CN111408721A - Aluminum alloy semi-solid state melting three-dimensional direct-writing forming method - Google Patents
Aluminum alloy semi-solid state melting three-dimensional direct-writing forming method Download PDFInfo
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- CN111408721A CN111408721A CN202010258373.4A CN202010258373A CN111408721A CN 111408721 A CN111408721 A CN 111408721A CN 202010258373 A CN202010258373 A CN 202010258373A CN 111408721 A CN111408721 A CN 111408721A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/115—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by spraying molten metal, i.e. spray sintering, spray casting
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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
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
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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
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
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Abstract
The invention relates to an aluminum alloy semi-solid melting three-dimensional direct-writing forming method, belonging to the technical field of nonferrous metal additive manufacturing, comprising the following steps: firstly, three-dimensional modeling software is adopted or an entity is scanned to obtain a part model to be printed; converting the obtained model part into a data format which can be identified by the software of the melting three-dimensional direct-writing forming equipment; preparing semisolid aluminum alloy forming, including raw materials, a spray head, a heating and melting device and equipment initial state inspection; depositing the aluminum alloy melt heated to the semi-solid state onto a forming platform from a spray head under the action of pressure along a preset motion track according to process parameters to finally obtain required parts; and finally, carrying out heat treatment or isostatic pressing treatment on the part after the direct writing forming. The invention combines the process advantages of low cost and high efficiency of the melting direct writing process with the characteristics of easy processing and high performance of the semi-solid aluminum alloy, and can produce part product objects with higher precision and better quality.
Description
Technical Field
The invention relates to an aluminum alloy semi-solid melting three-dimensional direct-writing forming method, belonging to the technical field of nonferrous metal additive manufacturing.
Background
The method is to deposit liquid metal on a substrate layer by layer according to a specified path to obtain a three-dimensional metal part. The high-performance flexible composite material has the characteristics of high efficiency, low cost, flexibility and greenness, and is widely applied to rapid and direct manufacturing of high-performance and complex-structure parts in high-end fields such as aviation, aerospace, military, medical treatment and the like at present.
The semi-solid forming is a novel technology developed in recent years, and has the advantages of lower forming temperature of materials, high dimensional precision of obtained parts, less material waste and realization of near-net forming. The existing semi-solid forming method is mainly limited to traditional process methods such as casting, forging, rolling and the like. The melting direct-writing process and the semi-solid forming are combined, the process advantages of low cost and high efficiency are combined with the characteristics of easy processing and high performance of the semi-solid aluminum alloy, and a part product object with higher precision and better quality can be produced.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide a method for semi-solid melting three-dimensional direct-writing forming of aluminum alloy. The method takes a semi-solid aluminum alloy thixotropic material as a raw material, and realizes accurate temperature control and automatic semi-solid aluminum alloy direct-writing forming through model design, data processing, forming preparation, direct-writing forming and post-processing processes, so that a near-net-shaped aluminum alloy melting direct-writing product is obtained, and the precision and the quality of the product are improved.
In order to achieve the purpose, the invention adopts the technical scheme that: the aluminum alloy semi-solid melting three-dimensional direct-writing forming method is characterized by comprising the following steps of:
step one, model design: scanning the entity by adopting three-dimensional modeling software to obtain a part model to be printed;
step two, data processing: converting the model part obtained in the step one into a data format which can be identified by the software of the melting three-dimensional direct-writing forming equipment;
step three, preparing semisolid aluminum alloy forming: preparing raw materials, a spray head, a heating and melting device and equipment initial state inspection;
step four, the melting direct-writing forming process: the method comprises two steps of a melting direct-writing heating process and a deposition process. Depositing the aluminum alloy melt heated to the semi-solid state onto a forming platform from a spray head under the action of pressure along a preset motion track according to process parameters to finally obtain required parts;
step five, post-treatment: and (4) carrying out heat treatment or isostatic pressing treatment on the part subjected to direct writing forming.
Further, in the first step, the model design means obtaining a part model by means of three-dimensional modeling software or scanning an entity, and the like, the model part should be capable of being converted into a data format recognizable by the software of the molten three-dimensional direct-write forming equipment, and the data format is one of PRT, AMF, 3MF, ST L, X-T, OBJ, and the like.
