CN109079284B - Method for enhancing CMT aluminum alloy additive manufacturing forming quality with assistance of multiple ultrasonic waves - Google Patents
Method for enhancing CMT aluminum alloy additive manufacturing forming quality with assistance of multiple ultrasonic waves Download PDFInfo
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- CN109079284B CN109079284B CN201810873643.5A CN201810873643A CN109079284B CN 109079284 B CN109079284 B CN 109079284B CN 201810873643 A CN201810873643 A CN 201810873643A CN 109079284 B CN109079284 B CN 109079284B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
Abstract
The invention provides a device and a method for enhancing CMT aluminum alloy additive manufacturing forming quality with the assistance of multiple ultrasounds. The comprehensive action of the high-frequency ultrasonic stirring in three directions and the micro high-frequency vibration of the substrate promotes the metal melt to flow, intervenes in the material crystallization process, re-forms fine and uniform grains, promotes the precipitation of gas dissolved in the melt, reduces the porosity of an additive manufactured part, and improves the mechanical property of the formed part. The ultrasonic impact treatment is carried out on the area which is formed just after the accumulation and has the surface easy to plastically deform, so that the residual stress at the position just after the accumulation can be reduced in real time in the forming process, the residual compressive stress is formed on the surface, the fatigue strength of a formed part is improved, and the deformation in the additive manufacturing process can be effectively controlled. And finally realizing high-quality forming of the CMT aluminum alloy additive manufacturing target part.
Description
Technical Field
The invention relates to the field of CMT aluminum alloy additive manufacturing, in particular to a method for enhancing the forming quality of CMT aluminum alloy additive manufacturing by multiple ultrasonic assistance.
Background
The CMT (cold metal welding) additive manufacturing technology is an advanced manufacturing technology which combines a metal CMT welding technology and a rapid forming discrete accumulation principle, obtains a three-dimensional CAD solid model of a target part through three-dimensional solid scanning or direct modeling, carries out layered slicing processing on the model along a certain coordinate direction according to a certain thickness, melts metal wires by taking electric arcs as heat sources, accumulates and forms each thin layer according to a set forming path, and finally accumulates layer by layer to form a three-dimensional solid part. The CMT additive manufacturing technology can finish the efficient, low-cost and rapid forming manufacturing of large metal structural parts, has great industrialized application prospect in the industries of aviation, aerospace, ships and automobiles, and plays an important role in the national strategy of 2025 intelligent manufacturing.
Aluminum alloy has a series of advantages of small density, high specific strength, good corrosion resistance, low cost and the like, and is one of the most widely applied materials in the aviation industry in the early 20 th century. Although the CMT additive manufacturing aluminum alloy technology has achieved certain achievements at present, the CMT additive manufacturing aluminum alloy technology still has a lot of problems in the aspect of practical application. Mainly expressed in the technical aspect, in the process of manufacturing a large-scale aluminum alloy structural member by CMT additive manufacturing, the residual stress is large due to large temperature gradient, the formed member is deformed excessively, and the forming process can not be continued. In addition, the CMT additive manufacturing aluminum alloy has a plurality of microstructure defects such as air holes, uneven grain sizes, microcracks and the like, which are reasons for poor mechanical properties of formed parts. For the reasons, the further industrial application of the CMT aluminum alloy additive manufacturing is greatly influenced.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides the method for enhancing the forming quality of the CMT aluminum alloy additive manufacturing by multiple ultrasonic aids, the used device has the advantages of unique structure, reasonable design, convenient use and obvious effect, the crystal grains of the formed part can be refined, the porosity of the formed part can be reduced, the residual stress at the position just after stacking can be reduced in real time, and the deformation in the additive manufacturing process can be effectively controlled.
The invention is realized by the following technical scheme:
the device for enhancing the CMT aluminum alloy additive manufacturing forming quality in a multi-ultrasonic-assisted mode comprises a workbench, a substrate fixing device, an X-direction ultrasonic excitation system, a Y-direction ultrasonic excitation system and a Z-direction ultrasonic excitation system, wherein the substrate fixing device is used for fixing the substrate on the workbench;
the X, Y and Z-direction ultrasonic excitation systems are respectively contacted with the substrate to carry out ultrasonic excitation, and simultaneously X, Y and Z-direction ultrasonic high-frequency energy waves are transmitted to a molten pool formed by an electric arc;
the substrate fixing device tightly presses and fixes the substrate on the workbench through the hard rubber cushion block.
Preferably, the substrate fixing device comprises a plurality of groups of same bolt pressing mechanisms, and the hard rubber cushion blocks comprise a first hard rubber cushion block and a second hard rubber cushion block;
the bolt pressing mechanism comprises a pressing plate, a fastening bolt, a fastening nut and a cushion block; the nut end of the fastening bolt is fixed in the workbench, and one side of the screw rod is provided with a clamping groove; a second hard rubber cushion block is tightly pressed between the clamping groove and the adjacent side surface of the substrate; the fastening bolt penetrates through the pressing plate and is fastened and matched with the fastening nut, a first hard rubber cushion block is arranged between one end of the pressing plate and the surface of the substrate in a pressing mode, and the other end of the pressing plate presses the workbench through the cushion block; after the substrate fixing device fixes the substrate through the hard rubber cushion block, the maximum vibration amplitude of the substrate is not more than 0.5 mm.
