CN106702375A - 一种激光‑感应复合熔化沉积纤维增强金属基复合材料的装置 - Google Patents

一种激光‑感应复合熔化沉积纤维增强金属基复合材料的装置 Download PDF

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CN106702375A
CN106702375A CN201611106546.0A CN201611106546A CN106702375A CN 106702375 A CN106702375 A CN 106702375A CN 201611106546 A CN201611106546 A CN 201611106546A CN 106702375 A CN106702375 A CN 106702375A
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戴晓琴
陈瀚宁
雷剑波
顾振杰
石川
周圣丰
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Abstract

本发明公开了一种激光‑感应复合熔化沉积纤维增强金属基复合材料的装置，该装置由半导体激光器、同轴自动送粉器、高频感应加热器、专用纤维编织模版、加工机床与数控系统组成，其中专用纤维编织模版由两个完全相同的具有群孔的304不锈钢板组成，其中一块304不锈钢板固定于激光器的加工头上，另一块304不锈钢板固定于基材上，由数控系统统一控制半导体激光器的扫描速度、激光功率、扫描路径、分层切片厚度、感应加热温度与自动送粉器的粉末流量。采用本发明的装置，可以在高效率、低成本的条件下，制备纤维增强金属基复合材料结构件；纤维作为强化相均匀分布于金属基复合材料内；纤维结构保持完整且纤维之间距离可调可控；纤维增强金属基复合材料显微组织致密，无气孔与裂纹，实现纤维增强金属基复合材料的激光‑感应复合熔化沉积。

