CN111515399A - Melting, stacking and additive manufacturing method for ceramic particle reinforced metal matrix composite material - Google Patents
Melting, stacking and additive manufacturing method for ceramic particle reinforced metal matrix composite material Download PDFInfo
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- CN111515399A CN111515399A CN202010414089.1A CN202010414089A CN111515399A CN 111515399 A CN111515399 A CN 111515399A CN 202010414089 A CN202010414089 A CN 202010414089A CN 111515399 A CN111515399 A CN 111515399A
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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
- 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
- B22F3/003—Apparatus, e.g. furnaces
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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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- 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
- B33Y70/00—Materials specially adapted for additive manufacturing
- B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
Abstract
The invention discloses a melting accumulation additive manufacturing method of a ceramic particle reinforced metal matrix composite, which is provided for a metal additive manufacturing process. In the forming process, firstly, the metal matrix material in the crucible is heated to a molten state by high-frequency electromagnetic induction, the melt flows out through a nozzle under the action of a piezoelectric ceramic exciting rod to form a molten drop with the diameter of about 2mm, and the impact velocity of the molten drop is 0.5-1m/s and falls into a molten pool formed by TIG electric arc on the surface of a metal substrate. The inclination angle of the polarity-variable TIG welding gun and the metal substrate is 65 degrees, the arc length is about 7mm, and the substrate keeps horizontal movement. Meanwhile, the ceramic particle reinforced phase is sent into the molten pool from the outside in a mode of carrying powder in an air way through a powder feeder, and a ceramic particle reinforced metal matrix composite structure is formed after solidification.
Description
Technical Field
The invention relates to a melting, stacking and additive manufacturing and forming method of a ceramic particle reinforced metal matrix composite, in particular to a melting, stacking and forming method of a SiC reinforced aluminum matrix composite.
Background
SiC is a common ceramic phase, and is an ideal composite material reinforcing phase due to the characteristics of high melting point, high rigidity, high hardness, good thermal stability, strong corrosion resistance at room temperature and low thermal expansion coefficient. In order to increase the mechanical properties such as strength of single metal, the SiC particle reinforced metal matrix composite can fully exert the respective advantages of each material, so that the ceramic particles and the metal matrix generate interface reaction, thereby changing the microstructure of the metal matrix and improving the mechanical properties of the matrix material. However, in the case of composite materials, whether the ceramic particles and the metal matrix are well infiltrated and whether the particles are uniformly distributed plays an important role in the strength and hardness of the formed materials. The selection of the forming process becomes one of the key factors affecting the ceramic particle reinforced metal matrix composite. At present, various processes for preparing the ceramic particle reinforced metal matrix composite material comprise a powder metallurgy method, an in-situ synthesis method, a stirring casting method, a laser cladding technology and the like.
The powder metallurgy method is a method which comprises the steps of fully mixing a ceramic reinforcing material and metal matrix powder by the technologies of common ball milling, mechanical alloying and the like, pressing the mixed material by using a grinding tool to obtain a required shape, and finally heating a blank to a high temperature below a melting point for sintering and finally solidifying. The method has the advantages of realizing the production of near-net shape, synthesizing the composite material containing the reinforcing particles with higher volume fraction, and preparing the composite material which can not be prepared by a liquid phase method under certain conditions. However, due to the difference of chemical properties, the difference of materials used has great influence on the diffusion process in the sintering process, and the densification is incomplete. In many cases, hot pressing sintering processes are often used to enhance the diffusion process to achieve full densification, which increases product cost, reduces production rates, and may damage the reinforcement. For SiCp/Al based composites and the like, powder metallurgy technology is still expensive compared to liquid phase methods and is only suitable for producing small and simple shapes.
In situ synthesis refers to a technique for synthesizing the reinforcement directly in the matrix by chemical reaction, wherein the reinforcement is formed by an exothermic reaction between an in situ element or an element and a compound. The reinforcing phase is generally subjected to a separate pre-treatment, the size of which is limited by the starting powder size, which is generally between a few microns and tens of microns, and is rarely less than 1 μm. It is also desirable to overcome the disadvantages of interfacial reaction between the reinforcement and the substrate, and poor wettability of the reinforcement and the substrate due to surface contamination of the reinforcement.
The stir casting method is a classic process because it is relatively simple, flexible and suitable for mass production. In a conventional process of the stir casting technique, a base material is melted in a vessel, then the molten metal is sufficiently stirred to form a vortex, and reinforcing particles are introduced through a vortex side. However, stir casting is prone to agglomeration and deposition of ceramic particles, fracture of ceramic particles during mechanical stirring, and local solidification of the melt. Furthermore, the formation of vortices not only entrains the reinforcing particles into the melt, but also any impurities formed on the surface of the melt. The vortex also entrains air into the molten metal, and as the viscosity of the solution increases, the entrapped gas is difficult to remove.