Preferably, the X-direction ultrasonic excitation system comprises an X-direction ultrasonic excitation device and a Y-direction motion mechanism;
the X-direction ultrasonic excitation device comprises a second excitation end, a second amplitude transformer, a second transducer and a second ultrasonic generator; the second ultrasonic generator is electrically connected with the second transducer, and the second transducer, the second amplitude transformer and the second excitation end are sequentially and fixedly connected and are installed and fixed on the Y-direction movement mechanism together; the second excitation end is in contact with one edge of the substrate parallel to the Y direction, and transmits the X-direction high-frequency ultrasonic vibration energy to the substrate and then to the forming piece through the substrate;
and the Y-direction movement mechanism is used for adjusting the position of the second excitation end to be always parallel to the X-axis direction with the connecting line of the arc forming molten pool.
Preferably, the Y-direction ultrasonic excitation system comprises a Y-direction ultrasonic excitation device and an X-direction motion mechanism;
the Y-direction ultrasonic excitation device comprises a third excitation end, a third amplitude transformer, a third transducer and a third ultrasonic generator; the third ultrasonic generator is electrically connected with the third transducer, and the third transducer, the third amplitude transformer and the third excitation end are sequentially and fixedly connected and are installed and fixed on the X-direction movement mechanism together; the third excitation end is in contact with one edge of the substrate parallel to the X direction, and transmits the high-frequency ultrasonic vibration energy in the Y direction to the substrate and then to the forming piece through the substrate;
and the X-direction movement mechanism is used for adjusting the position of the third excitation end to be always parallel to the Y-axis direction of a connecting line of an arc forming molten pool.
Preferably, the Z-direction ultrasonic excitation system comprises a Z-direction ultrasonic excitation device and a fixing device;
the Z-direction ultrasonic excitation device comprises a first excitation end, a first amplitude transformer, a first energy converter and a first ultrasonic generator; the first ultrasonic generator is electrically connected with the first transducer, and the first transducer is fixedly connected with the first amplitude transformer and the first excitation end in sequence and is installed and fixed on the fixing device together; the first excitation end penetrates through the workbench to be in contact with the center of the bottom of the substrate, and transmits the Z-direction high-frequency ultrasonic vibration energy to the substrate and then to the forming piece through the substrate;
the fixing device fixes the Z-direction ultrasonic excitation device under the substrate.
Preferably, the ultrasonic impact system also comprises a stacking back surface ultrasonic impact system and a temperature control system;
the ultrasonic impact system of the surface after accumulation is used for carrying out ultrasonic impact treatment on the surface after accumulation;
and the temperature control system is used for monitoring the surface temperature of the starting point of each layer after the accumulation is started according to a preset value in a temperature interval of plastic deformation of the aluminum alloy, and when the temperature is lower than the preset value, a signal is sent to the ultrasonic impact system of the surface after the accumulation to start the ultrasonic impact on the surface after the accumulation.
Further, the ultrasonic impact system on the surface after accumulation comprises a robot motion mechanism, a fourth ultrasonic generator, an ultrasonic impact gun and an industrial personal computer;
the industrial personal computer is used for controlling the motion track of the robot motion mechanism and setting the power of the fourth ultrasonic generator and the amplitude of the ultrasonic impact gun; the system is also used for controlling the motion of the X-direction ultrasonic excitation system and the Y-direction ultrasonic excitation system in the corresponding directions, and the ultrasonic frequency and the excitation amplitude of the X-direction ultrasonic excitation system, the Y-direction ultrasonic excitation system and the Z-direction ultrasonic excitation system;
the robot motion mechanism clamps the ultrasonic impact gun and moves according to the path track according to the instruction of the industrial personal computer;
the temperature control system comprises a thermal imager; the thermal imager is used for monitoring the temperature in the forming process, and the output end of the thermal imager is connected with the input end of the industrial personal computer to transmit monitoring data; and the industrial personal computer determines whether to start ultrasonic impact according to the comparison of the surface temperature of the starting point after each layer starts to be stacked with a preset value.
The method for enhancing the forming quality of the CMT aluminum alloy additive manufacturing by multiple ultrasonic aids comprises the following steps:
1) aligning the central position of the bottom of the substrate to the excitation end of the Z-direction ultrasonic excitation device, fixing the substrate on a workbench by using a substrate fixing device, adjusting the central position of the bottom of the substrate to align to the first excitation end of the Z-direction ultrasonic excitation device, and keeping the first excitation end in contact with the bottom surface of the substrate;
2) taking the initial position of the welding gun at which the CMT aluminum alloy additive first layer starts to be printed as a reference, and adjusting the Y-direction movement mechanism to enable the second excitation end of the X-direction ultrasonic excitation device to be parallel to the X direction with the connection line of the welding gun; adjusting the X-direction movement mechanism to enable a third excitation end of the Y-direction ultrasonic excitation device to be parallel to the Y direction with a welding gun connecting line;
3) presetting power and amplitude when X, Y, Z is used for printing different layers by the ultrasonic excitation device according to different aluminum alloy materials, process parameters and optimal values of power and amplitude of X, Y, Z to the ultrasonic excitation device corresponding to the different layers when the different layers are printed, and controlling to turn on the X, Y, Z ultrasonic excitation device by an industrial personal computer;
4) starting a CMT welding device to move a welding gun to start printing a first layer, and simultaneously opening an X, Y, Z-direction ultrasonic excitation device;
5) in the printing process, the industrial personal computer controls and adjusts the Y-direction movement mechanism to move, so that the second excitation end of the X-direction ultrasonic excitation device is always parallel to the X direction with the connection line of the welding gun; controlling and adjusting the X-direction movement mechanism to move, so that a third excitation end of the Y-direction ultrasonic excitation device is always parallel to the Y direction with a welding gun connecting line;
6) the thermal imager monitors the surface temperature of the starting point after each layer starts to be stacked, and when the temperature of the position where the printing is started is reduced to a preset value T1, the industrial personal computer controls the ultrasonic impact gun to start to perform ultrasonic impact on the stacked surface at the same speed as the printing forming speed;
7) after each layer of printing is finished and the ultrasonic impact is finished, the industrial personal computer closes the ultrasonic vibration excitation devices and the ultrasonic impact devices in the three directions;
taking the initial position of the welding gun to be printed on the next layer as a reference, adjusting the Y-direction movement mechanism to enable the second excitation end of the X-direction ultrasonic excitation device to be parallel to the welding gun connecting line in the X direction, and adjusting the X-direction movement mechanism to enable the third excitation end of the Y-direction ultrasonic excitation device to be parallel to the welding gun connecting line in the Y direction; activating a thermal imager to monitor the temperature of the formed layer, and when the measured highest temperature is reduced to a set temperature T2; starting a CMT welding device to move a welding gun to start the formation of the next layer, and simultaneously opening an X, Y, Z-direction ultrasonic excitation device;
8) and (5) repeating the steps 5), 6) and 7) to sequentially finish the stacking and forming of each layer, and finally obtaining a formed piece.
