CN108907191B - Additive manufacturing method of 30CrMnSiA metal model suitable for high-speed wind tunnel test - Google Patents
Additive manufacturing method of 30CrMnSiA metal model suitable for high-speed wind tunnel test Download PDFInfo
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Abstract
The invention discloses a 30CrMnSiA metal model additive manufacturing method suitable for a high-speed wind tunnel test, which determines a model additive manufacturing process by combining a material additive manufacturing model design with a metal powder particle and test piece performance test result aiming at a 30CrMnSiA metal material, improves the surface roughness, the size precision and the strength rigidity performance of a metal model for the high-speed wind tunnel test, and solves the application problem of an additive manufacturing technology in the high-speed wind tunnel test model manufacturing.
Description
Technical Field
The invention relates to an additive manufacturing technology, in particular to a 30CrMnSiA metal model additive manufacturing method suitable for a high-speed wind tunnel test.
Background
The wind tunnel is a tubular test device which can generate controllable uniform airflow. The wind tunnel test model is a metal or nonmetal model processed by a real aircraft according to a scaling ratio, the wind tunnel test is to support the model in a test section, and the aerodynamic characteristics of the test model are obtained through a blowing test, so that relevant data are provided for aircraft design.
The conventional test model processing adopts a mechanical cutting processing mode, namely: the design drawing of the test model is submitted to a machining factory, the factory prepares materials according to the drawing size, cuts and processes the materials according to the drawing requirement, and various processing means can be adopted from various section blanks or casting and forging blanks to finished products, but the basic principles are the same, namely the materials are removed to obtain the size requirement, and the method can be called as 'material reduction manufacturing'. The method depends on numerical control cutting processing, so that the mass distribution and the counterweight ratio of the wind tunnel model are difficult to control, the manufacturing period is long, and the cost is high. Taking the machining of the wings as an example, machining stress can be caused after numerical control machining, so that the wings deform, and therefore, a plurality of heat treatment processes must be arranged, the machining residual stress is eliminated, and the model manufacturing period and the cost are increased; in addition, the mounting holes/pipes of the measuring devices on the model are difficult to process, and the manufacturing period and cost of the pressure measuring model are rapidly increased along with the increase of the number of the pressure measuring holes. With the progress of science and technology and the updating of the design concept of an aircraft, the requirements on light, hollow, special-shaped and high-strength rigidity test models are more and more strong, scientific personnel expect to be capable of quickly realizing the innovative design of the personnel and promoting the scientific innovation, and the traditional machining obviously cannot adapt to the manufacturing requirements of the special models.
Additive Manufacturing (Additive Manufacturing), also called 3D printing (3D printing), or Rapid Manufacturing (Rapid Manufacturing), is a brand new Manufacturing technology, is different from the traditional subtraction method of machining "removing material", is a processing technology of adding "adding material", and is widely considered to possibly cause the revolution of Manufacturing industry. The basic working process of additive manufacturing is as follows: (1) designing a three-dimensional model diagram of a required object in a computer by utilizing CAD software; (2) the method comprises the following steps of (1) carrying out layered slicing on a model by utilizing software in 3D printing equipment to obtain a two-dimensional graph of each layer of section; (3) under the guidance of a design file instruction, the 3D printing equipment sprays solid powder or molten liquid material or sintering powder spreading material to solidify the solid powder or the molten liquid material into a plane thin layer, a layer 2 is formed on the basis after the layer 1 is solidified, and the steps are repeated in this way, and adjacent sections are solidified or bonded layer by layer in sequence; (4) and removing the supporting material required in the printing process, and finally forming the three-dimensional object.
The additive manufacturing technology adopts a discrete/stack forming principle, can process parts with any complex shape through conversion from three-dimension to two-dimension, has short manufacturing period and lower cost, has unique advantages which are not possessed by the traditional mechanical cutting processing, and has wide application prospect in the wind tunnel test model processing.
The 30CrMnSiA is widely applied to structural processing of wind tunnel test models, balances, struts and the like due to the advantages of high strength, rigidity, good toughness and the like, so that the research on the additive manufacturing method of the 30CrMnSiA metal model has strong necessity.
Disclosure of Invention
An object of the present invention is to solve at least the above problems and/or disadvantages and to provide at least the advantages described hereinafter.