Laser cladding is one of the ideal methods for preparing metal-based particle reinforced composite materials. Compared with the traditional surfacing and spraying, the laser cladding technology has the advantages of low dilution rate, few defects of air holes and cracks, compact structure, concentrated energy, small heat affected zone and the like. The powder feeding type laser cladding technology is easy to realize automatic control, high in laser energy absorption rate and good in processing formability, but has high requirements on the quality of powder, large porosity of a cladding layer and low utilization rate of the powder, and directly brings about high cost and dust pollution. The surface layer prepared by the wire feeding type laser cladding technology has good density and almost zero porosity. The adoption of the wire can save materials and reduce the cost, and the prepared surface layer has larger thickness.
Analysis and comparison of different methods show that the powder metallurgy method and the in-situ synthesis method both require different forms of pretreatment and sufficient mixing of the powdery matrix or the reinforcing phase, and have higher preparation cost. The stirring casting method is easy to generate the phenomena of uneven particle mixing, air inclusion, inclusion and the like. The laser cladding technology has good processing and forming performance, but has the defects of low powder utilization rate, difficult preparation of matrix wires with reinforcements, low forming efficiency and the like.
The SiC ceramic particle reinforced metal matrix composite material is widely applied to the fields of aerospace, automobiles and electronics. The SiC has the characteristics of high melting point, high rigidity, high hardness, good thermal stability, strong corrosion resistance at room temperature and low thermal expansion coefficient. The metal matrix has wide sources, has the characteristics of low cost, relatively low processing temperature, low density, excellent strength, toughness, corrosion resistance and the like, but has poor mechanical property and friction property, so that the wider application of the metal matrix is limited. Therefore, the formed structure of the SiC ceramic particle reinforced metal matrix composite material can not only ensure the light weight and high strength of the structure, but also improve the hardness and the wear resistance of the structure to a certain extent.
At present, the ceramic particle reinforced metal matrix composite is prepared by adopting the traditional powder metallurgy, in-situ synthesis and stirring casting processes, but the preparation cost is high and the pretreatment process is complex. Although the laser cladding process gives consideration to both preparation and forming, the laser cladding process has the defects of low forming efficiency, high material requirement and the like, and cannot meet the requirement of the forming rate of the particle reinforced metal matrix composite material, so that a simple and efficient particle implantation mode and a high-rate forming synchronous process method are needed.
Disclosure of Invention
The present invention aims to overcome the disadvantages of the prior art and to provide an advanced forming method which can improve the mechanical properties of composite materials. The method utilizes the metal micro-spray molten drop principle and uses a composite TIG electric arc as an auxiliary heat source to send SiC ceramic particles into a molten pool formed by combining molten drops and a substrate in an airborne powder mode. The forming flexibility, the forming speed and the equipment cost are well considered while the performances are ensured.
The technical scheme of the invention is realized as follows:
a method for preparing the ceramic particles reinforced metal-base composite material by smelting deposition includes such steps as preparing the micro-spray molten drop, combining it with TIG arc, heating the metal-base material to molten state by high-frequency electromagnetic induction, under the action of the piezoelectric ceramic exciting rod, the liquid metal flows out through the nozzle and falls onto the metal substrate in the form of molten drops, simultaneously, the welding machine arcs, the electric arc force acts under the molten drop at an inclination angle of 40-70 degrees with the metal substrate, a liquid molten pool is formed at the position of the electric arc action on the surface of the metal substrate, the molten drop is combined with the metal substrate in a liquid-liquid manner, meanwhile, ceramic particles are sent into a molten pool in the form of airborne powder, and a metal matrix composite structure reinforced by the ceramic particles is formed after cooling, by controlling the welding current at 200-260A, the moving speed of the metal substrate is 5-8mm/s and the drop falling frequency is 20 Hz.
The metal-based material refers to an aluminum alloy base material and a magnesium alloy base material, the electric arc force and the inclination angle of the metal base plate are 65 degrees, and the ceramic particle reinforced items comprise SiC and Al2O3、ZrO2WC or TiB2The metal substrate is 2024 aluminum alloy substrate and magnesium alloy substrate of individual grade.
The invention technically improves the metal micro-spray molten drop process by taking TIG electric arc as an auxiliary heat source, so that the metal molten drop and a metal substrate are subjected to liquid-liquid combination in an electric arc action area, and simultaneously, SiC ceramic particles are fed into a molten pool in an air-borne powder mode by using a powder feeder, thereby achieving the technical effect of forming the ceramic particle reinforced metal matrix composite.
Drawings
FIG. 1 is a schematic view of the overall equipment of the present invention;
fig. 2 is a schematic view of the molding principle.