Further, in the step 3), the rated power of an ultrasonic generator in the X, Y, Z ultrasonic excitation device is between 100W and 1KW, the ultrasonic frequency is 20KHZ, and the maximum amplitude of an excitation end is 30 to 80 microns.
Further, in the step 6), when the surface temperature at the starting point of each layer after the stacking is started is reduced to a preset value T1 between 200 ℃ and 400 ℃, the industrial personal computer controls the ultrasonic impact gun to start to perform ultrasonic impact on the stacked surface at the same speed as the printing forming speed; the working frequency of the ultrasonic impact gun is 20KHZ, the maximum amplitude is 50-100 mu m, and the rated power of a fourth ultrasonic generator connected with the input end of the ultrasonic impact gun is 1-3 KW; when the maximum temperature of the formed layer is reduced to a preset value T2 between 70 and 100 ℃, the CMT welding device is started to move the welding gun to start the formation of the next layer.
Compared with the prior art, the invention has the following beneficial technical effects:
the invention not only introduces ultrasonic coupling action in three directions at the position of an electric arc forming molten pool and can generate obvious ultrasonic stirring action on a metal molten pool, but also adopts a substrate fixing device to fix a substrate through a hard seat rubber cushion block, so that the substrate generates micro high-frequency vibration in three directions while transmitting ultrasonic high-frequency energy waves, and the metal molten pool can generate micro high-frequency vibration in three directions along with the micro high-frequency vibration in three directions because the vibration amplitude is very small and the forming effect cannot be influenced. Because of the comprehensive action of high-frequency ultrasonic stirring in three directions and micro high-frequency vibration of the substrate in the process of solidifying the metal in the molten pool, the metal melt is promoted to flow, the material crystallization process is interfered, large crystal grains are crushed, fine and uniform crystal grains are formed again, the separation of gas dissolved in the melt is promoted, the porosity of the formed part made by additive materials is reduced, and the mechanical property of the formed part is improved. The ultrasonic impact treatment is carried out on the area which is formed just after the accumulation and has the surface easy to plastically deform, so that the residual stress at the position just after the accumulation can be reduced in real time in the forming process, the residual compressive stress is formed on the surface, the fatigue strength of a formed part is improved, and the deformation in the additive manufacturing process can be effectively controlled. And finally realizing high-quality forming of the CMT aluminum alloy additive manufacturing target part.
Drawings
FIG. 1 is a top view of a multi-ultrasonic-assisted CMT aluminum alloy additive manufacturing forming quality enhancement device according to an embodiment of the invention.
Fig. 2 is a cross-sectional view AA of fig. 1.
In the figure: 1-a robot motion mechanism, 2-a fourth ultrasonic generator, 3-an ultrasonic impact gun, 4-a welding gun, 5-a forming part, 6-a substrate, 7-a first hard rubber cushion block, 8-a second hard rubber cushion block, 9-a pressing plate, 10-a fastening bolt, 11-a cushion block, 12-a first excitation end, 13-a first amplitude transformer, 14-a first transducer, 15-a first ultrasonic generator, 16-a workbench, 17-an industrial personal computer, 18-a thermal imager, 19-a second ultrasonic generator, 20-a second transducer, 21-a second amplitude transformer, 22-a second excitation end, 23-a Y-direction motion mechanism, 24-an X-direction motion mechanism, 25-a third excitation end and 26-a third amplitude transformer, 27-third transducer, 28-third sonotrode.
Detailed Description
The present invention will now be described in further detail with reference to specific examples, which are intended to be illustrative, but not limiting, of the invention.
The invention aims at the difficulty of the forming process of the CMT aluminum alloy additive manufacturing technology, and provides a device and a method for enhancing the forming quality of the CMT aluminum alloy additive manufacturing by multiple ultrasonic assistance; the device and the method introduce the coupling stirring effect of high-frequency ultrasonic energy in three directions at a welding pool formed by electric arc, and the substrate fixing device is adopted to be matched with the hard rubber cushion block to fix the substrate, so that the substrate generates micro high-frequency vibration while transmitting ultrasonic high-frequency energy waves, the metal solidification process of the welding pool is subjected to the comprehensive effect of the high-frequency ultrasonic stirring in three directions and the micro high-frequency vibration of the substrate, large grains are crushed in the crystallization process of the material, small grains are formed again, the separation of gas dissolved in the melt is promoted, the porosity of the material-adding manufactured part is reduced, and the mechanical property of the formed part is improved.