To achieve these objects and other advantages in accordance with the present invention, a method for additive manufacturing of a 30CrMnSiA metal model for high speed wind tunnel testing is provided, comprising the steps of:
selecting the size of a3D printing forming cavity according to the size and the quality of an additive manufacturing wind tunnel test model, determining the powder demand, and preparing a 30CrMnSiA bar;
crushing the 30CrMnSiA bar by adopting a vacuum argon atomization method to form basic powder particles, and further spheroidizing the basic powder particles by adopting a radio frequency plasma technology to form spherical powder particles meeting the additive manufacturing requirement;
step three, testing the performance of the prepared 30CrMnSiA powder particles, including particle size components, particle size distribution range and fluidity;
manufacturing and testing a test piece by using the prepared 30CrMnSiA powder particles, wherein the test content of the test piece comprises surface roughness, relative density, size precision, tensile property and fatigue property;
step five, determining whether the model additive manufacturing process meets the requirements or not according to the test result of the test piece, if so, turning to step six, otherwise, turning to step four;
sixthly, performing additive manufacturing design on the metal model;
step seven, determining whether the model additive manufacturing design meets the design specification of the wind tunnel test model and the requirements of the additive manufacturing process, if so, turning to step eight, and otherwise, turning to step six;
and step eight, manufacturing and post-processing a 30CrMnSiA metal model additive.
Preferably, in the first step, the required amount of powder is calculated according to the following formula:
m＝ρ·(L·W·H)
wherein m is the mass of the powder, rho is the density of 30CrMnSiA, L is the length of the molding cavity, W is the width of the molding cavity, and H is the height of the molding cavity; the material quality of the 30CrMnSiA forged bar material is more than 10% of the calculated value of m.
Preferably, in the second step, the 30CrMnSiA bar is crushed to a size of less than about 150 μm by a vacuum argon atomization method; the technological parameters of the vacuum argon atomization method are as follows: the temperature of the melt is 1580 +/-10 ℃, the holding time is 30-40 min, the temperature of the leakage package is 1070 +/-30 ℃, and the atomization pressure of high-purity argon is 3.0-3.2 MPa.
Preferably, the process parameters of the rf plasma technology are: the power is 35kW, the sheath gas flow is 55L/min, the plasma gas flow is 15L/min, the dispersion gas flow is 5L/min, the powder feeding rate is 40g/min, and the carrier gas flow is 7 slpm.
Preferably, in the third step, the performance of the 30CrMnSiA powder particles is tested, and the particle size diameter distribution range is required to be between 10 and 90 μm, the median diameter is about 38 μm, and the particle size distribution is in normal distribution; the powder flowability BFE is 3915mJ, the stability index SI of the flowing energy is 0.89, the sensitivity FRI of the flowing generated under different speeds is 1.07, the bridging and occluding capability SE among particles is 3.18mJ/g, and the apparent density CBD is 4.27 g/mL.
Preferably, in the fourth step, a Selective Laser Melting (SLM) method is adopted for manufacturing the test piece, and a selective laser melting and molding experiment is carried out by adopting powder bed laser melting and molding equipment; the powder bed laser melting molding apparatus includes: the device comprises a forming cavity, a laser light source system, a laser scanning system, a powder paving system, an atmosphere control system and a software control system; the device adopts a 200W optical fiber laser, the wavelength is 1070nm, and the maximum working size of a forming cavity is 250mm multiplied by 300 mm; the SLM method comprises the following specific processes: vacuumizing the forming cavity, introducing high-purity argon, preheating the substrate to 160 ℃, sending 30CrMnSiA powder into the forming cavity by a powder feeding cylinder mechanism in the powder paving system, starting a laser source in a laser source system, expanding the laser through a dichroic mirror after passing through a laser control mechanism, and entering a scanning vibrating mirror, and performing two-dimensional scanning forming on the 30CrMnSiA powder in the forming cavity after passing through a focusing lens by the laser output by the scanning vibrating mirror; after single-layer scanning forming, the substrate is lowered by one layer of height, and the previous step is repeated until the 30CrMnSiA test piece is formed; the test piece manufacturing and forming process parameters are as follows: the thickness of the powder layer is 30 μm; the diameter of the laser beam is 135 μm; the laser power is 180W; the scanning speed is 300 mm/s; the exposure time was 130. mu.s.
Preferably, in the fifth step, it is determined whether the model additive manufacturing process meets the index requirements, and the test qualification index includes: the surface roughness can reach Ra of 0.8 mu m by polishing under the condition of ensuring that the molded surface is not damaged; the relative density reaches more than 95 percent of the forged piece; the size precision is less than 0.2 mm; the tensile strength is more than 1080MPa, and the yield strength is more than 835 MPa; cycle life of 107The fatigue limit above is more than 205 MPa.
