CN109202094B - Method for manufacturing iron-based amorphous sensor probe through laser melting three-dimensional forming - Google Patents

Method for manufacturing iron-based amorphous sensor probe through laser melting three-dimensional forming Download PDF

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CN109202094B
CN109202094B CN201811187473.1A CN201811187473A CN109202094B CN 109202094 B CN109202094 B CN 109202094B CN 201811187473 A CN201811187473 A CN 201811187473A CN 109202094 B CN109202094 B CN 109202094B
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iron
based amorphous
sensor probe
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CN109202094A (en
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杨卫明
刘海顺
陈元广
杨其奥
朱恒
李宇鸿
吕昊岩
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China University of Mining and Technology CUMT
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00Making metallic powder or suspensions thereof
    • B22F9/002Making metallic powder or suspensions thereof amorphous or microcrystalline
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80Data acquisition or data processing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00Making metallic powder or suspensions thereof
    • B22F9/02Making metallic powder or suspensions thereof using physical processes
    • B22F9/06Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00Processes of additive manufacturing
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C45/00Amorphous alloys
    • C22C45/008Amorphous alloys with Fe, Co or Ni as the major constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10Formation of a green body
    • B22F10/12Formation of a green body by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50Means for feeding of material, e.g. heads
    • B22F12/53Nozzles
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Measurement Of Length, Angles, Or The Like Using Electric Or Magnetic Means (AREA)
  • Powder Metallurgy (AREA)

Abstract

The invention discloses a method for manufacturing an iron-based amorphous sensor probe by laser melting three-dimensional forming, which comprises the following steps: firstly, preparing an alloy ingot, and preparing the master alloy ingot into amorphous powder by using a gas atomization technology; drawing a corresponding stereogram according to the sensor probe by using CAD software to obtain a CAD model; opening the metal 3D printer; hanging amorphous powder as a consumable material in a material rod; leveling a platform of the metal 3D printer; slicing by using slicing software to generate an executable file; starting printing through a metal 3D printer; and after printing is finished, shoveling the model by using a shovel to obtain the iron-based amorphous sensor probe. The invention enriches the theory of magnetic monitoring and early warning of mine supports, improves the production safety of the coal mine industry, and has great promotion effect on promoting the application of the iron-based amorphous alloy material, thereby having great theoretical value and potential economic benefit.