In the figure, 1, an electric cylinder, 2, a support frame, 3, a glove box, 4, a linear motor, 5, a Fornes TIG welding machine, 6, an industrial personal computer, 7, a control cabinet, 8, a piezoelectric controller, 9, a powder feeder, 10, an air bottle, 11, a guide pillar, 12, a motion platform, 13, a TIG welding gun, 14, a welding gun clamping handle, 15, a high-pressure injection pipe, 16, a graphite crucible, 17, an induction heating coil, 18, a piezoelectric ceramic excitation rod, 19, a metal melt, 20, a nozzle, 21, a molten drop, 22, a metal substrate, 23, SiC ceramic particles, 24 and a deposition layer.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
The specific equipment of the invention is placed in a glove box filled with argon, and the oxygen content of water in the glove box is less than 2ppm, and the water content is less than 20 ppm. The high frequency electromagnetic induction heater heats the crucible melting system to 700 ℃ to sufficiently melt the metal in the crucible. Meanwhile, the piezoelectric controller generates vibration with certain frequency to act on the piezoelectric ceramic, so that the piezoelectric ceramic generates displacement, and the extrusion diaphragm changes the volume of the melt in the crucible to force the melt to flow out of the nozzle to form micro-droplets. The three-dimensional motion platform controlled by the computer control system consists of X, Y linear motors and electric cylinders driven by rotary motors. The metal substrate is fixed on a motion platform driven by a two-dimensional linear motor, and the platform is provided with loads such as a heat insulation plate, a cooling plate, a heating plate and the like. A servo rotating motor with a band-type brake enables a linear electric cylinder to push a platform to move in the Z direction through a speed reducer. A preposed arc heat source provided by a TIG welding gun at one side of the nozzle acts on the metal substrate at an inclination angle of 65 degrees, the welding gun is fixed on a back plate of the glove box by a welding gun clamping mechanism and keeps an arc starting distance of 8mm with the substrate, and the vertical distance between the nozzle and the surface of the substrate is 37.5 mm. And on the other side of the nozzle, sending the ceramic particle reinforced phase into the molten pool through a lateral powder feeding nozzle, combining with the molten drop falling into the molten pool, and solidifying to obtain the SiC particle reinforced metal matrix composite forming layer.
Referring to fig. 1 and 2, the invention mainly comprises a glove box 3, a micro-spray molten drop device, a TIG welding device, a powder feeding device and a motion control system thereof, wherein the glove box is arranged on a support frame 2. The linear motor 4 is installed on the motion platform 12, and the platform is pushed by the electric cylinder 1 to do Z-direction motion along the guide post 11. The metal substrate is arranged on the linear motor, and the substrate does X, Y-direction plane motion along with the linear motor. A high-frequency electromagnetic induction coil 17 is sleeved outside a graphite crucible 16 above the substrate, and the lower part of the crucible is connected with a nozzle 20. One side of the nozzle is respectively provided with a TIG welding gun with an inclination angle of 65 degrees with the substrate and a SiC particle high-pressure injection pipe, and particles are sprayed out from the nozzle and combined with the molten drops 21. The droplet is generated by a piezoelectric ceramic excitation rod 18 located within the graphite crucible, the displacement of which is controlled by the waveform output by the piezoelectric controller 8.
According to the metal 3D printing principle, TIG electric arc is introduced as an auxiliary heat source on the basis of the original metal micro-spray droplet process, firstly, 2024 aluminum alloy metal matrix is heated to a molten state by high-frequency electromagnetic induction heating, under the excitation action of piezoelectric ceramics, metal droplets are broken at a nozzle and fall onto a 2024 aluminum alloy substrate, meanwhile, a welding machine starts arcing, electric arc force acts under the droplet at an inclination angle of 65 degrees with the substrate, so that the part acted by the electric arc on the surface of the substrate is locally liquefied to form a molten pool. And (3) sending SiC ceramic particles into a molten pool in a high-pressure gas-borne powder mode while liquid-liquid combination is carried out between the molten drops and the substrate, and cooling to form a ceramic particle reinforced aluminum-based composite forming layer. By controlling the welding current, the substrate movement speed, the droplet falling frequency and the powder feeding rate, the forming quality can be stable and reliable, and a formed piece has good surface appearance and excellent mechanical property.
The welding gun is fixed on a back plate of a glove box 3 through a welding gun clamping mechanism, the angle between a welding gun 13 and a substrate 22 is adjusted to 65 degrees, a welding gun clamping handle 14 is parallel to the substrate, the arc starting distance between the tip of a tungsten needle of the welding gun and the substrate is kept to be 8mm, the distance between the tail end of a nozzle and the substrate is 37.5mm, a molten drop falls onto a formed substrate at the frequency of 20Hz, the moving speed of the substrate is controlled to be 5-8mm/s, the welding current is 200-fold 260A, and the substrate is heated to 280-fold 320 ℃, so that the optimal forming effect of the process can be obtained.
