CN109807564B - Electric arc additive manufacturing method for Al-Zn-Mg-Cu alloy wire - Google Patents
Electric arc additive manufacturing method for Al-Zn-Mg-Cu alloy wire Download PDFInfo
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Abstract
An electric arc additive manufacturing method of a wire of Al-Zn-Mg-Cu alloy comprises the following steps of 1, carrying out electric arc additive forming by using cooling roll pressing assistance; step 2, milling the side surface and the top surface of the additive body; step 3, performing friction stir processing on the additive body by using friction stir processing equipment, and simultaneously applying cooling rolling to the side wall of the additive body by using a cooling rolling device in the friction stir processing process; step 4, performing finish milling on the upper surface of the additive body for the next electric arc additive forming; and 5, circularly and repeatedly executing the steps until the final forming of the part is finished. The invention can completely eliminate dendritic crystal growth and grain refinement in the Al-Zn-Mg-Cu alloy additive forming process, effectively repair defects such as air holes and cracks, and simultaneously prevent the additive body from overheating and microstructure coarsening caused by overheating by cooling in the wire electric arc additive manufacturing and modification processes, thereby greatly improving the mechanical properties, particularly the plasticity and the fatigue property of the additive body.
Description
Technical Field
The invention belongs to the technical field of metal additive manufacturing, and relates to an Al-Zn-Mg-Cu alloy wire electric arc additive manufacturing method, in particular to an Al-Zn-Mg-Cu alloy wire electric arc additive manufacturing method assisted by cooling rolling and friction stir processing.
Background
The Wire and Arc Additive manufacturing technology (WAAM) of metal Wire is an advanced manufacturing technology which adopts Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW) or Plasma Arc Welding (PAW) as a heat source, utilizes the principle of dispersion and accumulation, and adopts the addition of metal wires to build up a three-dimensional metal part layer by layer from a line-surface-body according to a three-dimensional digital model under the control of a program. Compared with the additive manufacturing technology taking laser and electron beams as heat sources, the method has the following advantages: 1) the deposition rate is high, the utilization rate of the wire is high, and the manufacturing cost is low; 2) materials with high laser reflectivity (such as aluminum alloy) can be formed; 3) the size of the manufactured part is not limited by the size of the equipment forming cylinder and the vacuum chamber, and the manufacture of large-size components is easy to realize.
The Al-Zn-Mg-Cu alloy belongs to a heat-treatable reinforced high-strength aluminum alloy, has the advantages of low density, high specific strength and specific stiffness, good fracture toughness and resistance performance, excellent forming performance and the like, and is widely applied to aerospace, transportation and other military and civil industries. At present, large-scale integral aluminum alloy components play an important role in improving the reliability and the light weight level of aircrafts, vehicles and the like. To ensure high performance, these large components are typically manufactured by forging. However, the heavy forging equipment and dies required by the forging method for manufacturing the large-scale integral member are expensive, the process is complex, the production period is long, and the material utilization rate is low (< 10%), so that the large-scale integral aluminum alloy member is difficult to prepare and high in cost. Therefore, the method has important practical significance for researching the Al-Zn-Mg-Cu alloy wire electric arc additive manufacturing technology with high forming efficiency, low manufacturing cost and flexible manufacturing form. The weldability of a material often determines its suitability in the field of additive manufacturing technology, the better the weldability the material is, the easier it is to perform melt-based metal additive manufacturing, and the better the properties of the additive component are. The Zn element in the Al-Zn-Mg-Cu alloy increases the solidification temperature range of the alloy, so that the alloy has higher crack sensitivity, and the Zn and Mg elements in the alloy are volatile in the welding process, so that the Al-Zn-Mg-Cu alloy is easy to generate metal metallurgical defects such as welding cracks, air holes and the like during fusion welding, and the Al-Zn-Mg-Cu alloy is very challenging in additive manufacturing based on fusion. Martin et al prepared an additive body having no solidification cracks and excellent properties by laser 3D printing using a 7075 aluminum alloy powder containing Zr (see J.H.Martin.3D printing of high-strength aluminum alloys. Nature, 2017, 549 (7672): 365.). However, no report is found on the current research on the electric arc additive manufacturing technology of the Al-Zn-Mg-Cu alloy wire. Therefore, the electric arc additive manufacturing technology of the Al-Zn-Mg-Cu alloy wire needs to be broken through urgently.
