. The second fixing block 33 is provided to be driven by the fifth motor 32 and moves in the second guide groove in the vertical direction of the second base 31.
In this manner, the second susceptor 31 is provided movably in the Y direction, and the second fixed block is provided movably in the Z direction, so that the induction heating device is driven to move in the Y-Z direction, and three-dimensional molding on the substrate can be realized by coordinating the movements in the X-Y-Z direction in conjunction with the movement of the substrate 5 in the X direction.
In this way, in the printing system of the illustrated embodiment, in the process of performing induction heating additive manufacturing printing on a metal wire or a metal alloy wire, a control system, such as the control box 200, controls the power of the induction heating device to control the metal wire or the metal alloy wire to be maintained in a semi-solid state, and the metal wire or the metal alloy wire falls onto the substrate 5 to deposit and form the deposited layer 101 under the action of the self gravity and the pushing of the upper wire, and then the substrate is driven to move along the X direction to the lower part of the roller, and the substrate is controlled to move along the X direction and the roller moves in the Z direction to perform combined rolling on the deposited layer.
Induction heating composite rolling semi-solid additive manufacturing method
With reference to the drawings and the continuous wire feeding induction heating combined rolling semi-solid additive manufacturing system, the present disclosure also provides a metal/metal alloy continuous wire feeding induction heating combined rolling semi-solid additive manufacturing method, which includes the following steps:
continuously conveying the metal/metal alloy wire along a set path;
correcting the wire material;
preheating the wire material;
heating the wire material to maintain the wire material in a semi-solid state between a liquid phase and a solid phase;
driving the induction heating device to move in the Y direction and the substrate to move in the X direction according to a layer-by-layer printing mode, and allowing continuous semi-solid wires to fall onto the substrate to deposit to form a layer of accumulation layer under the action of self gravity and the propelling of the wires above the continuous semi-solid wires;
the driving base plate moves to the position below the roller along the X direction, and the roller is driven to perform multi-pass rolling to realize rolling compounding;
and repeating the forming and rolling of the accumulation layer until the printing of the workpiece is finished.
In a preferred embodiment, each rolling process comprises at least 3 rolling processes, the deformation of single-pass rolling is more than 10%, and the total deformation is more than 40%.
Wherein the wire is one of an aluminum alloy wire, a TC4 titanium alloy wire or a copper alloy wire.
[ example 1 ]
Firstly, the whole metal additive manufacturing system is vacuumized and filled with inert protective gas. And starting the mechanical pre-pumping pump to pre-pump the equipment, starting the roots pump to continue to perform vacuum pumping on the equipment after the vacuum gauge indicates that the system pressure is less than 200Pa until the pressure value in the equipment is less than 5 Pa. Then the mechanical pre-pump and the roots pump are closed in sequence, then the diffusion pump is started for high vacuum pumping, and the vacuum degree of the equipment is lower than 10-2And (4) after Pa, closing the diffusion pump, and finishing the integral vacuumizing of the equipment, wherein the vacuumizing time is 15min (the vacuumizing time is required to be controlled within 20 min). And then filling 99.999% high-purity inert gas argon into the equipment for protection, and measuring the oxygen content in the inner cavity of the equipment by an oxygen analyzer at any time in the process to ensure that the oxygen content is controlled within 100 ppm.
Secondly, the 6061 aluminum alloy wire fixed on the cylinder uniformly and stably moves forward by virtue of uniform-speed circular motion of the cylinder. The cross-sectional diameter of the 6061 aluminum alloy wire is 1.0mm, and the chemical components are as follows: 0.34% copper, 0.94% magnesium, 0.73% silicon, 0.72% iron, the remainder being aluminium and minor amounts of other alloying elements. The forward uniform motion speed of the wire is 1500 mm/min.
Subsequently, the 6061 aluminum alloy wire is enabled to be changed from horizontal forward to vertical downward through the action of the correcting device, the same moving direction between the semi-solid metal formed by softening the wire and the wire is ensured, and the guarantee is provided for the high quality of a subsequent formed part. Wherein the linear speed of the roller motion in the straightening device is maintained at 1500 mm/min.