Further, in the first step, the forming equipment comprises an illumination system, a forming process video monitoring system, an atmosphere protection system, a temperature control and feedback regulation system and a metal melting and heating system.
Further, in the second step, the data processing means that the part forming direction is set according to the complexity of the formed part, and the designed model is converted into a forming G code which can be recognized by equipment under the special melting direct-writing forming software.
Further, in the third step, the raw material is an aluminum alloy semi-solid thixotropic material, the temperature is controlled to be 580-620 ℃ in the heating process, the temperature is controlled to be 710-720 ℃ in the direct writing process, the size of the raw material is a square block which is not more than 20mm × 20mm and × 20mm, and the surface oxide skin is removed.
Further, in the third step, the diameter of the spray head is 0.2mm-1.0 mm.
Further, in the third step, the raw materials and the spray head are cleaned by ultrasonic waves until the surface is free of oil stains and impurities, and then the raw materials and the spray head are dried by hot air, wherein the drying temperature is more than or equal to 100 ℃, and the drying time is more than or equal to 10 min.
Further, in the third step, the cleaned and dried raw materials are preheated, the temperature is 180-220 ℃, and the preheating time is 5-10 min.
Further, in the third step, the heating and melting device is prepared to pretreat the inner wall surface, the coating is uniformly coated on the inner wall surface, the device is preheated to more than 100 ℃ before coating, the thickness of the coating layer is 0.3-0.5mm, and more preferably, the coating formula is zinc oxide: titanium oxide: the mass ratio of water is 1: 1: 20.
further, in the third step, the initial state of the equipment is checked to see whether the pressure gauge pointer of the atmosphere protection system including the motion system is in the initial position.
Further, the heating process in the fourth step comprises a first substep and a second substep which are carried out in sequence, wherein in the first substep, the semi-solid aluminum alloy raw material is carried out in a heating and melting device (2), a resistance heater (3) and an insertion type thermocouple (4) are arranged on the semi-solid aluminum alloy raw material, the heating temperature is 580-620 ℃, the heating time is 15-30min, more preferably 595-605 ℃, the heating time is 25min, and further, the semi-solid aluminum alloy raw material is continuously heated to 710-720 ℃ for heat preservation, and the heat preservation time is 15-30 min; in the second substep, the temperature of the aluminum alloy semi-solid slurry for direct-write forming is within the range of the heat preservation temperature +/-3 ℃.
Further, in step four, the deposition process includes the following six substeps performed in sequence.
Further, in the fourth step, in the first deposition process substep, an illumination system, a forming process video monitoring system, an atmosphere protection system, a temperature control and feedback regulation system and a metal melting heating system in the forming equipment are sequentially turned on.
Further, in the fourth step, in the second deposition process, after the forming parameters are set according to the reference setting range of the process parameters, the special metal melting three-dimensional direct-writing forming software is opened, and the processed model data forming codes are downloaded to a forming software interface.
Further, in the fourth step, in the third deposition process substep, the shielding gas valve at the top of the heating and melting device is opened, and after the molten metal flows out from the bottom of the spray head and contacts the forming substrate, the forming is started until the forming process is finished.
Further, in the fourth step, in the deposition process, in the fourth step, after the forming procedure of the part to be formed is finished, the protective gas valve of the metal melting device is closed, and after the forming is finished, the atmosphere protection system valve is closed.
Further, in the fourth step, in the fifth substep of the deposition process, the heating switch of the metal melting heating device and the heating switch of the bottom plate in the metal melting heating system are sequentially turned off, the forming chamber is opened when the formed part is cooled to be below 100 ℃, and the formed part is taken out from the forming substrate by using a special tool.
And further, in the fourth step, in the deposition process, the substep six, the forming software is turned off, the motion system is reset, and the lighting system, the forming process video monitoring system and the master control power supply are sequentially turned off.
Further, in the fourth step, the pressure is that nitrogen top blowing is carried out through an air inlet device (5) at the top of the heating and melting device, preferably, the pressure value of the nitrogen making machine is more than 0.4MPa, the purity is more than 99.9 percent, the top blowing pressure is less than or equal to 0.1MPa, and the pressure in the heating and melting device is kept above 0.02 MPa.