Description

Method for manufacturing iron-based amorphous sensor probe through laser melting three-dimensional forming
Technical Field
The invention relates to a method for three-dimensionally molding an iron-based amorphous sensor probe by laser melting.
Background
The mine pressure accident is one of three major disasters in coal mine production, which not only causes great economic loss, but also seriously threatens the life safety of underground workers. At present, the number of coal mine accidents and the number of death caused by the coal mine accidents are always high. According to analysis, most of mine death accidents are caused by mine pressure support failure or failure in timely and accurate early warning. With the progress of supporting technology, supports and hydraulic props made of ferromagnetic materials such as steel and the like are more and more widely applied to mine supporting, and it is important to monitor the stress and the working state of the supports in a real-time and nondestructive manner. The method has the advantages that the local stress change rule of the mine support equipment before the accident happens is known timely and accurately, relevant theories and technologies of nondestructive monitoring and early warning of the mine support are researched systematically, relevant sensor magnetic core materials are researched, and a mine pressure early warning system is established, so that the method has great significance for reducing and preventing the occurrence of roof accidents.
At present, a sensor for stress test is mainly a resistance strain gauge, and is favored due to small volume, light weight and low price. However, the resistance strain gauge is easily affected by the environment and short in service life, the work of derusting, polishing, bonding and the like must be performed on the support before the resistance strain gauge is used, time and labor are wasted, the bonding quality depends on factors such as the proficiency of an operator, the type of a bonding agent and the bonding firmness, the uncertainty greatly affects the reliability of a test result, the stress of supporting equipment is difficult to accurately monitor, and even serious errors can occur. Therefore, it is necessary to further research the relevant basic theory of stress monitoring, develop a novel sensor to improve the stress magnetic monitoring device of mine support, and try a new stress testing means. For ferromagnetic mine supporting equipment, the magnetic method for stress test has great superiority: the price is low; the device is small and exquisite, convenient to carry and flexible to test; the information acquisition speed is high; and surface treatment is not needed; the method can be used for contact measurement and can also be used for non-contact and on-line measurement. Stress testing by using a magnetic method is also a hotspot of current research, is widely concerned by engineering technicians, and many scholars conduct productive theoretical and experimental exploration in the field. Of particular importance are nine-pole magnetic stress sensors designed by t.isono and s.abuku et al. The sensor can measure the stress condition of any point on the material without rotating once, as shown in figure 1, the sensor is the most ideal magnetic stress measurement sensor magnetic core designed so far, and a magnetic stress measurement instrument prepared by using the sensor magnetic core with the shape is expected to thoroughly solve the problems of insufficient test precision, complex process, poor reliability and the like of a mine pressure early warning system for years.
However, the sensor magnetic core with a complex shape is convenient to use and extremely difficult to manufacture, and the popularization and application of the sensor magnetic core are severely limited. The materials and methods which can be used for preparing the sensor magnetic core with complex shape at present mainly comprise: (1) the method has the advantages of complex process, high cost, high energy consumption and high pollution, and the prepared point magnetic core has low magnetic conductivity and large coercive force due to the limitation of the soft magnetic performance of the material; (2) the ferrite powder is hot rolled, and the magnetic core prepared by the method has poor mechanical property and is easy to damage. The methods are not ideal enough, the magnetic core sensors manufactured by the methods not only have large required current and high loss, but also have easy signal distortion, and can induce safety accidents in high gas mines, and thus no suitable nine-grade sensing magnetic core is put into application so far. The iron-based amorphous alloy is a novel soft magnetic material which is researched for many years, and has the advantages of high magnetic conductivity, low coercive force, low cost, low loss, wear resistance, corrosion resistance and compression strength of more than 4000 MPa. The magnetic core is selected as the magnetic core, so that the exciting current can be effectively reduced, the energy is saved, the efficiency and the precision are improved, and the safety of coal mine production can be enhanced. But due to the limitation of the forming capability of the iron-based amorphous alloy, an extremely high cooling rate is required in the preparation process. Only some sensor magnetic cores with relatively simple shapes can be prepared by adopting the copper mold casting method widely adopted at present, so that the requirement for preparing the iron-based amorphous alloy sensor magnetic core with the shape shown in figure 1 is urgent.
The laser melting three-dimensional forming (3D printing) technology is a high and new preparation technology widely advocated in recent years, and the method can be used for quickly forming and easily preparing components with extremely complex shapes, and is simple to operate. The basic principle is that a layer of powder is firstly paved on a substrate plate, then the powder is welded by a high-energy laser beam through a point-by-point scanning method, and then a layer is paved after one layer is welded until a designed product is obtained. The method can overcome the defect of insufficient forming capability of the iron-based amorphous alloy, obtain an ultra-large-size iron-based amorphous alloy device, and design a complex component with any shape.
Therefore, in order to reduce and prevent coal mine safety accidents, it is necessary to develop an iron-based amorphous alloy material with excellent performance, a magnetic core with a required shape is formed in one step by a 3D printing technology and applied to nondestructive monitoring and early warning of ferromagnetic mine support equipment, a mine pressure early warning system is upgraded, and the application field of the iron-based amorphous alloy is expanded.
Disclosure of Invention
The invention aims to provide a method for manufacturing an iron-based amorphous sensor probe by laser melting three-dimensional forming, which overcomes the defects that the magnetic stress sensor in the prior art is not high enough in precision, not stable enough in performance, high in energy consumption and difficult to apply in severe environment, and overcomes the defect that iron-based amorphous alloy is difficult to form in a complex way.
In order to achieve the purpose, the invention adopts the technical scheme that:
a method for manufacturing an iron-based amorphous sensor probe by laser melting three-dimensional forming comprises the following steps:
step one, preparing an alloy ingot: weighing raw materials according to the components of the iron-based amorphous alloy, then putting the raw materials into a high-temperature furnace, and repeatedly smelting the raw materials in the presence of protective gas to prepare a master alloy ingot;
step two, preparing the master alloy ingot obtained in the step one into amorphous powder by using a gas atomization technology;
step three, using CAD software to establish three coordinate axes of x, y and z, drawing a corresponding stereogram according to the sensor probe to obtain a CAD model;
step four, preparing before printing: opening the metal 3D printer;
step five, feeding: preheating a spray head of a metal 3D printer before feeding; hanging the amorphous powder prepared in the step two in a material rod as a consumable material, and enabling the consumable material to pass through a material breakage detection switch and then turn on a blue lamp; pressing the compression spring clamp to enable the consumable to penetrate through the extrusion gear; stopping feeding if consumable materials are discharged from the observation nozzle, and finishing feeding;