Preferably, in the step eight, a Selective Laser Melting (SLM) method is adopted to perform additive manufacturing on the 30CrMnSiA metal model; the post-treatment comprises annealing, flaw detection, surface polishing, assembly and three-coordinate detection; the annealing adopts a vacuum stress relief annealing mode, the temperature is set to be 800 ℃, the heating rate is 10 ℃/min, and the annealing is carried out after 2 hours of heat preservation and is cooled to the room temperature along with the furnace and taken out; magnetic powder inspection is adopted for flaw detection, so that no cracks are formed on the surface and in the inner part; and the three-coordinate detection is mainly used for evaluating the precision deviation of the manufactured dimension of the model, and the deviation between a real object and a digital model is not more than 0.15 mm.
Preferably, in the second step, the base powder particles are further spheroidized by using a radio frequency plasma technology after being pretreated, and the pretreatment process is as follows: adding the basic powder particles into a supercritical device, and soaking for 10-30 min in a supercritical acetone-water system with the temperature of 350-370 ℃ and the pressure of 8-14 MPa; the volume ratio of acetone to water in the supercritical acetone-water system is 5: 1; the process of the radio frequency plasma technology comprises the following steps: sending the pretreated basic powder particles into an atmospheric pressure low-temperature plasma device, and enabling the basic powder particles to be located at a spraying outlet of the atmospheric pressure low-temperature plasma for 50-100 mm; introducing gas into an atmospheric pressure low-temperature plasma device according to the gas flow of 15-25L/h, applying working voltage to form plasma jet, controlling the moving speed of a jet outlet of the atmospheric pressure low-temperature plasma device to be 5-10 mm/s, jetting the plasma jet on basic powder particles, and treating for 10-30 min; the working voltage is provided by a high-voltage alternating current power supply, the working voltage is 35-100 kV alternating current voltage, and the frequency is 100-300 kHz; the gas is one or a mixture of more of air, rare gas/oxygen, nitrogen and ammonia.
Preferably, in the second step, the formed spherical powder particles are reprocessed, and the reprocessing process is as follows: adding spherical powder particles into a stainless steel spherical container, adding cleaning liquid, then placing the spherical container on a four-axis grinding instrument, starting the four-axis grinding instrument, driving the stainless steel spherical container to randomly rotate for 60-90 min, then filtering and drying to obtain reprocessed spherical powder particles; the feed inlet of the stainless steel spherical container is sealed by a threaded cover, and the threaded cover is flush with the surface of the stainless steel spherical container after being connected in a sealing way; the rotating speed of a rotating shaft of the four-shaft grinding instrument is 100-150 rpm, and the random conversion frequency is 30-60 s; the cleaning solution comprises the following raw materials in parts by weight: 3-5 parts of sodium citrate, 1-3 parts of alkyl glycoside, 1-3 parts of hydroxyethylidene diphosphonic acid, 2-5 parts of thiosemicarbazide, 3-5 parts of glycine, 0.5-1.5 parts of 1-ethyl-3-methylimidazolium lactic acid, 1-3 parts of cocoyl diethanol amine and 80-120 parts of water.
In the invention, the material additive manufacturing of the 30CrMnSiA material high-speed wind tunnel test model is carried out by adopting a Selective Laser Melting (SLM) technology in the fourth step, the powder in a powder feeding system is uniformly spread on the surface of a substrate in a forming cavity by using a powder spreading device, and laser beams scan point by point on a powder layer according to the data information of each layer of the CAD model of the part to be processed, so that the powder is completely melted. And after the scanning of one layer is finished, the substrate descends by one layer thickness, the powder spreading device spreads a layer of powder on the substrate again, and the processing is carried out for a new round and is repeated until the three-dimensional solid part is molded. In order to prevent the powder from being oxidized, the whole process is finished under the argon environment.
The invention at least comprises the following beneficial effects:
the invention discloses a 30CrMnSiA metal model additive manufacturing method suitable for a high-speed wind tunnel test, which aims at a 30CrMnSiA metal material, determines a model additive manufacturing process by combining a test result of metal powder particles and a test piece performance and an additive manufacturing model design, improves the surface roughness, the size precision and the strength rigidity performance of a metal model for the high-speed wind tunnel test, and solves the application problem of an additive manufacturing technology in the manufacturing of a high-speed wind tunnel test model.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention.