The ultrasonic impact treatment is carried out on the area which is formed just after the accumulation and is easy to plastically deform on the surface, so that the residual stress at the position just after the accumulation is finished can be reduced in real time in the forming process, a trace amount of plastic deformation is generated, the residual compressive stress is formed on the surface, and the deformation in the additive manufacturing process can be effectively controlled.
The high-quality forming of the CMT aluminum alloy target part additive manufacturing can be realized under the multi-ultrasonic action, the stress deformation is reduced, the aluminum alloy elements are uniformly distributed, the crystal grains are refined, the porosity is reduced, and the mechanical property of the formed part is greatly improved.
The invention discloses a device for enhancing CMT aluminum alloy additive manufacturing forming quality with multiple ultrasonic assistance, which is shown in figures 1 and 2 and comprises: the device comprises a surface ultrasonic impact system, an X-direction ultrasonic excitation system, a Y-direction ultrasonic excitation system, a Z-direction ultrasonic excitation system, a substrate fixing device and a temperature control system after stacking. The ultrasonic impact system for the surface after accumulation is used for carrying out ultrasonic impact treatment on the surface after accumulation. The X-direction ultrasonic excitation system acts on the forming substrate 6 and is used for transmitting X-direction ultrasonic high-frequency energy waves at a molten pool formed by an electric arc. The Y-direction ultrasonic excitation system acts on the forming substrate 6 and is used for transmitting Y-direction ultrasonic high-frequency energy waves at a molten pool formed by an electric arc. The Z-direction ultrasonic excitation system acts on the bottom of the forming substrate 6 and is used for transmitting Z-direction ultrasonic high-frequency energy waves to a molten pool formed by the electric arc. The substrate fixing device is used for fixing the substrate, when the substrate is subjected to the action of an X-direction ultrasonic excitation system, a Y-direction ultrasonic excitation system and a Z-direction ultrasonic excitation system, micro high-frequency vibration is generated, and after the substrate fixing device fixes the substrate through the hard rubber cushion block, the vibration amplitude of the substrate is not more than 0.5mm at most. And the temperature control system starts to perform ultrasonic impact on the surface after accumulation according to the condition that the surface temperature of the starting point after each layer starts to accumulate is at a certain preset value in the plastic deformation temperature interval of the aluminum alloy.
As shown in fig. 2, the substrate fixing device is composed of four groups of identical bolt pressing mechanisms, a nut of a fastening bolt 10 in each bolt pressing mechanism is positioned in a workbench 16, a clamping groove is formed in one side of a thread-free part of a screw, a rectangular second hard rubber cushion block 8 next to the side surface of the substrate is clamped through the clamping groove, a rectangular first hard rubber cushion block 7 on the upper surface of the substrate is pressed through a pressing plate 9, the position of the bolt is fixed through screwing a fastening nut, and the degree of freedom of the substrate 6 in the horizontal direction and the vertical direction is limited respectively; a first hard rubber cushion block 7 is tightly pressed between one end of the pressing plate 9 and the surface of the substrate, and the other end of the pressing plate 9 is tightly pressed on the workbench 16 through a cushion block 11 to support the other end of the pressing plate 9. As the hard rubber cushion block is contacted with the substrate, when the substrate is subjected to the action of an X-direction ultrasonic excitation system, a Y-direction ultrasonic excitation system and a Z-direction ultrasonic excitation system, the hard rubber cushion block can generate micro elastic deformation in three directions, so that the substrate generates micro high-frequency vibration while transmitting ultrasonic high-frequency energy waves, and the vibration amplitude of the substrate is not more than 0.5mm at most. The vibration of the substrate can refine the grains of the formed part, which is beneficial to the overflow of gas in the molten pool and the reduction of the porosity of the formed part. The four groups of same bolt pressing mechanisms can be uniformly and symmetrically arranged, can be respectively arranged on two symmetrical edges, can also be respectively arranged on four edges, and can also increase the number of the bolt pressing mechanisms; in the preferred embodiment, four groups of identical bolt pressing mechanisms are respectively and vertically arranged on four sides of the substrate 6, and are respectively and correspondingly arranged at adjacent positions of four corners in a swastika type arrangement.
The ultrasonic impact system for the surface after accumulation comprises a robot motion mechanism 1, a fourth ultrasonic generator 2, an ultrasonic impact gun 3 and an industrial personal computer 17. The industrial personal computer 17 controls the motion track of the robot motion mechanism 1 and sets the power of the fourth ultrasonic generator 2 and the amplitude of the ultrasonic impact gun 3. The robot motion mechanism 1 clamps the ultrasonic impact gun 3 and moves according to the part forming path track according to the instruction of the industrial personal computer 17, so that the moving track of the ultrasonic impact gun is the same as the part forming path track. The rated power of the fourth ultrasonic generator 2 is 1KW-3KW, and 2KW is taken as an example in the preferred embodiment for explanation. The working frequency of the ultrasonic impact gun 3 is 20KHZ, and the maximum amplitude is 50-100 μm, and the preferred embodiment is described by taking 80 μm as an example. The robot motion mechanism 1 is used for clamping the ultrasonic impact gun 3, and can flexibly move the ultrasonic impact gun 3 to perform ultrasonic impact on the surface after accumulation.