step six, leveling a platform: clicking a 'preparation' button and an 'automatic return to the original point' button of the metal 3D printer, and clicking a 'step driving closing' button after the metal 3D printer stops moving; manually moving the touch head to the lower left corner of the forming platform, screwing a nut by adjusting a corresponding hand below the leveling platform to ensure that the platform is just contacted with the nozzle, and sequentially adjusting the other three corners by using the method; printing can be started after leveling is finished;
step seven, slicing: slicing by using slicing software to generate an executable file, namely, a geocode;
step eight, starting printing: importing the CAD model obtained in the step three into slicing software, and sequentially clicking the File-Save G Code after setting parameters to generate a G Code; copying the G code to an SD card, inserting the SD card into a card slot of a metal 3D printer, pressing a knob to enter a menu, selecting 'from a memory card', finding a file name to be printed, pressing the knob to determine, starting automatic heating of a nozzle, and starting printing when the preset temperature is reached;
and step nine, after printing is finished, the spray head can automatically return, and when the temperature of the spray nozzle and the hot bed is reduced to room temperature, the model is shoveled down by a shovel to obtain the iron-based amorphous sensor probe.
In the first step, the chemical formula of the iron-based amorphous alloy is Fe36Co36Si4B20Nb4The mass percent is converted from the atomic percent, and high-purity raw materials of Fe, Co, Si, B and Nb are adopted.
In the first step, the protective gas is one or a mixture of several of argon and nitrogen; the purity of the shielding gas requires a volume percentage of greater than 98%.
In the second step, the gas adopted by the gas atomization technology is argon.
In the sixth step, if the consumable material cannot be adhered to the platform in the process of printing the first layer, the distance between the nozzle and the platform is too far, and the platform adjusting knob at the corresponding position is finely adjusted.
The invention has the beneficial effects that:
the invention creatively provides the magnetic core made of the iron-based amorphous alloy, which has the advantages of excellent soft magnetic performance, wear resistance, corrosion resistance, high strength, controllable Curie temperature, low cost and the like, and not only can effectively reduce exciting current, save energy, improve efficiency and precision, but also can enhance the safety of coal mine production. The nine-pole magnetic stress measurement sensor can measure the stress condition of any point on a material without rotating once, is the most ideal magnetic stress measurement sensor magnetic core designed so far, and a magnetic stress measurement instrument prepared by using the sensor magnetic core with the shape is expected to solve the problems of insufficient test precision, complex process, poor reliability and the like of a mine pressure early warning system for years, and has important significance in promoting the development of the fields of intelligent monitoring, safe production, automatic control and the like.
The invention enriches the theory of magnetic monitoring and early warning of mine supports, improves the production safety of the coal mine industry, and has great promotion effect on promoting the application of the iron-based amorphous alloy material, thereby having great theoretical value and potential economic benefit.
Drawings
Fig. 1a and 1b are schematic diagrams of an ideal magnetic core of a mine pressure early warning sensor, wherein fig. 1a is a perspective view and fig. 1b is a top view;
FIG. 2 shows the gas atomized powder Fe36Co36B20Si4Nb4Scanning an electron microscope;
FIG. 3 is a CAD drawing of a nine-pole sensor probe at different angles;
fig. 4 is a real object diagram of a nine-pole sensor probe.
Detailed Description
The present invention will be further described with reference to the accompanying drawings.
The invention discloses a method for manufacturing an iron-based amorphous sensor probe by laser melting three-dimensional forming, which comprises the following steps of:
step one, preparing an alloy ingot: the chemical formula of the iron-based amorphous alloy is Fe36Co36Si4B20Nb4Converting the atomic percent into mass percent; adopts high-purity raw materials of Fe, Co,Si, B and Nb, weighing the raw materials according to the components of the iron-based amorphous alloy, then putting the raw materials into a prepared high-temperature furnace, and repeatedly melting the alloy at high temperature in the presence of protective gas to prepare a master alloy ingot; wherein the protective gas comprises one or more of argon, nitrogen and the like; the purity of the protective gas requires that the volume percentage is more than 98 percent;
step two, preparing the master alloy ingot obtained in the step one into amorphous powder by using an air atomization technology, wherein the morphology and the structure of the amorphous powder are shown in figure 2; the gas atomization technology adopts argon gas;
step three, using CAD software; establishing three coordinate axes of x, y and z; drawing a corresponding stereo image according to the sensor probe to obtain a CAD model;
step four, preparing before printing: opening the metal 3D printer, inserting a randomly distributed three-pin power line at the back of the case, and opening a switch at the back of the case;
step five, feeding: the spray head needs to be preheated before feeding, and the preparation button and the preheating button are clicked, so that feeding can be carried out when the temperature is heated to the specified temperature; hanging the amorphous powder prepared in the step two in a material rod as a consumable material, and enabling the consumable material to pass through a material breakage detection switch and then turn on a blue lamp; pressing the compression spring clamp to enable the consumable to penetrate through the extrusion gear; stopping feeding if consumable materials are discharged from the observation nozzle, and finishing feeding;
step six, leveling a platform: clicking a 'preparation' button and an 'automatic return to the original point' button of the metal 3D printer, and clicking a 'step driving closing' button after the metal 3D printer stops moving; manually moving the touch head to the lower left corner of the forming platform, screwing a nut by adjusting a corresponding hand below the leveling platform to ensure that the platform is just contacted with the nozzle, and sequentially adjusting the other three corners by using the method; printing can be started after leveling is finished; if the consumable fails to stick to the platen during the printing of the first layer, it indicates that the nozzle is too far from the platen. The platform adjustment knob at the corresponding position should be finely adjusted appropriately.
Step seven, slicing: slicing by using slicing software to generate an executable file, namely, a geocode;
step eight, starting printing: importing the drawn CAD model into slicing software, and clicking File-Save G Code (Save slice) after setting parameters to generate a G Code; before printing, copying the G code to an SD card, and inserting the SD card into a card slot at the lower right of the machine; pressing a knob to enter a menu, selecting 'from a memory card', finding a file name to be printed, pressing the knob to determine that a nozzle starts to automatically heat to reach a preset temperature, and starting to print;
and step nine, after printing is finished, the spray head can automatically return, when the temperature of the spray nozzle and the hot bed is reduced to room temperature, the model is shoveled down by a randomly distributed shovel, the model is shoveled safely, and the printing platform is not damaged as much as possible. At this point, the sensor probe shown in fig. 4 can be printed.
The above description is only of the preferred embodiments of the present invention, and it should be noted that: it will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the principles of the invention and these are intended to be within the scope of the invention.