Friction Stir Processing (FSP) technology is a technology developed on the basis of Friction Stir Welding (FSW) for modifying microstructure of materials and preparing new materials. The basic principle of the method is similar to that of FSW, a stirring pin rotating at a high speed is pressed into the material, the processed material is subjected to severe plastic deformation, mixing and crushing under the strong stirring action of a stirring head, and the densification, homogenization and refinement of the microstructure of the material are realized, so that the performance of the material is improved. At present, the FSP technology has achieved good effects in the preparation of fine-grained/ultra-fine-grained materials and surface/block composite materials, the modification of the microstructure of heterogeneous materials, the local hardening/defect repair of workpieces, and the like. The advantages are embodied in the following aspects: (1) the crystal grains are refined, and the material performance is improved. In the friction stir processing process, under the composite condition of large strain and high temperature, the uniformly refined equiaxial crystal grains are obtained by dynamic recrystallization in the stirring area, and the mechanical property of the material is further improved. (2) The defects of the tissue structure of the material are eliminated, and a uniform and compact tissue structure is obtained. The cast aluminum alloy is subjected to stirring friction processing, coarse second-phase particles and aluminum dendrites of the cast alloy are crushed, casting pores are closed, matrix grains are refined, and the mechanical properties, particularly the plasticity and the fatigue property of the material are obviously improved. T.S.Mahmoud modifies eutectic A390 Al-Si alloy by FSP Technology, and research shows that casting shrinkage can be reduced by FSP Technology, and that the eutectic A390 Al-Si alloy has obvious refining effect on alpha-Al and Si particles (see T.S.Mahmoud, Surface modification of A390 hypereutectic Al-Si cast alloy processing. Surface & Coatings Technology, 2013, 228 (9): 209-220.). In addition, it has been reported that the weld joint of a fusion welded joint is subjected to FSP treatment to dynamically recrystallize the weld joint, thereby eliminating weld defects such as cast structure, blowholes, and thermal cracks of the weld joint, and improving the overall performance of the joint (see G.K. Paddy. front base welding and processing technologies-processes, parameters, microstructures and applications: A view. journal of Materials Science & Technology, 2018, 34 (9): 1-38.). Therefore, the technology is expected to enable the additive manufacturing of alloy (such as Al-Zn-Mg-Cu alloy) wires with strong crack sensitivity, thereby increasing the types of materials for the additive manufacturing of metal wires. (3) And the residual stress of the structure is reduced. The FSP belongs to a solid processing technology, the heat input is low, and the thermal deformation and residual stress of the processed material are small.
In conclusion, if the modification of interlayer stirring friction processing is combined in the electric arc additive manufacturing process of the Al-Zn-Mg-Cu alloy wire, the refining of the microstructure in the additive body is facilitated, the defects of air holes, cracks and the like can be eliminated, the microstructure with compact structure and uniform chemical components is obtained, the thermal deformation can be reduced, the residual stress is reduced, and the mechanical property of the additive body is improved. When the additive body is modified by using a stirring friction processing method, the action area of a stirring pin is limited, the metal on the side wall of the additive body is difficult to treat, and the metal on the side wall still retains the casting structure characteristics; in addition, in the subsequent electric arc additive manufacturing or friction stir processing modification process of the deposited metal of which the front layer is modified by friction stir processing, the microstructure can be coarsened under the action of multiple thermal cycles, so that the performance of the additive is reduced.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides an Al-Zn-Mg-Cu alloy wire electric arc additive manufacturing method, which adopts the following technical scheme:
an Al-Zn-Mg-Cu alloy wire electric arc additive manufacturing method comprises the following steps:
the method comprises the following steps of 1, drawing a part model by using three-dimensional drawing software, carrying out layered slicing processing on the part model by using slicing software to obtain layered slicing data, carrying out simulation on the layered slicing data by using simulation software and optimizing a forming path to generate a robot control code, introducing the robot control code into a welding robot, carrying out Al-Zn-Mg-Cu alloy wire arc additive forming on a prepared substrate by using the welding robot, co-depositing 2-4 layers to form multilayer deposited metal, applying cooling rolling on the side wall of the multilayer deposited metal by using a cooling rolling device in the forming process, wherein the temperature of cooling water in the cooling rolling process is 5-25 ℃, the flow of the cooling water is 500-2000L/h, and the rolling stress borne by the multilayer deposited metal is 50-300 MPa;
step 5, circularly and repeatedly executing the steps until the multilayer deposited metal reaches a preset shape and size, and obtaining an additive body;
the cooling rolling device comprises a roller, a heat-conducting cylinder body and a heat-conducting outer ring, the heat-conducting outer ring is rotatably assembled on the outer wall of the heat-conducting cylinder body, an inner cavity is formed in the heat-conducting cylinder body, a cooling water inlet communicated with the inner cavity is formed in the upper surface of the heat-conducting cylinder body, a cooling water outlet communicated with the inner cavity is formed in the lower surface of the heat-conducting cylinder body, the roller is vertically fixedly assembled in the center of the upper surface of the heat-conducting cylinder body, and the roller and a welding gun of a welding robot or a stirring head of friction stir processing equipment synchronously act.