The temperature control system includes a thermal imager 18 and an industrial personal computer 17. The thermal imager 18 is used for monitoring the temperature of the forming process and transmits the data to the industrial control computer 17. The industrial personal computer 17 determines whether ultrasonic impact is started or not according to the surface temperature of the starting point after each layer starts to be stacked, the thermal imager 18 acquires the surface temperature of the starting point after each layer starts to be stacked of the formed part, and temperature data are transmitted to the industrial personal computer 17. When the temperature of the starting point is reduced to T when the temperature of the aluminum alloy is at a certain preset value T1 between 200 ℃ and 400 ℃, the industrial personal computer 17 controls the robot motion mechanism 1 to enable the ultrasonic impact gun 3 to start ultrasonic impact on the surface after accumulation at the same speed as that of printing and forming, and in the preferred embodiment, when the temperature at the position where printing is started is reduced to 300 ℃, the ultrasonic impact is started.
The X-direction ultrasonic excitation system includes an X-direction ultrasonic excitation device and a Y-direction movement mechanism 23. The X-direction ultrasonic excitation device comprises a second excitation end 22, a second amplitude transformer 21, a second transducer 20 and a second ultrasonic generator 19, wherein the second ultrasonic generator 19 is electrically connected with the second transducer 20, and the second transducer 20, the second amplitude transformer 21 and the second excitation end 22 are mechanically connected together. The X-direction ultrasonic excitation device is in contact with one edge of the substrate 6 parallel to the Y-direction through the second excitation end 22, and transmits the X-direction high-frequency ultrasonic vibration energy to the substrate 6 and then to the molding 5 through the substrate 6. The rated power of the second ultrasonic generator 19 is between 100W and 1KW, the ultrasonic frequency is 20KHZ, and the maximum amplitude of the excitation end is 30-80 μm. In the preferred embodiment, the second ultrasonic generator 19 has a rated power of 150W, an ultrasonic frequency of 20KHZ and a maximum vibration amplitude of 50 μm at the vibration exciting end. The Y-direction movement mechanism 23 is used for adjusting the position of the second excitation end 22 to be always positioned in the X-axis direction parallel to the connecting line of the arc forming molten pool, so that the ultrasonic energy in the X direction can be transmitted to act on the molten pool in the shortest distance and the optimal direction. In the process of forming the target part, the industrial personal computer 17 controls the Y-direction movement mechanism 23 according to the position of the welding gun so that the connecting line of the second excitation end 22 and the welding gun 4 is always parallel to the X direction. So that the ultrasonic energy in the X direction can act on the molten pool in the shortest distance and the optimal direction.
The Y-direction ultrasonic excitation system includes a Y-direction ultrasonic excitation device and an X-direction movement mechanism 24. The Y-direction ultrasonic excitation device comprises a third excitation end 25, a third amplitude transformer 26, a third transducer 27 and a third ultrasonic generator 28, wherein the third ultrasonic generator 28 is electrically connected with the third transducer 27, and the third transducer 27 is mechanically connected with the third amplitude transformer 26 and the third excitation end 25. The Y-direction ultrasonic excitation device is in contact with one side of the substrate 6 parallel to the X-direction through the third excitation end 25, and transmits the Y-direction high-frequency ultrasonic vibration energy to the substrate 6 and then to the molding 5 through the substrate 6. The rated power of the third ultrasonic generator 28 is 100W-1KW, the ultrasonic frequency is 20KHZ, the maximum amplitude of the second excitation end is 30 μm-80 μm, in the preferred embodiment, the rated power of the third ultrasonic generator 28 is 150W, the ultrasonic frequency is 20KHZ, and the maximum amplitude of the third excitation end is 25 μm. The X-direction movement mechanism 24 is used for adjusting the position of the third excitation end 25 to be always positioned in the Y-axis direction parallel to the connecting line of the arc forming molten pool, so that the ultrasonic energy in the Y direction can be transmitted to act on the molten pool in the shortest distance and the optimal direction. In the process of forming the target part, the industrial personal computer 17 controls the X-direction motion executing mechanism 23 according to the position of the welding gun so that the connecting line of the third excitation end 25 and the welding gun 4 is always parallel to the Y direction. So that the ultrasonic energy in the Y direction can act on the molten pool in the shortest distance and the optimal direction.
The Z-direction ultrasonic excitation system comprises a Z-direction ultrasonic excitation device and a fixing device. The Z-direction ultrasonic excitation device comprises a first excitation end 12, a first amplitude transformer 13, a first transducer 14 and a first ultrasonic generator 15, wherein the first ultrasonic generator 15 is electrically connected with the first transducer 14, and the first transducer 14 is mechanically connected with the first amplitude transformer 13 and the first excitation end 12. The Z-direction ultrasonic vibration excitation device passes through the worktable 16 through the first vibration excitation end 12 to contact the bottom center position of the substrate 6, and transmits the Z-direction high-frequency ultrasonic vibration energy to the substrate 6 and then to the forming member 5 through the substrate 6. The rated power of the first ultrasonic generator 15 is 100W-1KW, the ultrasonic frequency is 20KHZ, the maximum amplitude of the third excitation end is 30 μm-80 μm, in the preferred embodiment, the rated power of the first ultrasonic generator 15 is 200W, the ultrasonic frequency is 20KHZ, and the maximum amplitude of the first excitation end 12 is 60 μm. The fixing device fixes the first transducer 14, the first amplitude transformer 13 and the first excitation end 12 of the Z-direction ultrasonic excitation device at corresponding proper positions.
