CN109202272B - Flow friction additive manufacturing device and additive manufacturing method - Google Patents
Flow friction additive manufacturing device and additive manufacturing method Download PDFInfo
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- CN109202272B CN109202272B CN201810234931.6A CN201810234931A CN109202272B CN 109202272 B CN109202272 B CN 109202272B CN 201810234931 A CN201810234931 A CN 201810234931A CN 109202272 B CN109202272 B CN 109202272B
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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
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/1215—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding for other purposes than joining, e.g. built-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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Abstract
The invention relates to a flow friction additive manufacturing device and an additive manufacturing method, wherein the additive manufacturing device comprises a shaft shoulder, a base material and a base body, a cavity is formed in the shaft shoulder, a central through hole communicated with the cavity is formed in the lower end of the shaft shoulder below the cavity, the base material is placed in the cavity in the shaft shoulder, upsetting force exists between the base material and the bottom surface of the cavity in the shaft shoulder, and upsetting force exists between the shaft shoulder and the base body; when the additive manufacturing is carried out, the shaft shoulder rotates and moves on the surface of the area to be additized of the base body, the base material does not rotate, the base material is thermoplasticized under the friction action of the base material, the thermoplasticized material flows out along the central through hole at the lower end of the shaft shoulder under the action of upsetting force, and the thermoplasticized material is diffused and deposited on the surface of the area to be additized of the base body under the relative rotation action and the upsetting force of the outer end surface of the shaft shoulder and the surface of the area to be additized of the. The device and the method can improve the material utilization rate and the manufacturing efficiency, and solve the problems of large machining allowance and low material utilization rate in the friction stir additive manufacturing.
Description
Technical Field
The invention relates to a flow friction additive manufacturing device and an additive manufacturing method, and belongs to the technical field of additive manufacturing.
Background
Additive Manufacturing (AM) is to create and plan a 3D model in advance by a computer technology, melt, clad or overlay a material layer by combining with a digitized controllable heat source, and quickly form a structural member or a functional member, has five technical characteristics of digital Manufacturing, dimension reduction Manufacturing, stacking Manufacturing, direct Manufacturing, quick Manufacturing and the like, receives wide attention of the world, brings a series of deep transformations to the traditional Manufacturing industry, and can be widely applied to the fields of aerospace, national defense, medical treatment, building design, automobile Manufacturing and the like.
Common metal additive manufacturing methods include laser, electron beam and arc additive manufacturing, and 3 methods have respective advantages and application ranges, but have more problems in the additive technology of light alloys. In the early-stage research of metal additive manufacturing, parts with complex structures are processed and prepared layer by layer mainly in a mode of sintering or melting metal materials, and when laser additive manufacturing is carried out on aluminum alloy due to the reasons of large linear expansion coefficient, high thermal conductivity and the like, the forming rate is low, the light reflectivity is high, the energy utilization rate is high, the deformation is large and the like; when electron beams are used for material increase, the size of a part is limited, and the deformation is large; and during arc material increase, the component is seriously deformed, the size is difficult to control, and the like. The flow friction additive manufacturing is a solid-phase additive manufacturing method, and has unique advantages in the aspect of light alloy additive manufacturing.
The existing similar solid-phase additive manufacturing technology is mainly a friction stir additive manufacturing method, which is essentially welding and overlapping of multiple layers of materials, wherein the additive process is similar to friction stir welding multilayer overlapping and is a spatial overlapping process, and comprises transverse additive perpendicular to the overlapping direction and additive parallel to the thickness direction of the materials. The data show that the structure performance of the friction stir welding overlap joint is closely related to the state of a combined interface, so that the interface distortion and the cold overlap defect are easy to occur, and the performance of the joint is reduced. Similar to overlapping in the friction stir additive manufacturing process, corresponding defects may also occur, thereby affecting the structural properties of the additive material. And the plate is subjected to additive manufacturing by layer by using the friction stir welding technology, the plate is clamped once again when one layer is superposed, and the digitization degree of the whole additive processing is not high compared with additive methods such as laser and electron beams. The realization of full-automatic digital processing of friction stir additive manufacturing is a major current problem. Another problem to be solved is how to improve the material utilization. The existing friction stir additive manufacturing method cannot realize high utilization rate of materials, and after the additive is finished, the friction stir blank still needs to be subjected to post-machining to remove the redundant base material. The more portions removed, the lower the material utilization.