Description of the drawings:
FIG. 1 is a flow chart of additive manufacturing of a 30CrMnSiA metal model in a high-speed wind tunnel test according to the invention;
FIG. 2 is a flow chart of the plasma spheroidization process of the 30CrMnSiA metal powder of the present invention;
FIG. 3 is a manufacturing flow chart of a high speed wind tunnel test 30CrMnSiA metal model Selective Laser Melting (SLM) according to the present invention;
fig. 4 is a 30CrMnSiA3D printed (L-way) laboratory air fatigue S-N curve of the present invention (Kt ═ 1R ═ 0.10).
The specific implementation mode is as follows:
the present invention is further described in detail below with reference to the attached drawings so that those skilled in the art can implement the invention by referring to the description text.
It will be understood that terms such as "having," "including," and "comprising," as used herein, do not preclude the presence or addition of one or more other elements or groups thereof.
Example 1:
a method for manufacturing a 30CrMnSiA metal model additive suitable for a high-speed wind tunnel test comprises the following steps as shown in figure 1:
selecting the size of a3D printing forming cavity according to the size and the quality of an additive manufacturing wind tunnel test model, determining the powder demand, and preparing a 30CrMnSiA bar; the powder demand is calculated according to the following formula:
m＝ρ·(L·W·H)
wherein m is the mass of the powder, rho is the density of 30CrMnSiA, L is the length of the molding cavity, W is the width of the molding cavity, and H is the height of the molding cavity; the material quality of the 30CrMnSiA forged bar material is more than 10% of the calculated value of m;
crushing the 30CrMnSiA bar by adopting a vacuum argon atomization method to form basic powder particles, and further spheroidizing the basic powder particles by adopting a radio frequency plasma technology to form spherical powder particles meeting the additive manufacturing requirement; crushing a 30CrMnSiA bar material to a size of less than about 150 mu m by adopting a vacuum argon atomization method; the technological parameters of the vacuum argon atomization method are as follows: the temperature of the melt is 1580 +/-10 ℃, the holding time is 30-40 min, the temperature of the leakage package is 1070 +/-30 ℃, the atomization pressure of high-purity argon is 3.0-3.2 MPa; the technological parameters of the radio frequency plasma technology are as follows: the power is 35kW, the sheath gas flow is 55L/min, the plasma gas flow is 15L/min, the dispersion gas flow is 5L/min, the powder feeding rate is 40g/min, and the carrier gas flow is 7 slpm; the length-diameter ratio of the 30CrMnSiA powder spheroidized by the process is close to 1:1, the spheroidization rate is close to 100 percent, and the powder is regular spherical powder;
step three, testing the performance of the prepared 30CrMnSiA powder particles, including particle size components, particle size distribution range and fluidity; the particle size diameter distribution range is required to be between 10 and 90 mu m, the median diameter is about 38 mu m, and the particle size diameter distribution range is normally distributed; the powder flowability BFE is 3915mJ, the stability index SI of the flowing energy is 0.89, the sensitivity degree FRI of the flowing generated under different rates is 1.07, the bridging and occluding capacity SE among particles is 3.18mJ/g, and the apparent density CBD is 4.27 g/mL;
manufacturing and testing a test piece by using the prepared 30CrMnSiA powder particles, wherein the test content of the test piece comprises surface roughness, relative density, size precision, tensile property and fatigue property; manufacturing a test piece by adopting a Selective Laser Melting (SLM) method, wherein the Selective Laser Melting (SLM) method adopts powder bed laser melting molding equipment to perform a selective laser melting molding experiment; the powder bed laser melting molding apparatus includes: the device comprises a forming cavity, a laser light source system, a laser scanning system, a powder paving system, an atmosphere control system and a software control system; the device adopts a 200W optical fiber laser, the wavelength is 1070nm, and the maximum working size of a forming cavity is 250mm multiplied by 300 mm; as shown in fig. 3, the SLM method for selective laser melting includes the following specific processes: vacuumizing the forming cavity, introducing high-purity argon, preheating the substrate to 160 ℃, sending 30CrMnSiA powder into the forming cavity by a powder feeding cylinder mechanism in the powder paving system, starting a laser source in a laser source system, expanding the laser through a dichroic mirror after passing through a laser control mechanism, and entering a scanning vibrating mirror, and performing two-dimensional scanning forming on the 30CrMnSiA powder in the forming cavity after passing through a focusing lens by the laser output by the scanning vibrating mirror; after single-layer scanning forming, the substrate is lowered by one layer of height, and the previous step is repeated until the 30CrMnSiA test piece is formed; the test piece manufacturing and forming process parameters are as follows: the thickness of the powder layer is 30 μm; the diameter of the laser beam is 135 μm; the laser power is any one of 180W, 190W and 200W; the scanning speed is 300 mm/s; the exposure time was 130 μ s;