The invention discloses a method for enhancing the additive manufacturing forming quality of CMT aluminum alloy by multiple ultrasonic aids, which comprises the following steps:
1) aligning the center position of the bottom of the substrate to the first excitation end 12 of the Z-direction ultrasonic excitation device, and fixing the substrate 6 by using the substrate fixing device; specifically, a first hard rubber cushion block 7, a pressure plate 9, a fastening bolt 10 and a cushion block 11 are adopted to fix a substrate 6 on a workbench 16, the center position of the bottom of the substrate is adjusted to be aligned with a first excitation end 12 of a Z-direction ultrasonic excitation device, and the first excitation end 12 is kept in contact with the substrate 6.
2) And taking the initial position of the CMT aluminum alloy additive first layer for starting printing as a reference, adjusting the Y-direction movement mechanism 23 to enable the connection line of the X-direction ultrasonic excitation device second excitation end 22 and the welding gun 4 to be parallel to the X direction, and adjusting the X-direction movement mechanism 24 to enable the connection line of the Y-direction ultrasonic excitation device third excitation end 25 and the welding gun 4 to be parallel to the Y direction.
3) Before each layer is printed and formed, according to different aluminum alloy materials and process parameters and the optimal values of power and amplitude corresponding to X, Y, Z to the ultrasonic excitation device when different layers are printed, according to the process optimization result, the power and amplitude corresponding to X, Y, Z to the ultrasonic excitation device when different layers are printed are preset to be equal to the corresponding optimal values. Specifically, for convenience of description, the rated power of an ultrasonic generator of the X, Y to the ultrasonic excitation device is 150W, the ultrasonic frequency is 20KHZ, and the maximum amplitude is 50 μm when different layers are printed. When different layers are printed, the rated power of an ultrasonic generator of the Z-direction ultrasonic excitation device is 200W, the ultrasonic frequency is 20KHZ, the maximum amplitude is 60 mu m, and the industrial personal computer 17 controls the on and off of the X, Y, Z-direction ultrasonic excitation device.
4) Start CMT welding device move gun 4 to start printing the first layer and simultaneously start the X, Y, Z ultrasonic excitation device.
5) In the printing process, the Y-direction movement mechanism is controlled and adjusted to move, so that the line connecting the second excitation end 22 of the X-direction ultrasonic excitation device and the welding gun 4 is parallel to the X direction, and the X-direction movement mechanism 24 is controlled and adjusted to move, so that the line connecting the third excitation end 25 of the Y-direction ultrasonic excitation device and the welding gun 4 is parallel to the Y direction.
6) The thermal imager monitors the surface temperature at the starting point after each layer starts to be stacked, when the temperature at the initial printing position is reduced to a certain preset value T1 between 200 ℃ and 400 ℃, which is 300 ℃ in the preferred embodiment, the industrial personal computer 17 controls the ultrasonic impact gun 3 to start to perform ultrasonic impact on the surface after being stacked at the same speed as the printing and forming when the temperature at the initial printing position is reduced to 300 ℃.
7) After the layer is printed and the ultrasonic impact is finished, the industrial personal computer 17 closes the ultrasonic vibration exciting devices and the ultrasonic impact devices in the three directions. And taking the initial position of the welding gun at the next layer for starting printing as a reference, adjusting the Y-direction movement mechanism 23 to enable the connection line of the second excitation end 22 of the X-direction ultrasonic excitation device and the welding gun 4 to be parallel to the X direction, and adjusting the X-direction movement mechanism 24 to enable the connection line of the third excitation end 25 of the Y-direction ultrasonic excitation device and the welding gun 4 to be parallel to the Y direction. The thermal imager is activated to monitor the maximum temperature of the formed layer, which is 70 ℃ in the preferred embodiment, when the measured maximum temperature is reduced to a predetermined value T2 between 70 ℃ and 100 ℃. The CMT welding apparatus is activated to move the welding gun 4 to begin the formation of the next layer and simultaneously open X, Y, Z to the ultrasonic excitation device.
8) Carrying out layer 2 stacking forming by the CMT welding device, and repeating the steps 5), 6) and 7); the welding device performs 3 rd layer stacking forming, and repeats steps 5), 6), 7) ·.
The invention can solve the difficult problem of the existing CMT additive manufacturing aluminum alloy process through the comprehensive action of multiple ultrasonic aids, the coupling action of high-frequency ultrasonic energy in three directions is introduced at the welding molten pool formed by electric arc, and a substrate fixing device is adopted, so that the substrate generates micro high-frequency vibration while transmitting ultrasonic high-frequency energy waves, the comprehensive action of the high-frequency ultrasonic energy waves in three directions and the micro high-frequency vibration of the substrate is applied in the molten pool metal solidification process, crystal grains can be refined in three directions, the precipitation of gas dissolved in a melt is promoted, the porosity of an additive manufacturing part is reduced, the mechanical property of the forming part is improved, the residual stress at the position just accumulated is reduced in real time in the forming process, the deformation of a target part is controlled, and the fatigue strength of the forming part is improved. Finally, high-quality forming of the CMT aluminum alloy additive manufacturing target part is realized, and the method has great practical value and wide application prospect.