Then, the 6061 aluminum alloy wire which vertically moves downwards is preheated by a low-power induction coil device, the working power of the preheating device is 350W, the temperature of the wire is controlled to be about 300 ℃, a temperature sensing system and a control system on the inner wall of the device constantly measure the temperature in the preheating device, and the temperature of the wire is ensured to meet the requirement by adjusting the induction heating power. The aluminum alloy material has a large heat conductivity coefficient and a small cross-sectional area, so that a large temperature gradient is easily generated in the same wire due to the effects of heat radiation, heat transfer and the like, the phenomena of tissue heterogeneity, even thermal cracks and the like are generated in the wire, and the comprehensive mechanical property of the formed parts is finally influenced. Therefore, the method of preheating the aluminum alloy wire is needed to adjust the temperature distribution in the wire, improve the uniformity of the structure and reduce the possibility of forming defects such as thermal cracks and the like; in addition, the absorption rate of the aluminum alloy wire to the energy of an induction heating heat source can be improved in the preheating process, and necessary conditions are provided for the subsequent full utilization of the energy of the high-power induction coil device.
And then, melting the preheated 6061 aluminum alloy wire by using a high-power induction coil device, wherein the working power of the melting and softening device is 500W, and a temperature sensing system and a control system are also arranged on the inner wall of the device to ensure that the temperature of the semi-solid aluminum alloy is controlled to be about 600 ℃. The induction heating mode does not need to utilize the resistance of the wire to generate heat, so the method is particularly suitable for the metal wire with low resistivity of aluminum alloy; meanwhile, the aluminum alloy has no reflection effect on the energy of the induction heating heat source, the absorption and utilization rate of the heat source energy is high, and the preheating of the aluminum alloy wire undoubtedly provides guarantee for the stability of the temperature of the semisolid aluminum alloy. At the temperature, the aluminum alloy wire is maintained in a semi-solid state between a liquid phase and a solid phase, so that the subsequent rolling and compounding are guaranteed; meanwhile, the reasonable temperature of the wire reduces the burning loss effect on the low-melting-point aluminum element, so that the chemical components of the formed part are more uniform and stable.
And subsequently, the continuous semi-solid 6061 aluminum alloy falls onto the substrate for deposition and forming under the action of self gravity and the pushing of the wire above. The temperature of the substrate is controlled to be about 300 ℃ through preheating, so that the phenomenon that the internal stress is increased due to the fact that the edges and the inside of the formed part present large temperature gradients is prevented, and the possibility of microcracks is reduced. In the process, the three-dimensional coordinated motion of the substrate, the 6061 aluminum alloy wire and the servo motor can realize the horizontal and vertical precise forming of the complex 6061 aluminum alloy part.
And finally, driving the conveying belt by a servo motor to drive the base plate to move below the roller, completing rolling compounding of the metal forming layer by movement of the roller in the Z-axis direction, repeating the rolling process for 3 times with the single-pass rolling deformation of 15 percent, and finally completing the rolling compounding process of the formed part with the final deformation of 45 percent. (in this step, the circulation process of printing forming and rolling combination can be carried out according to specific process requirements)
The alloy components of the formed 6061 aluminum alloy part comprise 0.32% of copper, 0.91% of magnesium, 0.75% of silicon, 0.71% of iron, and the balance of aluminum and a small amount of other alloying elements, so that the chemical composition requirement of the target aluminum alloy is met. The surface roughness, tensile strength, yield strength and elongation after fracture of the three groups of cut samples were respectively tested and compared, and the results are shown in table 1.
Table 1-example 1 data
[ example 2 ]
Firstly, the whole metal additive manufacturing system is vacuumized and filled with inert protective gas. And starting the mechanical pre-pumping pump to pre-pump the equipment, starting the roots pump to continue to perform vacuum pumping on the equipment after the vacuum gauge indicates that the system pressure is less than 200Pa until the pressure value in the equipment is less than 5 Pa. Then the mechanical pre-pump and the roots pump are closed in sequence, then the diffusion pump is started for high vacuum pumping, and the vacuum degree of the equipment is lower than 10-2And (4) after Pa, closing the diffusion pump, and finishing the integral vacuumizing of the equipment, wherein the vacuumizing time is 13min (the vacuumizing time is required to be controlled within 20 min). Then introducing 99.999 percent high-purity inert gas nitrogen into the equipment for protection, and passing oxygen in the processThe time analyzer measures the oxygen content in the inner cavity of the equipment at any time, and ensures that the oxygen content is controlled within 100 ppm.
Secondly, the CuSn10 copper alloy wire fixed on the cylinder uniformly and stably moves forward by virtue of uniform circular motion of the cylinder. The cross-sectional diameter of the CuSn10 copper alloy wire is 1.0mm, and the chemical components are as follows: 10.5% of tin, 0.8% of phosphorus, and the balance of copper and a small amount of other alloying impurity elements. The forward uniform motion speed of the wire is 1500 mm/min.