In the step 1, the welding current used in the electric arc additive forming process is 62-300A, the welding voltage is 17-25.0V, the welding wire swing amplitude is 2.0-5.2 mm, the welding wire swing speed is 600-1500 mm/min, the forming speed is 140-400 mm/min, and the lifting height of each layer of welding gun is 0.8-2.3 mm.
The width of the multilayer deposited metal subjected to electric arc additive forming in the step 1 is 7-50 mm.
The multi-layer deposited metal in the step 1 is obtained by single-channel multi-layer deposition or multi-channel multi-layer deposition.
In the step 2, the milling amount of the side surface of the multilayer deposited metal is 0.1-0.5 mm, and the milling amount of the top surface is 0.3-2.2 mm.
And 3, the length of a pintle of a stirring head of the friction stir processing equipment is greater than the height of the multilayer deposited metal after washing and cutting, and the diameter of a shaft shoulder of the stirring head is slightly smaller than the width of the multilayer deposited metal after washing and cutting.
The diameter of a shaft shoulder of a stirring head adopted by the stirring friction processing equipment is 6-46 mm, the length of a stirring needle is 2-5 mm, the rotating speed of the stirring head is 400-2000 r/min, the advancing speed is 80-450 mm/min, and the inclination angle of the stirring head is 1.5-3 degrees.
The invention provides an auxiliary Al-Zn-Mg-Cu alloy wire electric arc additive manufacturing method for cooling rolling and friction stir processing, wherein in the process of cooling rolling auxiliary electric arc additive forming of an Al-Zn-Mg-Cu alloy, after 2-4 layers of Al-Zn-Mg-Cu alloy are deposited, multilayer deposited metal is modified by cooling rolling and friction stir processing;
the cooling rolling auxiliary electric arc additive forming means that in the process of depositing Al-Zn-Mg-Cu alloy layer by electric arc, a cooling rolling device is used for rolling and cooling the side wall of the multilayer deposited metal, so that the heat influence of the deposition process on the front layer metal is reduced, and the geometric dimension of the multilayer deposited metal can be controlled by rolling; in the process of cooling, rolling and friction stir processing modification of the deposited metal, a rolling device and a stirring head shaft shoulder are utilized to form a local cavity, so that a defect-free forged structure is formed by the multilayer deposited metal surrounded by the cavity under the action of a pressing roller and the stirring head, and meanwhile, the cooling device on the pressing roller can avoid the structure coarsening caused by overheating of a friction stir processing area and the front layer metal. Thereby obtaining the multi-layer deposited metal with excellent structure and further improving the mechanical property of the multi-layer deposited metal. In addition, the problem of poor dimensional accuracy and roughness of the additive manufacturing part can be solved.
Compared with the prior art, the method has obvious advantages in the aspects of improving the dimensional precision and the roughness of the component, and most importantly, the method can completely eliminate dendritic crystal growth and grain refinement in the Al-Zn-Mg-Cu alloy additive forming process, effectively repair defects such as air holes and cracks, and simultaneously prevent overheating and microstructure coarsening caused by overheating of multilayer deposited metal by cooling in the wire electric arc additive manufacturing and modification processes, thereby greatly improving the mechanical properties, particularly the plasticity and the fatigue property of the multilayer deposited metal. In addition, the cooling roller pressing device has higher flexibility, and is not only suitable for wire electric arc additive manufacturing of a straight-wall structural member, but also suitable for wire electric arc additive manufacturing of a curved-surface structural member.
Drawings
FIG. 1 is a schematic diagram of an electric arc additive forming process using chill roll assist according to the present invention;
FIG. 2 is a schematic cross-sectional view of a chill roll apparatus according to the present invention;
FIG. 3 is a schematic view of the milling of the side and top surfaces of a multilayer deposited metal of the present invention;
FIG. 4 is a schematic diagram of friction stir processing with the aid of chill roll application according to the present invention.