Claims (10)
1. The method for enhancing the forming quality of the CMT aluminum alloy additive manufacturing by multiple ultrasonic aids is characterized by comprising the following steps of:
1) aligning the center position of the bottom of the substrate to the excitation end of a Z-direction ultrasonic excitation device, fixing the substrate (6) on a workbench (16) by adopting a substrate fixing device, adjusting the center position of the bottom of the substrate (6) to align to the first excitation end (12) of the Z-direction ultrasonic excitation device, and keeping the first excitation end (12) in contact with the bottom surface of the substrate (6);
2) taking the initial position of the welding gun at which the CMT aluminum alloy additive first layer begins to be printed as a reference, adjusting a Y-direction movement mechanism (23) to enable the connection line of a second excitation end (22) of the X-direction ultrasonic excitation device and the welding gun (4) to be parallel to the X direction; adjusting an X-direction movement mechanism (24) to enable a connecting line of a third excitation end (25) of the Y-direction ultrasonic excitation device and the welding gun (4) to be parallel to the Y direction;
3) according to different aluminum alloy materials, process parameters and optimal values of power and amplitude of X, Y, Z to the ultrasonic excitation device corresponding to different layers when the different layers are printed, the power and the amplitude of X, Y, Z to the ultrasonic excitation device when the different layers are printed are preset, and the industrial personal computer (17) controls the ultrasonic excitation device to be opened X, Y, Z;
4) starting a CMT welding device to move a welding gun (4) to start printing a first layer, and simultaneously opening an X, Y, Z-direction ultrasonic excitation device;
5) in the printing process, the industrial personal computer (17) controls and adjusts the Y-direction movement mechanism (23) to move, so that the connection line of the second excitation end (22) of the X-direction ultrasonic excitation device and the welding gun (4) is parallel to the X direction all the time; controlling and adjusting the X-direction movement mechanism (24) to move, so that the connection line of a third excitation end (25) of the Y-direction ultrasonic excitation device and the welding gun (4) is parallel to the Y direction all the time;
6) the thermal imager monitors the surface temperature of the starting point after each layer starts to be stacked, and when the temperature of the position where the printing is started is reduced to a preset value T1, the industrial personal computer (17) controls the ultrasonic impact gun (3) to start to perform ultrasonic impact on the stacked surface at the same speed as the printing forming speed;
7) after each layer of printing is finished and the ultrasonic impact is finished, the industrial personal computer (17) closes the ultrasonic vibration exciting devices and the ultrasonic impact devices in the three directions;
taking the initial position of the welding gun which starts to be printed on the next layer as a reference, adjusting the Y-direction movement mechanism (23) to enable the connecting line of the second excitation end (22) of the X-direction ultrasonic excitation device and the welding gun (4) to be parallel to the X direction, and adjusting the X-direction movement mechanism (24) to enable the connecting line of the third excitation end (25) of the Y-direction ultrasonic excitation device and the welding gun (4) to be parallel to the Y direction; activating a thermal imager to monitor the temperature of the formed layer, and when the measured highest temperature is reduced to a set temperature T2; starting the CMT welding device to move the welding gun (4) to start the formation of the next layer, and simultaneously opening the X, Y, Z-direction ultrasonic excitation device;
8) and (5) repeating the steps 5), 6) and 7) to sequentially finish the stacking and forming of each layer, and finally obtaining a formed piece (5).
2. The method for enhancing the CMT aluminum alloy additive manufacturing forming quality by multiple ultrasonic assistance according to claim 1, wherein in the step 3), the rated power of an ultrasonic generator in an X, Y, Z-direction ultrasonic excitation device is 100W-1KW, the ultrasonic frequency is 20KHZ, and the maximum amplitude of an excitation end is 30-80 μm.
3. The method for multi-ultrasonic-assisted enhancement of CMT aluminum alloy additive manufacturing forming quality according to claim 1, characterized in that in the step 6), when the surface temperature at the starting point of each layer after the start of stacking is reduced to a preset value T1 between 200 ℃ and 400 ℃, the industrial personal computer (17) controls the ultrasonic impact gun (3) to start ultrasonic impact on the surface after the stacking at the same speed as that of printing forming; the working frequency of the ultrasonic impact gun (3) is 20KHZ, the maximum amplitude is 50-100 micrometers, and the rated power of a fourth ultrasonic generator (2) connected with the input end of the ultrasonic impact gun (3) is 1-3 KW; when the maximum temperature of the formed layer is reduced to a preset value T2 between 70 and 100 ℃, the CMT welding device is started to move a welding gun (4) to start the formation of the next layer.
4. The method for multi-ultrasonic-assisted enhancement of CMT aluminum alloy additive manufacturing forming quality according to claim 1, wherein the adopted devices comprise a workbench (16), a substrate (6), a substrate fixing device for fixing the substrate (6) on the workbench (16), and an X-direction ultrasonic excitation system, a Y-direction ultrasonic excitation system and a Z-direction ultrasonic excitation system;
the X, Y and Z-direction ultrasonic excitation systems are respectively contacted with the substrate (6) to carry out ultrasonic excitation, and simultaneously X, Y and Z-direction ultrasonic high-frequency energy waves are transmitted to a molten pool formed by an electric arc;
the substrate fixing device tightly presses and fixes the substrate (6) on the workbench (16) through the hard rubber cushion block.
5. The method for multi-ultrasonic-assisted enhancement of CMT aluminum alloy additive manufacturing forming quality of claim 4, wherein the substrate fixture comprises a plurality of identical sets of bolt pressing mechanisms, and the hard rubber blocks comprise a first hard rubber block (7) and a second hard rubber block (8);
the bolt pressing mechanism comprises a pressing plate (9), a fastening bolt (10), a fastening nut and a cushion block (11); the nut end of the fastening bolt (10) is fixed in the workbench (16), and one side of the screw rod is provided with a clamping groove; a second hard rubber cushion block (8) is tightly pressed between the clamping groove and the adjacent side surface of the substrate; a fastening bolt (10) penetrates through a pressure plate (9) and is fastened and matched with a fastening nut, a first hard rubber cushion block (7) is tightly pressed between one end of the pressure plate (9) and the surface of the substrate, and the other end of the pressure plate tightly presses a workbench (16) through a cushion block (11); after the substrate fixing device fixes the substrate through the hard rubber cushion block, the maximum vibration amplitude of the substrate is not more than 0.5 mm.