Subsequently, the CuSn10 copper alloy wire was passed through a corrective device so that the direction of motion of the wire changed from horizontal forward to vertical downward. Wherein, the linear speed of the roller motion in the straightening device is still maintained at 1500 mm/min.
Then, the CuSn10 copper alloy wire which moves vertically downwards is preheated by a low-power induction coil device, the working power of the preheating device is 400W, the preheating temperature of the wire is controlled to be about 350 ℃, a temperature sensing system and a control system on the inner wall of the device constantly measure the temperature in the preheating device, and the preheating temperature of the wire is ensured to meet the requirement by adjusting the induction heating power.
And then, melting the preheated CuSn10 copper alloy wire by a high-power induction coil device, wherein the working power of the melting softening device is 900W, and the inner wall of the device is also provided with a temperature sensing system and a control system to ensure that the temperature of the copper alloy molten drop is controlled to be about 950 ℃. At the temperature, the CuSn10 copper alloy is maintained in a semi-solid state between a solid phase and a liquid phase, and necessary preparation conditions are provided for subsequent rolling and compounding.
And subsequently, the continuous semi-solid CuSn10 copper alloy falls onto the substrate to be deposited and molded under the action of self gravity and the propelling of the wire above. The temperature of the substrate is controlled to be about 300 ℃ through preheating, so that defects such as microcracks and the like caused by large temperature gradient in the formed part are prevented. In the process, the precise forming of the complex CuSn10 copper alloy parts in the horizontal and vertical directions can be realized through the three-dimensional coordinated motion of the substrate, the CuSn10 copper alloy wire and the servo motor.
And finally, after the single-layer semi-solid CuSn10 copper alloy is formed on the substrate, the servo motor drives the conveyor belt to drive the substrate to move to the position below the roller, the roller moves in the Z-axis direction to finish rolling compounding of the metal forming layer, the single-pass rolling deformation is 10%, the rolling is repeated for 5 times, and the final deformation is 50%. After the rolling of the single-layer deposition layer is finished, the servo motor drives the conveying belt to drive the substrate to move to the position below the CuSn10 copper alloy wire, then the printing forming and rolling compounding process is circularly and repeatedly finished, and finally the rolling compounding of the whole formed part is finished.
The alloy components of the formed CuSn10 copper alloy part are 10.2% of tin and 0.9% of phosphorus, and the balance is copper and a small amount of other alloying impurity elements, so that the chemical composition requirement of the target copper alloy is met. The surface roughness, tensile strength, yield strength and elongation after fracture of the three groups of cut samples were respectively tested and compared, and the results are shown in table 2.
Table 2-example 2 data
[ example 3 ]
Firstly, the whole metal additive manufacturing system is vacuumized and filled with inert protective gas. And starting the mechanical pre-pumping pump to pre-pump the equipment, starting the roots pump to continue to perform vacuum pumping on the equipment after the vacuum gauge indicates that the system pressure is less than 200Pa until the pressure value in the equipment is less than 5 Pa. Then the mechanical pre-pump and the roots pump are closed in sequence, then the diffusion pump is started for high vacuum pumping, and the vacuum degree of the equipment is lower than 10-2And (4) after Pa, closing the diffusion pump, and finishing the overall vacuumizing of the equipment, wherein the vacuumizing time is 16min (the vacuumizing time is required to be controlled within 20 min). And then filling 99.999% high-purity inert gas argon into the equipment for protection, and measuring the oxygen content in the inner cavity of the equipment by an oxygen analyzer at any time in the process to ensure that the oxygen content is controlled within 100 ppm.
Secondly, the TC4 titanium alloy wire fixed on the cylinder advances uniformly and stably by the uniform circular motion of the cylinder. The cross-sectional diameter of the TC4 titanium alloy wire is 1.0mm, and the chemical components are as follows: 6.2% of aluminum, 4.1% of vanadium, 0.15% of iron, 0.11% of oxygen, and the balance of titanium and a small amount of other alloying elements. The forward uniform motion speed of the wire is 1500 mm/min.
Subsequently, the TC4 titanium alloy wire was passed through a straightening device so that the direction of motion of the wire changed from horizontal to front to vertical to down. Wherein, the linear speed of the roller motion in the straightening device is still maintained at 1500 mm/min.