In a word, the metal additive manufacturing method has many advantages, and is a material preparation and processing integrated method with great development potential. In the early stage of additive manufacturing, researchers mainly adopt a mode of melting materials for forming and manufacturing, and limit materials, for example, an aluminum alloy laser additive chamber has the problems of energy surface spheroidization, low utilization rate and the like, and electron beam additive has the problems of metal gasification, deformation and the like. As a solid-phase additive manufacturing method, the friction additive manufacturing technology has the advantages of fine grains, compact structure and the like, is a potential additive manufacturing method, and has the problems of large machining allowance, low material utilization rate and the like.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides a flow friction additive manufacturing device and an additive manufacturing method, which can realize high-quality additive manufacturing of light metal materials such as aluminum alloy and the like, can improve the material utilization rate and the manufacturing efficiency, and solve the problems of large machining allowance and low material utilization rate in friction stir additive manufacturing.
In order to realize the invention, the following technical scheme is adopted:
the flow friction additive manufacturing device is characterized by comprising a shaft shoulder, a base material and a base body, wherein a cavity is formed in the shaft shoulder, a central through hole communicated with the cavity is formed in the lower end of the shaft shoulder below the cavity, the base material is placed in the cavity in the shaft shoulder, upsetting force exists between the base material and the bottom surface of the cavity in the shaft shoulder, the outer end face of the shaft shoulder is placed on the surface of a material-to-be-added area of the base body, and upsetting force exists between the shaft shoulder and the base body; when the base material is in work, the shaft shoulder rotates and moves on the upper surface of the base material to be added, the base material does not rotate, the base material is thermoplasticized under the friction effect generated by the relative rotation of the base material and the shaft shoulder, the thermoplasticized material flows out along the central through hole at the lower end of the shaft shoulder under the action of upsetting force, and the flowing thermoplasticized material is diffused and deposited on the surface of the base material to be added under the relative rotation effect and the upsetting force of the outer end surface of the shaft shoulder and the surface of the base material to be added.
Further, a friction stir welding device is adopted to drive the shaft shoulder to rotate, and upsetting force between the shaft shoulder and the base body is applied;
further, an upsetting force between the base material and the bottom surface of the cavity inside the shoulder is applied by an applied load, such as a hydraulic device;
furthermore, the outer end face of the shaft shoulder and the bottom surface of the cavity are both provided with one or more spiral grooves; the rotating direction of the spiral groove can be designed according to the rotating direction of a shaft shoulder in the additive manufacturing process;
further, a spiral groove is machined in the side wall of the cavity; the rotating direction of the spiral groove can be designed according to the rotating direction of a shaft shoulder in the additive manufacturing process;
further, lateral constraint fixtures are additionally arranged on two sides of a to-be-additized area of the base body; the distance between the lateral restraining clamps on the two sides depends on the required additive width, and the height of the lateral restraining clamps depends on the required additive height;
further, the shaft shoulder is cylindrical, and the base material is cylindrical, powdery, flaky or granular.
Further, the substrate is a plate or a complex curved surface structural member, such as a ribbed wallboard, a frame beam structure or an air inlet channel.