Claims (2)

1. A method for manufacturing an iron-based amorphous sensor probe by laser melting three-dimensional forming is characterized by comprising the following steps: the method comprises the following steps:
step one, preparing an alloy ingot: weighing raw materials according to the components of the iron-based amorphous alloy, then putting the raw materials into a high-temperature furnace, and repeatedly smelting the raw materials in the presence of protective gas to prepare a master alloy ingot;
wherein the chemical formula of the iron-based amorphous alloy is Fe36Co36Si4B20Nb4Converting the atomic percent into mass percent, and adopting high-purity raw materials of Fe, Co, Si, B and Nb;
step two, preparing the master alloy ingot obtained in the step one into amorphous powder by using a gas atomization technology;
step three, using CAD software to establish three coordinate axes of x, y and z, drawing a corresponding stereogram according to the sensor probe to obtain a CAD model;
step four, preparing before printing: opening the metal 3D printer;
step five, feeding: preheating a spray head of a metal 3D printer before feeding; hanging the amorphous powder prepared in the step two in a material rod as a consumable material, and enabling the consumable material to pass through a material breakage detection switch and then turn on a blue lamp; pressing the compression spring clamp to enable the consumable to penetrate through the extrusion gear; stopping feeding if consumable materials are discharged from the observation nozzle, and finishing feeding;
step six, leveling a platform: clicking a 'preparation' button and an 'automatic return to the original point' button of the metal 3D printer, and clicking a 'step driving closing' button after the metal 3D printer stops moving; manually moving the touch head to the lower left corner of the forming platform, screwing a nut by adjusting a corresponding hand below the leveling platform to ensure that the platform is just contacted with the nozzle, and sequentially adjusting the other three corners by using the method; printing can be started after leveling is finished;
step seven, slicing: slicing by using slicing software to generate an executable file, namely, a geocode;
step eight, starting printing: importing the CAD model obtained in the step three into slicing software, and sequentially clicking the File-Save G Code after setting parameters to generate a G Code; copying the G code to an SD card, inserting the SD card into a card slot of a metal 3D printer, pressing a knob to enter a menu, selecting 'from a memory card', finding a file name to be printed, pressing the knob to determine, starting automatic heating of a nozzle to reach a preset temperature, and starting printing;
step nine, after printing is finished, the spray head can automatically return, and when the temperature of the spray nozzle and the hot bed is reduced to room temperature, a shovel is used for shoveling the model down to obtain the iron-based amorphous sensor probe;
in the first step, the protective gas is one or a mixture of several of argon and nitrogen; the purity of the protective gas requires that the volume percentage is more than 98 percent;
in the second step, the gas adopted by the gas atomization technology is argon.
2. The method for manufacturing the iron-based amorphous sensor probe by laser melting stereolithography according to claim 1, wherein: in the sixth step, if the consumable material cannot be adhered to the platform in the process of printing the first layer, the distance between the nozzle and the platform is too far, and the platform adjusting knob at the corresponding position is finely adjusted.
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CN111141436A (en) * 2019-12-31 2020-05-12 中国特种设备检测研究院 Method and device for reconstructing residual stress field of ferromagnetic component
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