Claims (2)
1. A melting, stacking and additive manufacturing method of a ceramic particle reinforced metal matrix composite material is characterized by comprising the following steps of: the method comprises the steps of compounding micro-spray molten drop forming with TIG electric arc, firstly heating a metal base material to a molten state by utilizing high-frequency electromagnetic induction heating, enabling liquid metal to flow out through a nozzle under the action of a piezoelectric ceramic exciting rod, enabling the liquid metal to fall onto a metal substrate in a molten drop form, simultaneously enabling a welding machine to carry out arc striking, enabling electric arc force to act under the molten drop at an inclination angle of 40-70 degrees with the metal substrate, enabling a liquid molten pool to be formed at the position where the electric arc on the surface of the metal substrate acts, enabling the molten drop to be combined with the metal substrate in a liquid-liquid mode, simultaneously sending ceramic particles into the molten pool in an air-borne powder mode, cooling to form a metal base composite structure enhanced by the ceramic particles, controlling the welding current to be 200-260A, enabling the movement speed of the metal substrate to be 5-8mm/s and.
2. The melt-packed additive manufacturing method of a ceramic particle reinforced metal matrix composite according to claim 1, wherein: the metal-based material refers to an aluminum alloy base material and a magnesium alloy base material, the electric arc force and the inclination angle of the metal base plate are 65 degrees, and the ceramic particle reinforced items comprise SiC and Al2O3、ZrO2WC or TiB2The metal substrate is 2024 aluminum alloy substrate and magnesium alloy substrate of individual grade.
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| CN202010414089.1A CN111515399A (en) | 2020-05-15 | 2020-05-15 | Melting, stacking and additive manufacturing method for ceramic particle reinforced metal matrix composite material |
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Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112388315A (en) * | 2020-11-02 | 2021-02-23 | 中国航空制造技术研究院 | Preparation device and method of metal structural member |
| CN112775437A (en) * | 2020-12-23 | 2021-05-11 | 西南交通大学 | Light metal-based composite material part and preparation method thereof |
| CN114378312A (en) * | 2021-11-30 | 2022-04-22 | 西安交通大学 | Steel/aluminum structure molten drop deposition composite TIG electric arc additive manufacturing device and method |
| CN114433819A (en) * | 2020-10-30 | 2022-05-06 | 上海交通大学 | High-toughness aluminum alloy and composite material thereof, and liquid assembly preparation method and application thereof |
| CN115055699A (en) * | 2022-06-24 | 2022-09-16 | 西安交通大学 | Particle reinforced aluminum-based composite material molten drop composite electric arc additive manufacturing device and method |
| CN116352233A (en) * | 2023-05-30 | 2023-06-30 | 中镱新材料智能制造研究院(山西)有限公司 | Manufacturing method for fused accumulation additive of ejection type ceramic particle reinforced composite material |
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2020
- 2020-05-15 CN CN202010414089.1A patent/CN111515399A/en active Pending
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114433819A (en) * | 2020-10-30 | 2022-05-06 | 上海交通大学 | High-toughness aluminum alloy and composite material thereof, and liquid assembly preparation method and application thereof |
| CN114433819B (en) * | 2020-10-30 | 2022-12-16 | 上海交通大学 | High-strength and high-toughness aluminum alloy, composite material thereof, liquid assembly preparation method and application thereof |
| CN112388315A (en) * | 2020-11-02 | 2021-02-23 | 中国航空制造技术研究院 | Preparation device and method of metal structural member |
| CN112775437A (en) * | 2020-12-23 | 2021-05-11 | 西南交通大学 | Light metal-based composite material part and preparation method thereof |
| CN114378312A (en) * | 2021-11-30 | 2022-04-22 | 西安交通大学 | Steel/aluminum structure molten drop deposition composite TIG electric arc additive manufacturing device and method |
| CN115055699A (en) * | 2022-06-24 | 2022-09-16 | 西安交通大学 | Particle reinforced aluminum-based composite material molten drop composite electric arc additive manufacturing device and method |
| CN115055699B (en) * | 2022-06-24 | 2024-03-29 | 西安交通大学 | Device and method for manufacturing particle reinforced aluminum matrix composite material by using molten drop composite arc additive |
| CN116352233A (en) * | 2023-05-30 | 2023-06-30 | 中镱新材料智能制造研究院(山西)有限公司 | Manufacturing method for fused accumulation additive of ejection type ceramic particle reinforced composite material |
| CN116352233B (en) * | 2023-05-30 | 2023-08-22 | 中镱新材料智能制造研究院(山西)有限公司 | Manufacturing method for fused accumulation additive of ejection type ceramic particle reinforced composite material |
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Application publication date: 20200811 |