The additive manufacturing method is carried out by adopting the flow friction additive manufacturing device, and is characterized in that: the method comprises the following steps:
(1) placing a base material in a cavity inside a shaft shoulder, and then placing the shaft shoulder on the upper surface of a to-be-additized area of a substrate;
(2) under the action of a driving force, the shaft shoulder rotates and moves in a region to be subjected to material increase on the surface of the base body, and meanwhile, an upsetting force is kept between the shaft shoulder and the region to be subjected to material increase of the base body;
(3) under the action of the constraint force, the base metal does not rotate, and simultaneously, the upsetting force is kept between the base metal and the bottom surface of the cavity in the shaft shoulder;
(4) the base material is thermoplasticized under the friction action generated by relative rotation with the shaft shoulder, the thermoplasticized material flows out along the central through hole of the shaft shoulder under the action of upsetting force, and the flowing out thermoplasticized material is diffused and deposited on the surface of the to-be-additized area of the base body under the relative rotation action and the upsetting force of the outer end surface of the shaft shoulder and the surface of the to-be-additized area of the base body, so that the single-layer material stacking of the to-be-additized area is realized;
(5) and (4) repeating single-layer material stacking in the area to be additized to realize multi-layer material stacking until the required additive height is reached.
The invention has the following technical effects:
(1) the flow friction additive manufacturing device and the additive manufacturing method provided by the invention can realize high-quality additive manufacturing of light metal materials such as aluminum alloy and the like, can improve the material utilization rate and the manufacturing efficiency, and solve the problems of large machining allowance and low material utilization rate in friction stir additive manufacturing.
(2) The flow friction additive manufacturing device and the additive manufacturing method provided by the invention can realize high-efficiency and low-cost manufacturing of the ribbed wallboard and the frame beam structure of the airplane, have high manufacturing process flexibility, refined material structure and high toughness, and have good application prospects in the structures such as the ribbed wallboard structure, the frame beam structure, the air inlet channel and the like of the aluminum alloy fuselage of the airplane.
(3) The flow friction additive manufacturing device and the additive manufacturing method provided by the invention can also realize the manufacturing of the aluminum alloy material reinforcing ribs and reinforcing frames with complex curved surface structures, can also realize the manufacturing of reinforcing structures distributed in any space curve based on design optimization, and solve the problems that the conventional manufacturing process is difficult to manufacture or the manufacturing cost is too high.
(4) The flow friction additive manufacturing device and the additive manufacturing method provided by the invention can be popularized and applied in the manufacturing of aluminum alloy ribbed wall plate structures or complex frame beam structures in the fields of carrier rockets, ships, automobiles and the like, and the high-efficiency, high-quality and low-cost manufacturing of the aluminum alloy complex structures is realized.
Drawings
FIG. 1 is a cross-sectional view of a flow friction additive manufacturing apparatus;
figure 2 schematic view of flow friction additive manufacturing.
In the figure: 1-base material, 2-shaft shoulder, 3-base body, 4-cavity side wall spiral groove, 5-cavity bottom surface spiral groove and 6-shaft shoulder outer end surface spiral groove.
Detailed Description
A flow friction additive manufacturing apparatus and an additive manufacturing method according to the present invention will be further described with reference to the following specific examples and drawings of the specification, but the present invention is not limited to the following examples.
Example 1
As shown in fig. 1, a flow friction additive manufacturing device comprises a shaft shoulder 2, a base material 1 and a base body 3, wherein the shaft shoulder 2 is cylindrical, the base material 1 is also cylindrical, the base body 3 is a plate with a cavity formed inside the shaft shoulder, a central through hole communicated with the cavity is formed at the lower end of the shaft shoulder below the cavity, the cylindrical base material is placed in the cavity inside the shaft shoulder, and the outer end face of the shaft shoulder is placed on the surface of a material-to-be-added area of the base body; the design of shaft shoulder cavity lateral wall has the helicla flute promptly cavity lateral wall helicla flute 4, and the design also has the helicla flute promptly cavity bottom surface helicla flute 5 in the cavity bottom surface, and the outer terminal surface of shaft shoulder also has the helicla flute promptly the outer terminal surface helicla flute 6 of shaft shoulder, and the rotation of helicla flute structure is to the direction of rotation that depends on shaft shoulder in the vibration material disk manufacture process, can design according to the direction of rotation of shaft shoulder. The spiral groove on the side wall of the shaft shoulder cavity is used for preventing a thermoplastic material formed by friction between the base material and the inner end surface of the shaft shoulder cavity from flowing upwards along a gap between the side wall of the shaft shoulder cavity and the base material. The spiral groove on the bottom surface of the shaft shoulder cavity is used for guiding the friction heat plastified materials of the base material and the inner end surface of the shaft shoulder cavity to flow to the central through hole of the end part of the shaft shoulder. The spiral groove on the outer end surface of the shaft shoulder is used for guiding the plasticized material flowing out of the through hole to quickly and uniformly spread along the radial direction. And upsetting force exists between the base metal and the bottom surface of the cavity in the shaft shoulder, and upsetting force exists between the shaft shoulder and the base body.