after the test piece is manufactured, test piece testing needs to be carried out, and test piece testing contents include but are not limited to surface roughness, relative density, dimensional accuracy, tensile property and fatigue property. The test procedures and results should be comparable or superior to the following:
the surface roughness Ra is less than 30 μm, the relative compactness and dimensional accuracy are required as in step five, and the tensile property test process results are as follows:
the constant strain/displacement rate is adopted for control in the tensile test process, the strain rate of the sample before yielding is 0.005 mm/mm/min, and the displacement per minute is controlled to be 1.8mm by adopting the constant displacement rate after the sample is yielded. And load, strain/displacement data are recorded in real time in the test process. Tensile Strength R of tensile Property testmElongation after fracture A, yield strength RP0.2The tensile elastic modulus E index and the test result respectively give test data of each sample; table 1 shows static tensile data (laser power 180W) for a 30CrMnSiA3D print test piece; table 2 shows static tensile data (laser power 190W) for a 30CrMnSiA3D printed test piece; table 3 shows static tensile data (laser power 200W) for a 30CrMnSiA3D print test piece;
TABLE 1
TABLE 2
TABLE 3
The fatigue test is carried out according to the GB/T3075-2008 'metal material fatigue test axial stress control method', the test is carried out on an electromagnetic resonance type high-frequency fatigue testing machine, the test frequency is 130Hz, the stress ratio R is 0.1, the test waveform is a sine wave, each S-N curve tests the group method 3-level stress level, and each level of stress level tests 2-3 samples. The fatigue limit is measured by a lifting method, and the corresponding fatigue limit is 107And obtaining 2-3 data pairs. Table 4 shows the 30CrMnSiA fatigue test data;
TABLE 4
Table 5 is 30CrMnSiA3D printed (L-way) laboratory air high cycle fatigue performance data; fig. 4 is a 30CrMnSiA3D printed (L-way) laboratory air fatigue S-N curve (Kt ═ 1R ═ 0.10).
Step five, determining whether the model additive manufacturing process meets the requirements or not according to the test result of the test piece, if so, turning to step six, otherwise, turning to step four; determining whether the model additive manufacturing process meets the index requirements, wherein the test qualification indexes comprise: the surface roughness can reach Ra of 0.8 mu m by polishing under the condition of ensuring that the molded surface is not damaged; the relative density reaches more than 95 percent of the forged piece; the size precision is less than 0.2 mm; the tensile strength is more than 1080MPa, and the yield strength is more than 835 MPa; cycle life of 107The corresponding fatigue limit is more than 205 MPa;
TABLE 5
Sixthly, performing additive manufacturing design on the metal model; according to the high-speed wind tunnel model design criterion (GJB 569A-2012) and the determined additive manufacturing process, carrying out the design of a 30CrMnSiA material high-speed wind tunnel model;
step seven, determining whether the model additive manufacturing design meets the design specification of the wind tunnel test model and the requirements of the additive manufacturing process, if so, turning to step eight, and otherwise, turning to step six; the conformity examination of the example is mainly to examine various required indexes by comparing with 'high-speed wind tunnel model design criteria' (GJB 569A-2012), and meanwhile, to examine the designed model aiming at the limitation requirements of additive manufacturing, such as minimum thickness, minimum diameter, maximum size and the like;
step eight, performing additive manufacturing and post-processing on a 30CrMnSiA metal model, and developing model manufacturing according to the additive manufacturing process determined in the step four, wherein the manufacturing steps are shown in FIG. 3; after the model is manufactured, post-processing, including annealing, flaw detection, surface polishing, assembly, three-coordinate detection and the like, is required. In the annealing of the embodiment, a vacuum stress relief annealing mode is adopted, the temperature is set to be 800 ℃, the heating rate is 10 ℃/min, and the annealing is carried out after heat preservation for a certain time (2h), cooled to room temperature along with a furnace and taken out; magnetic powder inspection is adopted for flaw detection, so that no cracks are formed on the surface and in the inner part; and the three-coordinate detection is mainly used for evaluating the precision deviation of the manufactured dimension of the model, and the deviation between a real object and a digital model is not more than 0.15 mm. After the indexes meet the requirements, the high-speed wind tunnel test can be carried out.