Further, in the fourth step, the process parameter settings comprise the aperture of the direct-writing nozzle, the height of the direct-writing nozzle, the scanning speed, the scanning mode and the substrate heating temperature, preferably, the aperture of the direct-writing nozzle is 0.2mm-1.0mm, the height of the direct-writing nozzle is 30mm-70mm, the scanning speed is 10-100mm/s, the scanning mode is along the long edge or along the short edge, and the substrate heating temperature is less than or equal to 300 ℃.
Further, in the fifth step, the post-treatment is solution treatment, the preferable solution temperature is 535-540 ℃, and the solution time is more than or equal to 5 hours; then carrying out aging treatment at 200 ℃ for more than or equal to 4h, and finally air-cooling to room temperature.
Further, in the fifth step, the hot isostatic pressing treatment is carried out, the formed part is coated by an aluminum foil, preferably, the hot isostatic pressing temperature is more than or equal to 350 ℃, the pressure is more than or equal to 100MPa, and the time is more than or equal to 1 h.
Compared with the prior art, the invention achieves the following technical effects
1. The semi-solid forming of the aluminum alloy is carried out by using a metal melting direct-writing forming method, the limitation that the existing semi-solid forming technology needs a die is eliminated, the semi-solid aluminum alloy can be formed at low cost and high efficiency, and an aluminum alloy product with a complex structure is obtained.
2. By using the semisolid aluminum alloy melting direct writing method, the aluminum alloy direct writing product with uniform structure, high precision and high performance can be obtained.
Drawings
FIG. 1 is a flow chart of a semi-solid melting direct-writing forming method of aluminum alloy.
Detailed Description
The invention will be further described in detail by embodiments with reference to the accompanying drawings, and the invention provides an aluminum alloy semi-solid melting three-dimensional direct-writing forming method, which comprises the following steps:
1. model design: and (3) scanning the entity by adopting three-dimensional modeling software to obtain a part model to be printed.
2. And (4) data processing, namely converting the model part obtained in the step one into a data format which can be recognized by the software of the melting three-dimensional direct-writing forming equipment, such as ST L format.
3. Preparing a semi-solid aluminum alloy raw material:
in the step, an A357 aluminum alloy semi-solid thixotropic blank is adopted, the raw material is cut into square blocks with the size of not more than 20mm × 20mm × 20mm, and surface oxide skin is removed, the A357 aluminum alloy semi-solid thixotropic blank and a spray head with the diameter of 0.4mm are selected, the blank is cleaned by ultrasonic waves until the surface of the blank is free of oil stains and impurities, hot air drying is carried out, the drying temperature is 120 ℃, the drying time is 10min, the cleaned and dried raw material is preheated, the temperature is 200 ℃, and the preheating time is 10 min;
4. preparation of a heating and melting device:
in this step, the inner wall surface of the heating and melting device is pretreated, preheated to 120 ℃, and the inner wall surface of the crucible is uniformly coated with a coating with a thickness of 0.3-0.5mm, and more preferably, the coating is prepared from zinc oxide: titanium oxide: the mass ratio of water is 1: 1: 20.
5. the initial state of the nozzle, the heating and melting device and the equipment is checked, and the pressure gauge pointers of the moving system and the atmosphere protection system are all in the initial positions; and sequentially opening a lighting system, a forming process video monitoring system, an atmosphere protection system, a temperature control and feedback regulation system and a metal melting heating system in the forming equipment.
6. Smelting a semi-solid aluminum alloy raw material:
in the step, the semi-solid aluminum alloy raw material is heated in a metal melting and heating device, the heating temperature is 600 ℃, the heating time is 25min, and further, the semi-solid aluminum alloy raw material is continuously heated to 710 ℃ for heat preservation, and the heat preservation time is 30 min.
7. Semi-solid aluminum alloy raw material heat preservation: the constant temperature of the aluminum alloy semi-solid slurry is 710 +/-3 ℃.
8. And (3) protective gas regulation: and top-blowing nitrogen through the top of the metal melting, wherein the pressure value of the nitrogen making machine is 0.6MPa, the purity of the nitrogen making machine is 99.95%, and the top-blowing pressure is 0.02 MPa.