When additive manufacturing is carried out, a base material is placed in a cavity inside a shaft shoulder, and then the shaft shoulder is placed on the upper surface of a to-be-additized area of a base body; under the action of a driving force, the shaft shoulder rotates and moves in a region to be subjected to material increase on the surface of the base body, and meanwhile, an upsetting force is kept between the shaft shoulder and the region to be subjected to material increase of the base body; under the action of the constraint force, the base metal does not rotate, and simultaneously, the upsetting force is kept between the base metal and the bottom surface of the cavity in the shaft shoulder; the base material is thermoplasticized under the friction action generated by relative rotation with the shaft shoulder, the thermoplasticized material flows out along the central through hole of the shaft shoulder under the action of upsetting force, and the flowing out thermoplasticized material is diffused and deposited on the surface of the to-be-additized area of the base body under the relative rotation action and the upsetting force of the outer end surface of the shaft shoulder and the surface of the to-be-additized area of the base body, so that the single-layer material stacking of the to-be-additized area is realized; and (4) repeating single-layer material stacking in the area to be additized to realize multi-layer material stacking until the required additive height is reached.
In the working state, as shown in fig. 2, the shaft shoulder rotates and moves on the upper surface of the substrate material increase area, the base material does not rotate, the base material is thermally plasticized under the friction action generated by the relative rotation of the base material and the shaft shoulder, the thermally plasticized material flows out along the central through hole at the lower end of the shaft shoulder under the action of upsetting force, and the flowed-out thermally plasticized material is diffused and deposited on the surface of the substrate material increase area under the relative rotation action and the upsetting force of the outer end surface of the shaft shoulder and the surface of the substrate material increase area.
Lateral restraining clamps may also be added on both sides of the equal additive area, with the width of the space between the clamps depending on the desired additive width and the height of the clamp depending on the desired additive height. In the flow friction additive manufacturing process, the shaft shoulder moves in the constraint fixture, the thermal plasticizing material flowing out from the central through hole at the lower end of the shaft shoulder is deposited on the surface of the base body, and meanwhile, the forced forming is realized under the constraint action of the constraint fixture.
The specific structure and materials of the flow friction additive manufacturing device are as follows: the shaft shoulder material is tool steel, the outer diameter of the shaft shoulder is about 16mm, the inner diameter of the shaft shoulder is about 10mm, the axial length of the shaft shoulder is about 20mm, the wall thickness of the end part is about 3mm, and the diameter of the through hole of the end part is about 2 mm; the parent metal is 2024 aluminum alloy bar, the diameter is about 8mm, and the length is about 100 mm; the substrate is a 2024 aluminum alloy plate with the thickness of 3 mm. And the conventional friction stir welding equipment is utilized to drive the shaft shoulder to rotate and apply upsetting force to the base body, and the upsetting force of the base metal relative to the bottom surface of the cavity of the shaft shoulder is realized by utilizing a hydraulic device.