6. The method for multi-ultrasonic-assisted enhancement of CMT aluminum alloy additive manufacturing forming quality of claim 4, wherein the X-direction ultrasonic excitation system comprises an X-direction ultrasonic excitation device and a Y-direction motion mechanism (23);
the X-direction ultrasonic excitation device comprises a second excitation end (22), a second amplitude transformer (21), a second transducer (20) and a second ultrasonic generator (19); the second ultrasonic generator (19) is electrically connected with a second transducer (20), and the second transducer (20), a second amplitude transformer (21) and a second excitation end (22) are sequentially and fixedly connected and are together installed and fixed on the Y-direction movement mechanism (23); the second excitation end (22) is in contact with one edge of the substrate (6) parallel to the Y direction, and transmits the high-frequency ultrasonic vibration energy in the X direction to the substrate (6) and then to the forming piece (5) through the substrate (6);
the Y-direction movement mechanism (23) is used for adjusting the position of the second excitation end (22) to be always parallel to the X-axis direction of a connecting line of an arc forming molten pool.
7. The method for multi-ultrasonic-assisted enhancement of CMT aluminum alloy additive manufacturing forming quality of claim 4, wherein the Y-direction ultrasonic excitation system comprises a Y-direction ultrasonic excitation device and an X-direction motion mechanism (24);
the Y-direction ultrasonic excitation device comprises a third excitation end (25), a third amplitude transformer (26), a third transducer (27) and a third ultrasonic generator (28); the third ultrasonic generator (28) is electrically connected with the third transducer (27), and the third transducer (27), the third amplitude transformer (26) and the third excitation end (25) are sequentially and fixedly connected and are installed and fixed on the X-direction movement mechanism (24) together; the third excitation end (25) is in contact with one edge of the substrate (6) parallel to the X direction, and transmits the high-frequency ultrasonic vibration energy in the Y direction to the substrate (6) and then to the forming piece (5) through the substrate (6);
the X-direction movement mechanism (24) is used for adjusting the position of the third excitation end (25) to be always parallel to the Y-axis direction of a connecting line of the arc forming molten pool.
8. The method for multi-ultrasonic-assisted enhancement of CMT aluminum alloy additive manufacturing forming quality of claim 4, wherein the Z-direction ultrasonic excitation system comprises a Z-direction ultrasonic excitation device and a fixing device;
the Z-direction ultrasonic excitation device comprises a first excitation end (12), a first amplitude transformer (13), a first transducer (14) and a first ultrasonic generator (15); the first ultrasonic generator (15) is electrically connected with the first transducer (14), and the first transducer (14), the first amplitude transformer (13) and the first excitation end (12) are sequentially and fixedly connected and are installed and fixed on the fixing device together; the first excitation end (12) penetrates through the workbench (16) to be in contact with the bottom center of the substrate (6), and transmits the Z-direction high-frequency ultrasonic vibration energy to the substrate (6) and then to the forming piece (5) through the substrate (6);
the fixing device fixes the Z-direction ultrasonic excitation device under the substrate (6).
9. The method of multi-ultrasonic assisted enhanced CMT aluminum alloy additive manufacturing forming quality of claim 4, further comprising a build-up back surface ultrasonic impact system and a temperature control system;
the ultrasonic impact system of the surface after accumulation is used for carrying out ultrasonic impact treatment on the surface after accumulation;
and the temperature control system is used for monitoring the surface temperature of the starting point of each layer after the accumulation is started according to a preset value in a temperature interval of plastic deformation of the aluminum alloy, and when the temperature is lower than the preset value, a signal is sent to the ultrasonic impact system of the surface after the accumulation to start the ultrasonic impact on the surface after the accumulation.
10. The method for multi-ultrasonic-assisted enhancement of CMT aluminum alloy additive manufacturing forming quality according to claim 9, wherein the post-stack surface ultrasonic impact system comprises a robot motion mechanism (1), a fourth ultrasonic generator (2), an ultrasonic impact gun (3) and an industrial personal computer (17);
the industrial personal computer (17) is used for controlling the motion track of the robot motion mechanism (1), setting the power of the fourth ultrasonic generator (2) and the amplitude of the ultrasonic impact gun (3); the system is also used for controlling the motion of the X-direction ultrasonic excitation system and the Y-direction ultrasonic excitation system in the corresponding directions, and the ultrasonic frequency and the excitation amplitude of the X-direction ultrasonic excitation system, the Y-direction ultrasonic excitation system and the Z-direction ultrasonic excitation system;
the robot motion mechanism (1) clamps the ultrasonic impact gun (3) and moves according to the path track according to the instruction of the industrial personal computer (17);
the temperature control system comprises a thermal imager (18); the thermal imager (18) is used for monitoring the temperature in the forming process, and the output end of the thermal imager is connected with the input end of the industrial personal computer (17) to transmit monitoring data; the industrial personal computer (17) determines whether to start ultrasonic impact according to the comparison of the surface temperature of the starting point after each layer starts to be stacked with a preset value.
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