9. Setting process parameters: the technological parameters comprise the aperture of the direct-writing nozzle, the height of the direct-writing nozzle, the scanning speed and the substrate heating temperature, preferably, the aperture of the direct-writing nozzle is 0.4mm, the height of the direct-writing nozzle is 50mm, the scanning speed is 80mm/s, the scanning mode is along the long edge, and the substrate heating temperature is 250 ℃.
10. And opening the special metal melting three-dimensional direct-writing forming software, and downloading the processed model data forming code to a forming software interface.
11. And opening a protective gas valve of the metal melting device, and starting forming until the molten metal flows out from the bottom of the spray head and contacts the forming substrate until the forming procedure is finished.
12. And after the forming procedure of the formed part is finished, closing a protective gas valve of the metal melting device, and closing an atmosphere protection system valve after the forming is finished.
13. And (3) sequentially closing a heating switch of the metal melting heating device and a heating switch of the bottom plate in the metal melting heating system, opening a forming chamber when the formed part is cooled to be below 100 ℃, and taking out the formed part from the forming substrate by adopting a special tool.
14. And (3) closing the forming software, resetting the motion system, and sequentially closing the lighting system, the forming process video monitoring system and the master control power supply.
15. And (3) post-treatment: and (4) carrying out heat treatment or isostatic pressing treatment on the part subjected to direct writing forming.
In the step, two modes of post-treatment are selected, namely solid solution treatment, preferably, the solid solution temperature is 535-540 ℃, and the solid solution time is 5 h; then carrying out aging treatment at 200 ℃ for 4h, and finally air-cooling to room temperature; and secondly, hot isostatic pressing treatment, namely coating the formed piece by using an aluminum foil, wherein the hot isostatic pressing temperature is preferably 350 ℃, the pressure is preferably 100MPa, and the time is preferably 1 h.
The above description is only a preferred embodiment of the present patent, and is not intended to limit the present patent, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention shall fall within the protection scope of the present invention.
Claims (6)
1. The aluminum alloy semi-solid melting three-dimensional direct-writing forming method is characterized by comprising the following steps of:
step one, model design: scanning the entity by adopting three-dimensional modeling software to obtain a part model to be printed;
step two, data processing: converting the model part obtained in the step one into a data format which can be identified by the software of the melting three-dimensional direct-writing forming equipment;
step three, preparing semisolid aluminum alloy forming: preparing raw materials, a spray head, a heating and melting device and equipment initial state inspection;
step four, the melting direct-writing forming process: depositing the aluminum alloy melt heated to the semi-solid state onto a forming platform from a spray head under the action of pressure along a preset motion track according to process parameters to finally obtain required parts;
step five, post-treatment: and (4) carrying out heat treatment or isostatic pressing treatment on the part subjected to direct writing forming.
2. The aluminum alloy semi-solid state melting three-dimensional direct-writing forming method as recited in claim 1,
in the first step, the model design refers to obtaining a part model through three-dimensional modeling software or scanning an entity and the like, the model part can be converted into a data format which can be recognized by fused three-dimensional direct-write forming equipment software, and the data format is one of PRT, AMF, 3MF, ST L, X-T, OBJ and the like, wherein the data format is one of PRT, AMF, 3MF, ST L, X-T, OBJ and the like
The forming equipment comprises an illumination system, a forming process video monitoring system, an atmosphere protection system, a temperature control and feedback regulation system and a metal melting and heating system.
3. The aluminum alloy semi-solid state melting three-dimensional direct-writing forming method as recited in claim 1,
in the second step, the data processing means that the forming direction of the part is set according to the complexity of the formed part, and the designed model is converted into a forming G code which can be identified by equipment under the special melting direct-writing forming software.