Wherein: a substrate 1; depositing a metal 2 in multiple layers; cooling the rolling device 3; a roller 31; a heat conductive cylinder 32; a heat conductive outer ring 33; an inner cavity 34; a cooling water inlet 35; a cooling water outlet 36; the balls 37; a stirring head 4; a welding gun 5; a milling cutter 6.
Detailed Description
It should be noted that all the directional indicators (such as up, down, left, right, front, and rear … …) in the embodiment of the present invention are only used to explain the relative position relationship between the components, the movement situation, etc. in a specific posture (as shown in the drawing), and if the specific posture is changed, the directional indicator is changed accordingly.
Example 1
As shown in fig. 1 to 4, the present embodiment provides
The 7075(Al-4.5Zn-1.1Mg) aluminum alloy wire electric arc additive manufacturing method for the straight wall comprises the following steps:
step 1, performing electric arc additive forming by using cooling rolling assistance: drawing a vertical wall model with the size of 200mm (length) × 40mm (height) × 12mm (width) by using three-dimensional drawing software, carrying out layered slicing processing on a part model by using slicing software to obtain layered slicing data, carrying out simulation on the layered slicing data by using simulation software and optimizing a forming path to generate a robot control code (or a numerical control code), introducing the robot control code into a welding robot, carrying out 7075 aluminum alloy wire electric arc material increase forming on a T-shaped substrate 1 prepared in advance by using the welding robot and an electric arc generated by an MIG (metal inert gas welding) welding machine as a heat source, and depositing 2-4 layers together to form multilayer deposited metal 2, wherein the width of the formed multilayer deposited metal 2 is 12mm, and the multilayer deposited metal 2 is obtained by single-channel multilayer deposition; the welding current used in the electric arc additive forming process is 95A, the welding voltage is 20.4V, the forming speed is 320mm/min, the lifting height of each layer of welding gun is 2mm, the swing amplitude of the welding wire is 2.75mm, and the swing speed of the welding wire is 851 mm/min.
Meanwhile, in the forming process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; the side wall of the multilayer deposited metal 2 is rolled and cooled by the cooling rolling device 3, which is beneficial to reducing the thermal influence of the deposition process on the front layer metal, and secondly, the geometric dimension of the multilayer deposited metal 2 can be controlled by the rolling action, the temperature of cooling water in the cooling rolling process is 10 ℃, the flow of the cooling water is 1500L/h, and the rolling stress of the multilayer deposited metal is 80 MPa.
2, milling the side surfaces and the top surfaces of the multilayer deposited metal 2 by using a milling cutter 6 of a milling robot; on one hand, in order to control the dimensional accuracy of the multilayer deposited metal 2 and on the other hand, a flat surface can be provided for the subsequent friction stir processing procedure to prevent the generation of friction stir processing defects, the milling amount of the two side surfaces of the multilayer deposited metal 2 is 0.3mm, the milling amount of the top surface is 1.5mm, and the milling amount, the feeding speed and other process parameters are set according to the accuracy required by the final part dimension in the milling process;
meanwhile, in the stirring friction processing process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; a rolling device and a shaft shoulder of a stirring head 4 are utilized to form a local cavity, so that a defect-free forged structure is formed by the multilayer deposited metal 2 surrounded by the cavity under the action of rolling and the stirring head 4, meanwhile, cooling water introduced into a cooling rolling device 3 can avoid a friction stir processing area and a thousand-layer metal from overheating to coarsen the structure, the temperature of the cooling water in the cooling rolling process is 15 ℃, the flow of the cooling water is 1800L/h, and the rolling stress borne by the multilayer deposited metal is 150 MPa.
and 5, circularly and repeatedly executing the steps until the multilayer deposited metal 2 reaches the preset shape and size, so as to obtain the additive body.
The cooling and rolling device 3 comprises a roller 31, a heat-conducting cylinder 32 and a heat-conducting outer ring 33, the heat-conducting outer ring 33 is rotatably assembled on the outer wall of the heat-conducting cylinder 32 through a ball 37, an inner cavity 34 is formed in the heat-conducting cylinder 32, a cooling water inlet 35 communicated with the inner cavity 34 is formed in the upper surface of the heat-conducting cylinder 32, a cooling water outlet 36 communicated with the inner cavity 34 is formed in the lower surface of the heat-conducting cylinder 32, the roller 31 is vertically and fixedly assembled in the center of the upper surface of the heat-conducting cylinder 32, and the roller 31 and a welding gun 5 of a welding robot or a stirring head 4 of a friction stir processing device synchronously act.