Description

一种激光-感应复合熔化沉积纤维增强金属基复合材料的 装置
技术领域
本发明涉及一种激光-感应复合熔化沉积的装置，它特别适合于制备纤维增强金属基复合材料。
背景技术
金属基复合材料由金属基体和增强相通过一定的工艺复合而成的新型结构材料，按增强相的形态可分为纤维增强金属基复合材料、晶须及短纤维增强金属基复合材料、颗粒增强金属基复合材料等几种形式。因此，金属基复合材料具有较高的比强度、比刚度以及良好的抗蠕变、耐高温性能，尤其是纤维增强金属基复合材料在其纤维方向上具有很高的强度和模量，在构件的受力状况基本确定时更能发挥其定向优势，在航空航天领域具有十分广阔的应用前景。
目前，纤维增强金属基复合材料的制备方法主要有粉末冶金法、真空压力浸渗法、挤压铸造法、搅拌铸造法等。粉末冶金法是预先将短纤维与金属粉末制成浆状并混合，经成型干燥热压烧结成型，该法较为复杂，不适宜制备大尺寸零件，成本很高。真空压力浸渗法是将增强相制成预制体，放入承压铸型内，加热、抽真空，通过真空产生的负压，使液态基体金属熔体浸渗到预制体中并凝固成形，该方法的设备复杂，工艺周期长，成本较高，适用于制备要求较高的小型零件；挤压铸造是将增强材料制成预制件，放入压型，用压机将液态金属压入凝固后得到成型件，其挤压铸造力大，一般在70-100MPa，所制成预制件必须有很高强度，同时需保证预制件的空隙度；搅拌铸造法是将金属熔化，在液态或半固态搅拌，同时加入增强材料(短纤维、晶须或粒子等)，制备出复合材料浆料，然后进行铸造、液态模锻、轧制或挤压成形。尽管挤压铸造法与搅拌铸造法在工业中得到较为广泛的应用，但是这两种方法制备的纤维增强金属基复合材料都存在纤维增强相分布不均、结构不完整以及与金属基体界面润湿性差等缺点，其综合性能有待进一步提高。
激光增材制造主要以金属粉末或金属丝材为原料，通过CAD模型预分层处理，采用高功率激光束熔化堆积生长，直径从CAD模型一步完成高性能构件的“近终成形”。与传统的制造工艺相比，激光增材制造属于“加法制造”，具有工艺流程短、无模具、制造周期短、小批量零件生产成本低、零件近净成型、材料利用率高以及可实现多种材料任意复合制造等优点。近年来，激光-感应复合熔化沉积技术可以在加工效率提高1～5倍的条件下，快速制备组织致密的高性能三维结构件。但是，采用激光-感应复合熔化沉积技术制备纤维增强金属基复合材料的方法未见文献报道，尤其是专用于制备纤维增强金属基复合材料的激光-感应复合熔化沉积装置还未见文献公开报道。
发明内容
本发明的目的在于提供一种激光-感应复合熔化沉积纤维增强金属基复合材料的装置。本发明的装置利用具有快速加热、快速凝固、柔性制造、易实现自动化等特点的激光-感应复合熔化热源，将粉末喷嘴喷射出的合金粉末熔化，并将镀有镍层的纤维包覆起来，结合分层切片技术形成纤维增强金属基复合材料。此外，专用纤维编织模版由两个完全相同的具有群孔的304不锈钢板组成，其中一块304不锈钢板固定于激光器的加工头上，另一块304不锈钢板固定于基材上，由数控系统统一控制半导体激光器的扫描速度、激光功率、扫描路径、分层切片厚度、感应加热温度与自动送粉器的粉末流量。因此，本装置的优点是根据镀镍后纤维的尺寸选择专用编织模版，实现了在高加工效率条件下，制备组织致密、无气孔与裂纹、纤维增强相结构完整且在复合材料内分布均匀与可控以及综合性能优异的纤维增强金属基复合材料结构件会，克服了传统制备工艺过程中，装置复杂与制造成本高，纤维分布不均匀、结构不完整、高性能易受热损伤以及力学性能有待进一步提高等问题。
附图说明
图1激光-感应复合熔化沉积纤维增强金属基复合材料的装置示意图
具体实施方式
下面结构附图和实例对本发明作进一小详细的说明。
如图1所示，本发明主要包括半导体激光器2、同轴自动送粉器8、高频感应加热器13、专用纤维编织模版、加工机床12与数控系统1。其中，专用纤维编织模版由两个完全相同且具有群孔的304不锈钢板5与5’构成。工作时，具体实施方法与步骤如下：
第一步：利用专用CAD软件生成纤维增强金属基复合材料零件的三维CAD实体模型，然后切割成若干相互平行的薄片，实现将零件的三维立体数据转换成一系列的二维平面数据，并在数控加工台上生成激光-感应复合熔化热源的扫描路径；
第二步：对直径为0.2～10μm的纤维进行粗化、敏化、活化与化学镀20～50μm的镍层，从而形成镀镍层纤维9，其中纤维为碳纤维、石英纤维或玻璃纤维；
第三步：采用三组专用纤维编织模板，将纤维编织成相互平行的结构，其中专用纤维编织模板由两个完全相同且表面均匀分布有群孔的304不锈钢板5与5’构成，编织的纤维9与304不锈钢板5、5’的表面垂直，304不锈钢板5与5，的尺寸为20×20×0.2cm3，纤维9的底部与基材18表面接触；
纤维经过化学镀镍后的直径为20.2～60μm，将编织模板分为三组：第一组模板①304不锈钢板5与5’的群孔孔径为35.1μm，孔间距为35.2～45μm；第二组模板②304不锈钢板5与5’的群孔孔径为45.1μm，孔间距为45.2～60μm；第三组模板③304不锈钢板5与5’群孔孔径为60.1μm，孔间距为60.2～70μm；当镀Ni层纤维9直径为20.2～35μm时，选用模板①；当镀Ni层纤维9直径为35.001～45μm时，选用模板②；当镀Ni层纤维9直径为45.001～60μm时，选用模板③；选定模板后，根据纤维编织的厚度，选择相邻或不相邻孔洞进行编制，实现纤维之间距离的可控；
第四步：专用纤维编织模板其中的一块304不锈钢板5’固定在基材18上，另一块304不锈钢板5固定在加工头4上，且位于激光-感应复合熔化热源前端5mm处，编织纤维9的长度方向与激光扫描方向平行；
第五步：半导体激光器2产生的激光束经反射镜3作用后，投向到透镜16上，并定位于感应加热区，同时自动送粉器9的粉末喷嘴14也定位于感应加热区内，实现激光热源与感应加热源的复合；同轴自动送粉器8的装料斗7内合金粉末通过氩气经导管6送入粉末喷嘴14，粉末喷嘴14将合金粉末均匀喷射入基材18表面的激光-感应复合熔化热源形成的熔池17内，合金粉末吸收激光-感应复合熔化热源的能量后快速熔化，当激光-感应复合熔化热源移开后，熔融的合金粉末快速凝固并将纤维9包覆起来，形成纤维增强金属基沉积层15；其中，感应加热线圈11上安装有导磁体10并与高频感应加热器13相连；
第六步：当在基材18表面沉积完一道之后，沿着激光扫描速度的垂直方向移动加工机床12，其移动的距离为激光束光斑直径的40～50％；
第七步：重复第五步-第六步，直到沉积层15的宽度满足零件宽度要求；
第八步：检测沉积层15是否满足零件高度要求，如果没有，将安装有另一块304不锈钢板5的加工头与感应加热线圈11沿Z轴向上升到与CAD二维薄片厚度相等的距离，然后按下一层的扫描轨迹进行激光-感应复合熔化沉积，当所有的二维薄片都被扫描完成后，最终形成三维纤维增强金属基复合材料。