In step two of this example, as shown in fig. 2, the detailed process of plasma spheroidization of 30CrMnSiA metal powder is as follows: vacuum drying the original 30CrMnSiA powder and grading and screening by using a powder sieving instrument (EndecottsD 300); the purpose of vacuum drying is to remove moisture in the powder, so as to avoid the powder from being blocked in a transmission pipeline and reduce oxidation in the spheroidizing process of the powder; the grading screening is to remove impurities in the powder, optimize the particle size range and improve the quality of the finished powder; sending the pretreated powder into a powder feeding system, starting a cooling system, and completing equipment system purification and vacuum-pumping treatment; then preheating the filament, starting high frequency when the pressure of the reaction chamber is reduced to 2psia, increasing the pressure of the reactor to about 7.4kV, and generating Joule heat by the coupling action of the plasma; opening a valve of a powder feeding system, a carrier gas and a controller of the powder feeding system in sequence, feeding graded raw material powder into a plasma torch (plasma) through a powder feeding system and a powder feeding pipe (probe) by taking argon as the carrier gas, instantly melting tungsten powder particles into spherical liquid drops under the action of high temperature, dispersing the liquid drops into fine liquid drops under the impact of airflow of high-speed dispersion gas, cooling at a very high speed, entering a cooling device (water cooled chamber) to be cooled and solidified into spherical powder, and finally entering a powder collecting system (powder collector) to be collected; after the system had cooled for a sufficient time, the powder collection system was turned on and the spherical powder of 30CrMnSiA was taken out.
In this embodiment, the laser selective melting (SLM) manufacturing process of the 30CrMnSiA metal model additive manufacturing in the step eight is as follows: vacuumizing the molding cavity, introducing high-purity argon to prevent the oxidation of 30CrMnSiA powder, and preheating a substrate (material grade: 304 steel) to 160 ℃ to reduce the deformation and cracking of a 30CrMnSiA molded piece; a powder feeding cylinder mechanism in the powder paving system feeds 30CrMnSiA powder into a forming chamber; starting a laser source in a light source system, expanding the laser beam through a dichroic mirror after the laser beam passes through a laser control mechanism, and enabling the laser beam to enter a scanning vibrating mirror, and focusing the laser beam output by the scanning vibrating mirror through a focusing lens to perform two-dimensional scanning forming on 30CrMnSiA powder in a forming chamber; and after single-layer scanning forming, the substrate is lowered by one layer of height, and the previous step is repeated until the forming of the three-dimensional part with the complex structure of the 30CrMnSiA wing is realized.
Example 2:
in the second step, the base powder particles are further spheroidized by adopting a radio frequency plasma technology after being pretreated, and the pretreatment process comprises the following steps: adding the base powder particles into a supercritical device, and soaking in a supercritical acetone-water system at 370 deg.C and 12MPa for 30 min; the volume ratio of acetone to water in the supercritical acetone-water system is 5: 1; the technological parameter process of the radio frequency plasma technology is replaced by: sending the pretreated basic powder particles into an atmospheric pressure low-temperature plasma device, and enabling the basic powder particles to be 60mm at a spraying outlet of the atmospheric pressure low-temperature plasma; introducing gas into an atmospheric pressure low-temperature plasma device according to the gas flow of 20L/h, applying working voltage to form plasma jet, controlling the moving speed of a jet outlet of the atmospheric pressure low-temperature plasma device to be 5mm/s, jetting the plasma jet on basic powder particles, and treating for 30 min; the working voltage is provided by a high-voltage alternating current power supply, the working voltage is 85kV alternating current voltage, and the frequency is 200 kHz; the gas is a mixture of air and ammonia gas.
The remaining process parameters and procedures were exactly the same as in example 1. Table 6 shows the 30CrMnSiA3D printed test piece static tensile data (laser power 180W) for this example;
TABLE 6
Example 3:
in the second step, the formed spherical powder particles are reprocessed, and the reprocessing process comprises the following steps: adding spherical powder particles into a stainless steel spherical container, adding cleaning liquid, placing the spherical container on a four-axis grinding instrument, starting the four-axis grinding instrument, driving the stainless steel spherical container to randomly rotate for 90min, filtering, and drying to obtain reprocessed spherical powder particles; the feed inlet of the stainless steel spherical container is sealed by a threaded cover, and the threaded cover is flush with the surface of the stainless steel spherical container after being connected in a sealing way; the rotating speed of a rotating shaft of the four-shaft grinding instrument is 150rpm, and the random conversion frequency is 60 s; the cleaning solution comprises the following raw materials in parts by weight: 3 parts of sodium citrate, 3 parts of alkyl glycoside, 3 parts of hydroxyethylidene diphosphonic acid, 2 parts of thiosemicarbazide, 5 parts of glycine, 0.5 part of 1-ethyl-3-methylimidazolium lactic acid, 2 parts of cocoyl diethanol amine and 100 parts of water.