The heat-conducting cylinder 32 and the heat-conducting outer ring 33 can be made of metal material with good heat conductivity.
The area structure processed by cooling rolling and stirring friction processing consists of fine equiaxial grains, and the defects of air holes, liquefied cracks and the like which are easily formed in the electric arc additive manufacturing process of common wire materials are eliminated, so that the mechanical property of a formed body is improved. Table 1 shows comparative data of mechanical properties of 7075 aluminum alloy thin-wall walls formed by cooling, rolling, friction stir processing, auxiliary arc additive forming, common arc additive forming, and casting.
TABLE 1
Example 2
The embodiment provides
The method for manufacturing the straight wall by 7075(Al-5.2Zn-2.2Mg-1.4Cu) aluminum alloy wire through electric arc additive manufacturing comprises the following steps:
step 1, performing electric arc additive forming by using cooling rolling assistance: drawing a vertical wall model with the size of 200mm (length) × 40mm (height) × 42mm (width) by using three-dimensional drawing software, carrying out layered slicing processing on a part model by using slicing software to obtain layered slicing data, carrying out simulation on the layered slicing data by using simulation software and optimizing a forming path to generate a robot control code (or a numerical control code), guiding the robot control code into a welding robot, carrying out 7075 aluminum alloy wire electric arc additive forming on a T-shaped substrate 1 prepared in advance by using the welding robot and an electric arc generated by a TIG welding machine as a heat source, and depositing 2-4 layers together to form multilayer deposited metal 2, wherein the width of the formed multilayer deposited metal 2 is 42mm, and the multilayer deposited metal 2 is obtained by multilayer and multichannel deposition; the welding current used in the electric arc additive forming process is 200A, the welding voltage is 23.5V, the forming speed is 300mm/min, the lifting height of each layer of welding gun is 1.8mm, the swing amplitude of the welding wire is 2.0mm, and the swing speed of the welding wire is 1500 mm/min.
Meanwhile, in the forming process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; the side wall of the multilayer deposited metal 2 is rolled and cooled by the cooling rolling device 3, which is beneficial to reducing the thermal influence of the deposition process on the front layer metal, and secondly, the geometric dimension of the multilayer deposited metal 2 can be controlled by the rolling action, the temperature of cooling water in the cooling rolling process is 10 ℃, the flow of the cooling water is 1000L/h, and the rolling stress of the multilayer deposited metal is 200 MPa.
2, milling the side surfaces and the top surfaces of the multilayer deposited metal 2 by using a milling cutter 6 of a milling robot; on one hand, in order to control the dimensional accuracy of the multilayer deposited metal 2 and on the other hand, a flat surface can be provided for the subsequent friction stir processing procedure to prevent the generation of friction stir processing defects, the milling amount of the two side surfaces of the multilayer deposited metal 2 is 0.3mm, the milling amount of the top surface is 1.4mm, and the milling amount, the feeding speed and other process parameters are set according to the accuracy required by the final part dimension in the milling process;
meanwhile, in the stirring friction processing process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; a rolling device and a shaft shoulder of a stirring head 4 are utilized to form a local cavity, so that a defect-free forged structure is formed by the multilayer deposited metal 2 surrounded by the cavity under the action of rolling and the stirring head 4, meanwhile, cooling water introduced into a cooling rolling device 3 can avoid the structure coarsening caused by the overheating of a friction stir processing area and a thousand layers of metal, the temperature of the cooling water in the cooling rolling process is 30 ℃, the flow of the cooling water is 2000L/h, and the rolling stress borne by the multilayer deposited metal is 350 MPa.
and 5, circularly and repeatedly executing the steps until the multilayer deposited metal 2 reaches the preset shape and size, so as to obtain the additive body.
The cooling and rolling device 3 comprises a roller 31, a heat-conducting cylinder 32 and a heat-conducting outer ring 33, the heat-conducting outer ring 33 is rotatably assembled on the outer wall of the heat-conducting cylinder 32 through a ball 37, an inner cavity 34 is formed in the heat-conducting cylinder 32, a cooling water inlet 35 communicated with the inner cavity 34 is formed in the upper surface of the heat-conducting cylinder 32, a cooling water outlet 36 communicated with the inner cavity 34 is formed in the lower surface of the heat-conducting cylinder 32, the roller 31 is vertically and fixedly assembled in the center of the upper surface of the heat-conducting cylinder 32, and the roller 31 and a welding gun 5 of a welding robot or a stirring head 4 of a friction stir processing device synchronously act.