4. The aluminum alloy semi-solid state melting three-dimensional direct-writing forming method as recited in claim 1,
in the third step, the raw material is an aluminum alloy semi-solid thixotropic material, the temperature is controlled to be 580-620 ℃ in the heating process, the temperature is controlled to be (710-720 ℃) plus or minus 3 ℃ in the direct writing process, the size of the raw material is a square block which is not more than 20mm × 20mm and × 20mm, and the surface oxide skin is removed;
the diameter of the spray head is 0.2mm-1.0 mm;
further, the raw materials and the spray head are cleaned by ultrasonic waves until the surfaces of the raw materials and the spray head are free of oil stains and impurities, and then the raw materials and the spray head are dried by hot air, wherein the drying temperature is more than or equal to 100 ℃, and the drying time is more than or equal to 10 min;
further, preheating the cleaned and dried raw materials at 180-220 ℃ for 5-10 min;
the heating and melting device is prepared for pretreating the surface of the inner wall, the coating is uniformly coated on the surface of the inner wall, the device is preheated to more than 100 ℃ before coating, the thickness of the coating layer is 0.3-0.5mm, and more preferably, the formula of the coating is zinc oxide: titanium oxide: the mass ratio of water is 1: 1: 20;
and checking whether the pressure gauge pointer of the motion system and the atmosphere protection system is at the initial position or not by the initial state of the equipment.
5. The aluminum alloy semi-solid state melting three-dimensional direct-writing forming method as recited in claim 1,
the heating process comprises a first substep and a second substep which are carried out in sequence, wherein in the first substep, the semi-solid aluminum alloy raw material is heated in a heating and melting device at 580-620 ℃ for 15-30min, more preferably 595-605 ℃ for 25min, and further continuously heated to 710-720 ℃ for heat preservation for 15-30 min; in the second substep, the temperature of the aluminum alloy semi-solid slurry for direct-write forming is within the range of the heat preservation temperature +/-3 ℃;
in step four, the deposition process comprises the following six substeps performed in sequence:
in the first substep, a lighting system, a forming process video monitoring system, an atmosphere protection system, a temperature control and feedback regulation system and a metal melting heating system in the forming equipment are sequentially turned on; after forming parameters are set according to the reference setting range of the process parameters, opening special metal melting three-dimensional direct-writing forming software, and downloading the processed model data forming codes to a forming software interface; opening a protective gas valve at the top of the heating and melting device, and starting forming until the forming procedure is finished after molten metal flows out from the bottom of the spray head and contacts the forming substrate; fourthly, after the forming procedure of the formed part is finished, closing a protective gas valve of the metal melting device, and closing an atmosphere protection system valve after the forming is finished; step five, a heating switch of a metal melting heating device and a heating switch of a bottom plate in the metal melting heating system are sequentially closed, a forming chamber is opened when a formed part is cooled to be below 100 ℃, and the formed part is taken out of a forming substrate by adopting a special tool; turning off the forming software, resetting the motion system, and sequentially turning off the lighting system, the forming process video monitoring system and the master control power supply;
in the fourth step, the pressure is nitrogen top blowing through the top of the heating and melting device, preferably, the pressure value of the nitrogen making machine is more than 0.4MPa, the purity is higher than 99.9 percent, the top blowing pressure is less than or equal to 0.1MPa, and the pressure in the heating and melting device is kept to be more than 0.02 MPa;
in the fourth step, the process parameter settings comprise the aperture of the direct-writing nozzle, the height of the direct-writing nozzle, the scanning speed, the scanning mode and the substrate heating temperature, preferably, the aperture of the direct-writing nozzle is 0.2mm-1.0mm, the height of the direct-writing nozzle is 30mm-70mm, the scanning speed is 10mm/s-100mm/s, the scanning mode is along the long edge or along the short edge, and the substrate heating temperature is less than or equal to 300 ℃.
6. The aluminum alloy semi-solid state melting three-dimensional direct-writing forming method as recited in claim 1,
in the fifth step, the post-treatment is solid solution treatment, the preferable solid solution temperature is 535-540 ℃, and the solid solution time is more than or equal to 5 hours; then carrying out aging treatment at 200 ℃ for more than or equal to 4h, and finally air-cooling to room temperature;
and fifthly, performing hot isostatic pressing treatment, and coating the formed part by using an aluminum foil, wherein the hot isostatic pressing temperature is preferably more than or equal to 350 ℃, the pressure is preferably more than or equal to 100MPa, and the time is preferably more than or equal to 1 h.
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| CN113290256A (en) * | 2021-05-27 | 2021-08-24 | 河南科技大学 | Metal pile casting forming device |
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Application publication date: 20200714 |