The remaining process parameters and procedures were exactly the same as in example 2.
TABLE 7
Table 7 shows the static tensile data (laser power 180W) for the 30CrMnSiA3D printed test piece of this example.
While embodiments of the invention have been described above, it is not limited to the applications set forth in the description and the embodiments, which are fully applicable in various fields of endeavor to which the invention pertains, and further modifications may readily be made by those skilled in the art, it being understood that the invention is not limited to the details shown and described herein without departing from the general concept defined by the appended claims and their equivalents.
Claims (5)
1. A30 CrMnSiA metal model additive manufacturing method suitable for a high-speed wind tunnel test is characterized by comprising the following steps:
selecting the size of a3D printing forming cavity according to the size and the quality of an additive manufacturing wind tunnel test model, determining the powder demand, and preparing a 30CrMnSiA bar;
crushing a 30CrMnSiA bar by adopting a vacuum argon atomization method to form base powder particles, adding the base powder particles into a supercritical device, and soaking for 10-30 min in a supercritical acetone-water system at the temperature of 350-370 ℃ and the pressure of 8-14 MPa; the volume ratio of acetone to water in the supercritical acetone-water system is 5: 1; sending the soaked basic powder particles into an atmospheric pressure low-temperature plasma device, and enabling the basic powder particles to be located at a spraying outlet of the atmospheric pressure low-temperature plasma for 50-100 mm; introducing gas into an atmospheric pressure low-temperature plasma device according to the gas flow of 15-25L/h, applying working voltage to form plasma jet, controlling the moving speed of a jet outlet of the atmospheric pressure low-temperature plasma device to be 5-10 mm/s, jetting the plasma jet on basic powder particles, and treating for 10-30 min to form spherical powder particles meeting the material increase manufacturing requirements; the working voltage is provided by a high-voltage alternating current power supply, the working voltage is 35-100 kV alternating current voltage, and the frequency is 100-300 kHz; the gas is one or a mixture of more of air, oxygen, nitrogen and ammonia;
step three, testing the performance of the prepared 30CrMnSiA powder particles, including particle size components, particle size distribution range and fluidity;
manufacturing and testing a test piece by using the prepared 30CrMnSiA powder particles, wherein the test content of the test piece comprises all of surface roughness, relative density, size precision, tensile property and fatigue property;
step five, determining whether the model additive manufacturing process meets the requirements or not according to the test result of the test piece, if so, turning to step six, otherwise, turning to step four; wherein, confirm whether model vibration material disk manufacturing process meets the requirements, its test qualification index includes: the surface roughness can reach Ra of 0.8 mu m by polishing under the condition of ensuring that the molded surface is not damaged; the relative density reaches more than 95 percent of the forged piece; the size precision is less than 0.2 mm; the tensile strength is more than 1080MPa, and the yield strength is more than 835 MPa; cycle life of 107The corresponding fatigue limit is more than 205 MPa;
sixthly, performing additive manufacturing design on the metal model;
step seven, determining whether the model additive manufacturing design meets the design specification of the wind tunnel test model and the requirements of the additive manufacturing process, namely determining whether the model additive manufacturing design meets the GJB 569A-2012 standard, if so, turning to step eight, and if not, turning to step six;
eighthly, manufacturing and post-processing a 30CrMnSiA metal model by an additive;
in the first step, the powder demand is calculated according to the following formula:
m=ρ·（L·W·H）
wherein m is the mass of the powder, rho is the density of 30CrMnSiA, L is the length of the molding cavity, W is the width of the molding cavity, and H is the height of the molding cavity; the material quality of the 30CrMnSiA forged bar material is more than 10% of the calculated value of m;
in the second step, a vacuum argon atomization method is adopted to crush the 30CrMnSiA bar material to a size of less than about 150 mu m; the technological parameters of the vacuum argon atomization method are as follows: the temperature of the melt is 1580 +/-10 ℃, the holding time is 30-40 min, the temperature of the leaky package is 1070 +/-30 ℃, and the atomization pressure of high-purity argon is 3.0-3.2 MPa.