Then, the TC4 titanium alloy wire moving vertically downwards is preheated by a low-power induction coil device, the working power of the preheating device is 700W, the preheating temperature of the wire is controlled to be about 600 ℃, a temperature sensing system and a control system on the inner wall of the device constantly measure the temperature in the preheating device, and the preheating temperature of the wire is ensured to meet the requirement by adjusting the induction heating power.
And then, melting the preheated TC4 titanium alloy wire by a high-power induction coil device, wherein the working power of the melting and softening device is 1500W, and the inner wall of the device is also provided with a temperature sensing system and a control system to ensure that the temperature of the titanium alloy molten drop is controlled to be about 1600 ℃. At the temperature, the TC4 titanium alloy is maintained in a semi-solid state between a solid phase and a liquid phase, and necessary preparation conditions are provided for subsequent rolling and compounding.
And subsequently, the continuous semi-solid TC4 titanium alloy falls onto the substrate to be deposited and molded under the action of self gravity and the propelling of the wire above. The temperature of the substrate is controlled to be about 300 ℃ through preheating, so that defects such as microcracks and the like caused by large temperature gradient in the formed part are prevented. In the process, the precise forming of the complex TC4 titanium alloy part in the horizontal and vertical directions can be realized through the three-dimensional coordinated motion of the substrate, the TC4 titanium alloy wire and the servo motor.
And finally, after the single-layer semi-solid TC4 titanium alloy is formed on the substrate, the servo motor drives the conveyor belt to drive the substrate to move to the position below the roller, the roller moves in the Z-axis direction to finish rolling compounding of the metal forming layer, the single-pass rolling deformation is 20%, the rolling compounding is repeated for 3 times, and the final deformation is 60%. After the rolling of the single-layer deposition layer is finished, the servo motor drives the conveying belt to drive the substrate to move to the position below the TC4 titanium alloy wire, then the printing forming and rolling compounding process is circularly and repeatedly finished, and finally the rolling compounding of the whole formed part is finished.
The alloy components of the formed TC4 titanium alloy part are 5.9% of aluminum, 4.2% of vanadium, 0.17% of iron and 0.16% of oxygen, and the balance is titanium and a small amount of other alloying impurity elements, so that the chemical composition requirement of the target titanium alloy is met. The surface roughness, tensile strength, yield strength and elongation after fracture of the three groups of cut samples were respectively tested and compared, and the results are shown in table 2.
Table 3-example 3 data
In the data tables 1 to 3, the surface roughness values were used to evaluate the dimensional accuracy of the alloy formed specimens, and lower surface roughness values indicate higher dimensional accuracy. The tensile strength value, the yield strength value and the elongation after fracture are jointly used for evaluating the comprehensive mechanical property of the alloy forming sample, and the larger the tensile strength value, the yield strength value and the elongation after fracture is, the better the comprehensive mechanical property is.
Comparing the above tables 1-3, it can be seen that the three alloy molded samples in the examples are significantly better than the corresponding wire-fed solid rolled piece and the common molded piece in four parameters of surface roughness value, tensile strength value, yield strength value and elongation after fracture, and the alloy parts manufactured by the additive manufacturing method and device of the invention have the characteristics of high dimensional accuracy and excellent comprehensive mechanical properties. The invention adopts induction heating as a heat source and a temperature feedback control system to control the temperature of the alloy wire in a semi-solid state, thereby not only improving the energy utilization rate of the alloy wire to the heat source, but also adopting the rolling composite forming process of the wire in the semi-solid state, reducing the burning loss of alloy elements as much as possible and obviously improving the comprehensive mechanical property of a formed part by refining grains. In addition, the induction heating preheating process reduces the temperature gradient inside the wire material on the premise of ensuring higher energy utilization rate of the alloy wire material, and provides necessary guarantee for obtaining an alloy forming sample with excellent comprehensive mechanical properties. The three-dimensional coordinated movement of the substrate and the wire provides guarantee for the high precision of the alloy parts, and finally the high-quality alloy parts are formed.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to be limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the invention. Therefore, the protection scope of the present invention should be determined by the appended claims.