The heat-conducting cylinder 32 and the heat-conducting outer ring 33 can be made of metal material with good heat conductivity.
The area structure processed by cooling rolling and stirring friction processing consists of fine equiaxial grains, and the defects of air holes, liquefied cracks and the like which are easily formed in the electric arc additive manufacturing process of common wire materials are eliminated, so that the mechanical property of a formed body is improved. Table 2 shows comparative data of mechanical properties of 7075 aluminum alloy thin-wall walls formed by cooling, rolling, friction stir processing, auxiliary arc additive forming, common arc additive forming, and casting.
TABLE 2
Example 3
As shown in fig. 1 to 4, the present embodiment provides
The 7075(Al-4.5Zn-1.1Mg) aluminum alloy wire electric arc additive manufacturing method for the straight wall comprises the following steps:
step 1, performing electric arc additive forming by using cooling rolling assistance: drawing a vertical wall model with the size of 200mm (length) × 40mm (height) × 12mm (width) by using three-dimensional drawing software, carrying out layered slicing processing on a part model by using slicing software to obtain layered slicing data, carrying out simulation on the layered slicing data by using simulation software and optimizing a forming path to generate a robot control code (or a numerical control code), introducing the robot control code into a welding robot, carrying out 7075 aluminum alloy wire electric arc material increase forming on a T-shaped substrate 1 prepared in advance by using the welding robot and an electric arc generated by an MIG (metal inert gas welding) welding machine as a heat source, and depositing 2-4 layers together to form multilayer deposited metal 2, wherein the width of the formed multilayer deposited metal 2 is 12mm, and the multilayer deposited metal 2 is obtained by single-channel multilayer deposition; the welding current used in the electric arc additive forming process is 65A, the welding voltage is 20.5V, the forming speed is 400mm/min, the lifting height of each layer of welding gun is 0.8mm, the swing amplitude of the welding wire is 5mm, and the swing speed of the welding wire is 600 mm/min.
Meanwhile, in the forming process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; the side wall of the multilayer deposited metal 2 is rolled and cooled by the cooling rolling device 3, which is beneficial to reducing the thermal influence of the deposition process on the front layer metal, and secondly, the geometric dimension of the multilayer deposited metal 2 can be controlled by the rolling action, the temperature of cooling water in the cooling rolling process is 10 ℃, the flow of the cooling water is 1500L/h, and the rolling stress of the multilayer deposited metal is 80 MPa.
2, milling the side surfaces and the top surfaces of the multilayer deposited metal 2 by using a milling cutter 6 of a milling robot; on one hand, in order to control the dimensional accuracy of the multilayer deposited metal 2 and on the other hand, a flat surface can be provided for the subsequent friction stir processing procedure to prevent the generation of friction stir processing defects, the milling amount of the two side surfaces of the multilayer deposited metal 2 is 0.3mm, the milling amount of the top surface is 1.5mm, and the milling amount, the feeding speed and other process parameters are set according to the accuracy required by the final part dimension in the milling process;
meanwhile, in the stirring friction processing process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; a rolling device and a shaft shoulder of a stirring head 4 are utilized to form a local cavity, so that a defect-free forged structure is formed by the multilayer deposited metal 2 surrounded by the cavity under the action of rolling and the stirring head 4, meanwhile, cooling water introduced into a cooling rolling device 3 can avoid a friction stir processing area and a thousand-layer metal from overheating to coarsen the structure, the temperature of the cooling water in the cooling rolling process is 15 ℃, the flow of the cooling water is 1800L/h, and the rolling stress borne by the multilayer deposited metal is 200 MPa.
and 5, circularly and repeatedly executing the steps until the multilayer deposited metal 2 reaches the preset shape and size, so as to obtain the additive body.
The cooling and rolling device 3 comprises a roller 31, a heat-conducting cylinder 32 and a heat-conducting outer ring 33, the heat-conducting outer ring 33 is rotatably assembled on the outer wall of the heat-conducting cylinder 32 through a ball 37, an inner cavity 34 is formed in the heat-conducting cylinder 32, a cooling water inlet 35 communicated with the inner cavity 34 is formed in the upper surface of the heat-conducting cylinder 32, a cooling water outlet 36 communicated with the inner cavity 34 is formed in the lower surface of the heat-conducting cylinder 32, the roller 31 is vertically and fixedly assembled in the center of the upper surface of the heat-conducting cylinder 32, and the roller 31 and a welding gun 5 of a welding robot or a stirring head 4 of a friction stir processing device synchronously act.