2. The method for manufacturing the 30CrMnSiA metal model additive material applicable to the high-speed wind tunnel test according to claim 1, wherein in the third step, the performance of the 30CrMnSiA powder particles is tested, and the particle size diameter distribution range is required to be between 10 μm and 90 μm, the median diameter is about 38 μm, and the particle size distribution range is normally distributed; the powder flowability BFE is 3915mJ, the stability index SI of the flowing energy is 0.89, the sensitivity FRI of the flowing generated under different speeds is 1.07, the bridging and occluding capability SE among particles is 3.18mJ/g, and the apparent density CBD is 4.27 g/mL.
3. The method for manufacturing the 30CrMnSiA metal model additive material applicable to the high-speed wind tunnel test according to claim 1, wherein in the fourth step, a Selective Laser Melting (SLM) method is adopted for manufacturing the test piece, and a selective laser melting and forming test is carried out by adopting a powder bed laser melting and forming device; the powder bed laser melting molding apparatus includes: the device comprises a forming cavity, a laser light source system, a laser scanning system, a powder paving system, an atmosphere control system and a software control system; the device adopts a 200W optical fiber laser, the wavelength is 1070nm, and the maximum working size of a forming cavity is 250mm multiplied by 300 mm; the SLM method comprises the following specific processes: vacuumizing the forming cavity, introducing high-purity argon, preheating the substrate to 160 ℃, sending 30CrMnSiA powder into the forming cavity by a powder feeding cylinder mechanism in the powder paving system, starting a laser source in a laser source system, expanding the laser through a dichroic mirror after passing through a laser control mechanism, and entering a scanning vibrating mirror, and performing two-dimensional scanning forming on the 30CrMnSiA powder in the forming cavity after passing through a focusing lens by the laser output by the scanning vibrating mirror; after single-layer scanning forming, the substrate is lowered by one layer of height, and the previous step is repeated until the 30CrMnSiA test piece is formed; the test piece manufacturing and forming process parameters are as follows: the thickness of the powder layer is 30 μm; the diameter of the laser beam is 135 μm; the laser power is any one of 180W, 190W and 200W; the scanning speed is 300 mm/s; the exposure time was 130. mu.s.
4. The additive manufacturing method for the 30CrMnSiA metal model suitable for the high-speed wind tunnel test according to claim 1, wherein in the eighth step, the 30CrMnSiA metal model is subjected to additive manufacturing by a Selective Laser Melting (SLM) method; the post-treatment comprises all of annealing, flaw detection, surface polishing, assembly and three-coordinate detection; the annealing adopts a vacuum stress relief annealing mode, the temperature is set to be 800 ℃, the heating rate is 10 ℃/min, and the annealing is carried out after 2 hours of heat preservation and is cooled to the room temperature along with the furnace and taken out; magnetic powder inspection is adopted for flaw detection, so that no cracks are formed on the surface and in the inner part; and the three-coordinate detection is mainly used for evaluating the precision deviation of the manufactured dimension of the model, and the deviation between a real object and a digital model is not more than 0.15 mm.
5. The method for manufacturing the 30CrMnSiA metal model additive material suitable for the high-speed wind tunnel test according to claim 1, wherein in the second step, the formed spherical powder particles are reprocessed, and the reprocessing process comprises the following steps: adding spherical powder particles into a stainless steel spherical container, adding cleaning liquid, then placing the spherical container on a four-axis grinding instrument, starting the four-axis grinding instrument, driving the stainless steel spherical container to randomly rotate for 60-90 min, then filtering and drying to obtain reprocessed spherical powder particles; the feed inlet of the stainless steel spherical container is sealed by a threaded cover, and the threaded cover is flush with the surface of the stainless steel spherical container after being connected in a sealing way; the rotating speed of a rotating shaft of the four-shaft grinding instrument is 100-150 rpm, and the random conversion frequency is 30-60 s; the cleaning solution comprises the following raw materials in parts by weight: 3-5 parts of sodium citrate, 1-3 parts of alkyl glycoside, 1-3 parts of hydroxyethylidene diphosphonic acid, 2-5 parts of thiosemicarbazide, 3-5 parts of glycine, 0.5-1.5 parts of 1-ethyl-3-methylimidazolium lactic acid, 1-3 parts of cocoyl diethanol amine and 80-120 parts of water.
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