When the additive manufacturing is carried out, proper shaft shoulder rotating speed, moving speed and upsetting force are selected, and the selection principle is as follows: the rotating speed of the shaft shoulder is required to ensure sufficient heat input and no overheating, the rotating speed is 100-2000rpm, the moving speed is required to ensure good surface forming of the material increase area, certain material increase efficiency is ensured, the moving speed is 30-1000mm/min, sufficient upsetting force is required to be ensured between the outer end face of the shaft shoulder and the base body, the surface of the base body area to be material increased is effectively thermoplasticized, the upsetting force is about 10-300kN, and sufficient upsetting force is required to be ensured between the base material and the bottom surface of the cavity of the shaft shoulder, the base material is effectively thermoplasticized, and the upsetting force is about 10-300 kN. For the base material and the base body of the above materials, the rotating speed of the shoulder was about 300rpm, the moving speed was about 100mm/min, the upsetting force between the outer end face of the shoulder and the base body was about 200kN, and the upsetting force between the base material and the bottom face of the cavity of the shoulder was about 100 kN. The shaft shoulder moves on the surface of the base body along a preset track, and meanwhile, the thermal plasticizing material flowing out of the central through hole at the lower end of the shaft shoulder is uniformly deposited on the surface of the base body, so that single-layer material stacking of the material adding area to be obtained is realized, and the single-layer material stacking is repeated in the material adding area to be obtained, so that multi-layer material stacking is realized until the required material adding height is reached. After the material increase is finished, the material increase area can be subjected to mechanical processing such as milling according to design requirements.
Claims (8)
1. A flow friction additive manufacturing device is characterized by comprising a shaft shoulder, a base material and a base body, wherein a cavity is formed in the shaft shoulder, a central through hole communicated with the cavity is formed in the lower end of the shaft shoulder below the cavity, the base material is placed in the cavity in the shaft shoulder, upsetting force exists between the base material and the bottom surface of the cavity in the shaft shoulder, the outer end face of the shaft shoulder is placed on the surface of a material to be added area of the base body, and upsetting force exists between the shaft shoulder and the base body; when the base material is in work, the shaft shoulder rotates and moves on the upper surface of the base material to be added, the base material does not rotate, the base material is subjected to thermoplasticity under the friction effect generated by relative rotation with the shaft shoulder, the thermoplasticity material flows out along the central through hole at the lower end of the shaft shoulder under the action of upsetting force, and the flowing thermoplasticity material is diffused and deposited on the surface of the base material to be added under the relative rotation effect and the upsetting force between the outer end surface of the shaft shoulder and the surface of the base material to be added;
and a spiral groove is processed on the side wall of the cavity.
2. The flow friction additive manufacturing device according to claim 1, wherein the shaft shoulder is driven to rotate by a friction stir welding device, and an upsetting force is applied between the shaft shoulder and the base body.
3. A flow friction additive manufacturing apparatus according to claim 1, wherein the upsetting force between the base material and the bottom surface of the cavity inside the shoulder is applied by an applied load.
4. The flow friction additive manufacturing device according to claim 1, wherein the outer end face of the shaft shoulder and the bottom face of the cavity are each provided with one or more spiral grooves.
5. The flow friction additive manufacturing device according to claim 1, wherein lateral restraining clamps are added on both sides of the substrate to-be-additized area.
6. The apparatus of claim 1, wherein the shoulder is cylindrical and the base material is cylindrical.
7. A flow friction additive manufacturing apparatus according to claim 1, wherein the substrate is a plate or a complex curved structure.