Claims (11)
1. A continuous wire feeding induction heating composite rolling semi-solid additive manufacturing system is characterized by comprising:
a continuous wire feeder configured to feed a wire along a set path;
the straightening device is arranged on the path and is used for straightening the conveyed wire;
the induction heating device comprises a low-power induction coil mechanism for preheating the straightened wire and a high-power induction coil mechanism for heating the preheated wire;
a substrate located below the induction heating device;
the X-direction linear motion mechanism is used for driving the substrate to move along the X direction;
a first support mechanism and a second support mechanism arranged along the X direction;
the first supporting mechanism is provided with a first base, a first fixed block and a roller fixed below the first fixed block, the first base is arranged to be movable along the Y direction, the first fixed block is arranged to be movable along the Z direction, and therefore the roller is driven to move in the Y-Z direction;
the second support mechanism is provided with a second base and a second fixed block, the straightening device is arranged above the second fixed block, the induction heating device is arranged below the second fixed block, the second base is arranged to move along the Y direction, and the second fixed block is arranged to move along the Z direction, so that the induction heating device is driven to move in the Y-Z direction;
and in the process of inductively heating, material-increasing, manufacturing and printing the metal wire or the metal alloy wire, controlling the power of the induction heating device through a control system to control the metal wire or the metal alloy wire to be maintained in a semi-solid state, falling into the substrate to deposit and form a deposit layer under the action of self gravity and the propelling of the upper wire, then driving the substrate to move to the lower part of the roller along the X direction, and controlling the substrate to move along the X direction and the roller to perform composite rolling on the deposit layer in the movement of the Z direction.
2. The continuous wire feed induction heating clad rolling semi-solid state additive manufacturing system of claim 1, wherein a heating mechanism is disposed within the base plate and configured to heat the base plate to a predetermined temperature.
3. The continuous wire feed induction heating clad rolling semi-solid state additive manufacturing system according to claim 1, wherein the X-direction linear movement mechanism comprises a first motor and a conveyor belt mechanism driven by the first motor and moving along the X-direction, and the substrate is fixed on the conveyor belt mechanism.
4. The continuous wire feed induction heating clad rolling semi-solid state additive manufacturing system according to claim 1, wherein the roller comprises a roller arranged along a Y-direction longitudinal square and a bracket supporting the roller, the bracket being fixed to a bottom of the first fixing block and moving synchronously therewith.
5. The continuous wire feed induction heating clad rolling semi-solid state additive manufacturing system according to claim 1, wherein the first support mechanism has a first beam transversely disposed above the X-direction linear motion mechanism, and the first base is disposed on the first beam and is movable along the first beam by the driving of the second motor.
6. The continuous wire feed induction heating clad rolling semi-solid state additive manufacturing system according to claim 5, wherein the first fixing block is configured to be driven by a third motor and to move along a first guide groove in a vertical direction of the first base.
7. The continuous wire feed induction heating clad rolling semi-solid state additive manufacturing system according to claim 1, wherein the second support mechanism has a second beam transversely disposed above the X-direction linear motion mechanism, and the second base is disposed on the second beam and is movable along the second beam by a fourth motor.
8. The continuous wire feed induction heating clad rolling semi-solid state additive manufacturing system according to claim 7, wherein the second fixing block is provided to be driven by a fifth motor and moves along a second guide groove in a vertical direction of the second base.
9. A metal/metal alloy continuous wire feeding induction heating composite rolling semi-solid additive manufacturing method of the continuous wire feeding induction heating composite rolling semi-solid additive manufacturing system according to any one of claims 1 to 8, characterized by comprising the following steps:
continuously conveying the metal/metal alloy wire along a set path;
correcting the wire material;
preheating the wire material;
heating the wire material to maintain the wire material in a semi-solid state between a liquid phase and a solid phase;
driving the induction heating device to move in the Y direction and the substrate to move in the X direction according to a layer-by-layer printing mode, and allowing continuous semi-solid wires to fall onto the substrate to deposit to form a layer of accumulation layer under the action of self gravity and the propelling of the wires above the continuous semi-solid wires;
the driving base plate moves to the position below the roller along the X direction, and the roller is driven to perform multi-pass rolling to realize rolling compounding;
and repeating the forming and rolling of the accumulation layer until the printing of the workpiece is finished.
10. The metal/metal alloy continuous wire feeding induction heating composite rolling semi-solid additive manufacturing method according to claim 9, wherein each layer of rolling process comprises at least 3 rolling processes, the single-pass rolling deformation is more than 10%, and the total deformation is more than 40%.
11. The metal/metal alloy continuous wire feeding induction heating composite rolling semi-solid state additive manufacturing method according to claim 9, wherein the wire is an aluminum alloy wire, a TC4 titanium alloy wire or a copper alloy wire.
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