Claims (2)

1.一种激光-感应复合熔化沉积纤维增强金属基复合材料的装置，包括：半导体激光器、同轴自动送粉器、高频感应加热器、专用纤维编织模版、加工机床与数控系统，其特征在于：该装置还包括粉末喷嘴(14)固定于激光器(2)的加工头(4)上，粉末喷嘴(14)喷出的合金粉末在透镜(16)的焦距之下5mm处会聚，专用纤维编织模版由具有群孔的304不锈钢板(5)与(5’)组成，其中304不锈钢板(5)固定于激光器(1)的加工头(4)上，304不锈钢板(5’)固定于基材(18)上，高频感应加热器(13)的感应加热线圈(11)与编织纤维(9)的距离为5mm，感应加热线圈(11)上安装有导磁体(10)，粉末喷嘴(14)的底部与编织纤维(9)的距离为8mm，工作时，同轴自动送粉器(8)的装料斗(7)内的合金粉末通过氩气经导管(6)送入粉末喷嘴(14)，粉末喷嘴(14)将合金粉末均匀喷射入基材(18)表面的熔池(17)内，合金粉末吸收激光-感应复合熔化热源的能量后快速熔化，当激光-感应复合熔化热源移开后，合金粉末快速凝固并将编织纤维(9)包覆起来形成沉积层(15)。
2.根据权利要求1所述的一种激光-感应复合熔化沉积纤维增强金属基复合材料的装置，其特征在于：使用的纤维直径为0.2～10μm，经过化学镀镍后的直径为20.2～60μm，将编织模板分为三组：第一组模板①304不锈钢板(5)与(5’)的群孔孔径为35.1μm，孔间距为35.2～45μm；第二组模板②304不锈钢板(5)与(5’)的群孔孔径为45.1μm，孔间距为45.2～60μm；第三组模板③304不锈钢板(5)与(5’)的群孔孔径为60.1μm，孔间距为60.2～70μm；当镀Ni层纤维(9)直径为20.2～35μm时，选用模板①；当镀Ni层纤维(9)直径为35.001～45μm时，选用模板②；当镀Ni层纤维(9)直径为45.001～60μm时，选用模板③；选定模板后，根据纤维编织的厚度，选择相邻或不相邻孔洞进行编制，实现纤维之间距离的可控。
CN201611106546.0A 2016-12-05 2016-12-05 一种激光-感应复合熔化沉积纤维增强金属基复合材料的装置 Expired - Fee Related CN106702375B (zh)

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