Example 4
The embodiment provides
The method for manufacturing the straight wall by 7075(Al-5.2Zn-2.2Mg-1.4Cu) aluminum alloy wire through electric arc additive manufacturing comprises the following steps:
Meanwhile, in the forming process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; the side wall of the multilayer deposited metal 2 is rolled and cooled by the cooling rolling device 3, which is beneficial to reducing the thermal influence of the deposition process on the front layer metal, and secondly, the geometric dimension of the multilayer deposited metal 2 can be controlled by the rolling action, the temperature of cooling water in the cooling rolling process is 10 ℃, the flow of the cooling water is 1000L/h, and the rolling stress of the multilayer deposited metal is 300 MPa.
2, milling the side surfaces and the top surfaces of the multilayer deposited metal 2 by using a milling cutter 6 of a milling robot; on one hand, in order to control the dimensional accuracy of the multilayer deposited metal 2 and on the other hand, a flat surface can be provided for the subsequent friction stir processing procedure to prevent the generation of friction stir processing defects, the milling amount of the two side surfaces of the multilayer deposited metal 2 is 0.3mm, the milling amount of the top surface is 1.4mm, and the milling amount, the feeding speed and other process parameters are set according to the accuracy required by the final part dimension in the milling process;
meanwhile, in the stirring friction processing process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; a rolling device and a shaft shoulder of a stirring head 4 are utilized to form a local cavity, so that a defect-free forged structure is formed by the multilayer deposited metal 2 surrounded by the cavity under the action of rolling and the stirring head 4, meanwhile, cooling water introduced into a cooling rolling device 3 can avoid a friction stir processing area and a thousand layers of metal from overheating to coarsen the structure, the temperature of the cooling water in the cooling rolling process is 30 ℃, the flow of the cooling water is 2000L/h, and the rolling stress borne by the multilayer deposited metal is 500 MPa.
and 5, circularly and repeatedly executing the steps until the multilayer deposited metal 2 reaches the preset shape and size, so as to obtain the additive body.
The cooling and rolling device 3 comprises a roller 31, a heat-conducting cylinder 32 and a heat-conducting outer ring 33, the heat-conducting outer ring 33 is rotatably assembled on the outer wall of the heat-conducting cylinder 32 through a ball 37, an inner cavity 34 is formed in the heat-conducting cylinder 32, a cooling water inlet 35 communicated with the inner cavity 34 is formed in the upper surface of the heat-conducting cylinder 32, a cooling water outlet 36 communicated with the inner cavity 34 is formed in the lower surface of the heat-conducting cylinder 32, the roller 31 is vertically and fixedly assembled in the center of the upper surface of the heat-conducting cylinder 32, and the roller 31 and a welding gun 5 of a welding robot or a stirring head 4 of a friction stir processing device synchronously act.
The heat-conducting cylinder 32 and the heat-conducting outer ring 33 can be made of metal material with good heat conductivity.
The invention has the advantages that in the wire electric arc additive manufacturing and the stirring friction modification process, the cooling rolling device is used for cooling to prevent the multilayer deposited metal from overheating and coarsening the microstructure caused by overheating, the mechanical property of the multilayer deposited metal is greatly improved, and the purpose of controlling the geometric dimension of the multilayer deposited metal is realized by the cooling rolling device.
The above examples are only for illustrating the technical solutions of the present invention and not for limiting the same, and although the present invention is described in detail with reference to the above examples, those of ordinary skill in the art should understand that: similar technical approaches can be derived from the solutions given in the figures and examples, as described above. For the method that the electric arc generated by an MIG, TIG or PAW welding machine is used as a heat source, Al-Zn-Mg-Cu alloy wires with different diameters and different alloy element contents are used as filling metal, the defects of pores, liquefied phases, cracks and the like of deposited metal can be eliminated by utilizing an interlayer cooling rolling and stirring friction processing method in the process of additive forming, and the structure is refined, so that the performance is improved.