8. A method of additive manufacturing using a flow friction additive manufacturing apparatus according to any one of claims 1-7, wherein: the method comprises the following steps:
(1) placing a base material in a cavity inside a shaft shoulder, and then placing the shaft shoulder on the upper surface of a material increase area of a substrate;
(2) under the action of a driving force, the shaft shoulder rotates and moves in a region to be subjected to material increase on the surface of the base body, and meanwhile, an upsetting force is kept between the shaft shoulder and the region to be subjected to material increase of the base body;
(3) under the action of the constraint force, the base metal does not rotate, and simultaneously, the upsetting force is kept between the base metal and the bottom surface of the cavity in the shaft shoulder;
(4) the base material is thermoplasticized under the friction action generated by relative rotation with the shaft shoulder, the thermoplasticized material flows out along the central through hole at the lower end of the shaft shoulder under the action of upsetting force, and the flowing out thermoplasticized material is diffused and deposited on the surface of the to-be-additized area of the base body under the relative rotation action and the upsetting force of the outer end surface of the shaft shoulder and the surface of the to-be-additized area of the base body, so that the single-layer material stacking of the to-be-additized area is realized;
(5) and (4) repeating single-layer material stacking in the area to be additized to realize multi-layer material stacking until the required additive height is reached.
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| US11845141B2 (en) | 2020-01-08 | 2023-12-19 | The Boeing Company | Additive friction stir deposition method for manufacturing an article |
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| CN110193658B (en) * | 2019-06-24 | 2021-03-12 | 哈尔滨工业大学 | Component-adjustable friction head capable of synchronously feeding materials and friction additive manufacturing method |
| CN111151742B (en) * | 2020-01-17 | 2021-10-01 | 广东省科学院中乌焊接研究所 | Additive manufacturing device and method |
| CN111151760B (en) * | 2020-01-20 | 2021-12-28 | 哈尔滨工业大学 | Deformation-driven solid-phase extrusion device and method for preparing alloy bar by using device through one-step method |
| CN111438433B (en) * | 2020-04-17 | 2021-09-14 | 哈尔滨万洲焊接技术有限公司 | Method for measuring peak temperature of FSW welding seam center area and welding tool |
| CN112828441B (en) * | 2020-12-30 | 2022-12-23 | 昆山万洲特种焊接有限公司 | Semi-solid additive manufacturing device and method |
| CN112958902A (en) * | 2021-02-05 | 2021-06-15 | 山东大学 | Wire-filling static shaft shoulder friction stir welding and material increase manufacturing device and method |
| CN114131176B (en) * | 2021-12-21 | 2022-08-02 | 天津大学 | Main shaft system for solid-phase friction extrusion additive manufacturing |
| CN114669858A (en) * | 2022-03-15 | 2022-06-28 | 北京索德瀚智能科技有限公司 | Friction heat additive manufacturing device and method |
| CN115519136B (en) * | 2022-10-09 | 2024-05-17 | 哈尔滨工业大学（威海） | Additive manufacturing device and hollow part solid-phase additive manufacturing method |
| CN116810045B (en) * | 2023-04-10 | 2024-03-15 | 北京科技大学 | Bar cutting discharging mechanism suitable for friction stir material adding device |
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| US5262123A (en) * | 1990-06-06 | 1993-11-16 | The Welding Institute | Forming metallic composite materials by urging base materials together under shear |
| CN100389231C (en) * | 2004-10-25 | 2008-05-21 | 西北工业大学 | Electrode for electrolgtic aluminium |
| US8875976B2 (en) * | 2005-09-26 | 2014-11-04 | Aeroprobe Corporation | System for continuous feeding of filler material for friction stir welding, processing and fabrication |
| US9511445B2 (en) * | 2014-12-17 | 2016-12-06 | Aeroprobe Corporation | Solid state joining using additive friction stir processing |
| EP1952931A1 (en) * | 2007-02-05 | 2008-08-06 | Siemens Aktiengesellschaft | Mechtrode with powder feed and method for utilising such mechtrode |
| JP2009107019A (en) * | 2007-10-11 | 2009-05-21 | Osaka Prefecture Univ | Twist forward extruding method and twist forward extruding apparatus |
| CN104785784B (en) * | 2015-04-03 | 2017-03-15 | 北京赛福斯特技术有限公司 | A kind of friction is piled up and increases material device and method |
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| US11845141B2 (en) | 2020-01-08 | 2023-12-19 | The Boeing Company | Additive friction stir deposition method for manufacturing an article |
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