Claims (6)
1. An Al-Zn-Mg-Cu alloy wire electric arc additive manufacturing method is characterized by comprising the following steps:
the method comprises the following steps of 1, drawing a part model by using three-dimensional drawing software, carrying out layered slicing processing on the part model by using slicing software to obtain layered slicing data, carrying out simulation on the layered slicing data by using simulation software to generate a robot control code, introducing the robot control code into a welding robot, carrying out Al-Zn-Mg-Cu alloy wire arc additive forming on a prepared substrate by using the welding robot, co-depositing for 2-4 layers to form multilayer deposited metal, applying cooling rolling on the side wall of the multilayer deposited metal by using a cooling rolling device in the forming process, wherein the temperature of cooling water in the cooling rolling process is 5-25 ℃, the flow of the cooling water is 500-2000L/h, and the rolling stress borne by the multilayer deposited metal is 50-300 MPa;
step 2, milling the side surfaces and the top surfaces of the multilayer deposited metal;
step 3, performing friction stir processing on the milled multilayer deposited metal by using friction stir processing equipment, applying cooling rolling on the side wall of the multilayer deposited metal by using a cooling rolling device in the friction stir processing process, forming a local cavity by using the rolling device and a stirring head shaft shoulder, and ensuring that the multilayer deposited metal surrounded by the cavity forms a defect-free forged structure under the action of rolling and the stirring head, wherein the temperature of cooling water in the cooling rolling process is 5-25 ℃, the flow of the cooling water is 500-2000L/h, and the rolling stress borne by the multilayer deposited metal is 80-500 MPa;
step 4, performing finish milling on the upper surface of the multilayer deposited metal to enable the processed surface to be flat for the next electric arc additive forming;
step 5, circularly and repeatedly executing the steps until the multilayer deposited metal reaches a preset shape and size, and obtaining an additive body;
the cooling rolling device comprises a roller, a heat-conducting cylinder and a heat-conducting outer ring, the heat-conducting outer ring is rotatably assembled on the outer wall of the heat-conducting cylinder, the heat-conducting cylinder is provided with an inner cavity, the upper surface of the heat-conducting cylinder is provided with a cooling water inlet communicated with the inner cavity, the lower surface of the heat-conducting cylinder is provided with a cooling water outlet communicated with the inner cavity, the roller is vertically and fixedly assembled in the center of the upper surface of the heat-conducting cylinder, and the roller and a welding gun of a welding robot or a stirring head of friction stir processing equipment synchronously act;
and 3, the length of a pintle of the stirring head of the friction stir processing equipment is greater than the height of the multilayer deposited metal after milling, and the diameter of a shaft shoulder of the stirring head is slightly smaller than the width of the multilayer deposited metal after milling.
2. The electric arc additive manufacturing method for the wire of the Al-Zn-Mg-Cu alloy according to claim 1, wherein the width of the multi-layer deposited metal subjected to electric arc additive forming in the step 1 is 7-50 mm.
3. The electric arc additive manufacturing method for the wire of the Al-Zn-Mg-Cu alloy according to claim 1, wherein the multi-layer deposited metal in the step 1 is obtained by single-pass multi-layer deposition or multi-pass multi-layer deposition.
4. The electric arc additive manufacturing method for the wire of the Al-Zn-Mg-Cu alloy according to claim 1, wherein the welding current used in the electric arc additive forming process in the step 1 is 62-300A, the welding voltage is 17-25.0V, the swing amplitude of the welding wire is 2.0-5.2 mm, the swing speed of the welding wire is 600-1500 mm/min, the forming speed is 140-400 mm/min, and the lifting height of each layer of welding gun is 0.8-2.3 mm.
5. The electric arc additive manufacturing method for the Al-Zn-Mg-Cu alloy wire according to claim 1, wherein the milling amount of the side surface of the multi-layer deposited metal in the step 2 is 0.1-0.5 mm, and the milling amount of the top surface is 0.3-2.2 mm.
6. The Al-Zn-Mg-Cu alloy wire electric arc additive manufacturing method according to claim 2, wherein a stirring head shoulder diameter adopted by the friction stir processing equipment is 6-46 mm, a stirring needle length is 2-5 mm, a stirring head rotation speed is 400-2000 r/min, a traveling speed is 80-450 mm/min, and a stirring head inclination angle is 1.5-3 °.
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| CN111411272B (en) * | 2020-03-23 | 2021-10-01 | 西安交通大学 | Al-Zn-Mg series aluminum alloy welding wire for electric arc additive manufacturing and preparation method thereof |
| CN115961189A (en) * | 2021-10-09 | 2023-04-14 | 贵州翰凯斯智能技术有限公司 | Al-Mg-Zn-Cu aluminum alloy test piece and preparation method and application thereof |
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