CN112427651B - Preparation method of intensive alloy material for additive repair of aluminum alloy part - Google Patents
Preparation method of intensive alloy material for additive repair of aluminum alloy part Download PDFInfo
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- 239000001257 hydrogen Substances 0.000 abstract description 3
- 229910052739 hydrogen Inorganic materials 0.000 abstract description 3
- 238000011160 research Methods 0.000 abstract description 3
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- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical group [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 2
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- B22F1/0003—
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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
- B22F3/24—After-treatment of workpieces or articles
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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
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
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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
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0408—Light metal alloys
- C22C1/0416—Aluminium-based alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- 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
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/248—Thermal after-treatment
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Abstract
A preparation method of an intensive alloy material for additive repair of aluminum alloy parts belongs to the field of laser additive manufacturing research. This invention adds a certain proportion of rare earth elements (Zr) x :Ce y :Sc z ) The novel intensified aluminum alloy powder is matched with quenching aging, and damaged aluminum alloy components in the fields of ships, aviation and the like are repaired and remanufactured. The rare earth elements in the novel aluminum alloy powder have higher affinity with hydrogen in the forming process, so that the hydrogen content in a molten pool is obviously reduced, the porosity is reduced, and the purification effect is achieved; in addition, the rare earth elements also play a role in refining grains and dendrites, eliminate coarse phases in original crystals and form intermetallic compounds with elements such as Al and the like to generate second phase strengthening. Compared with the original component, the newly prepared component not only obtains better surface glossiness, but also greatly improves the comprehensive mechanical properties such as strength, elongation, high temperature resistance, fracture toughness, wear resistance, corrosion resistance and the like.
Description
Technical Field
The invention relates to a preparation method of novel intensive aluminum alloy powder, and relates to laser additive manufacturing of parts with excellent comprehensive performance for emergency replacement of various aluminum alloy components in the fields of ships, aviation and the like.
Background
The aluminum alloy has the advantages of small density, high specific strength, good plasticity, small expansion coefficient, high corrosion resistance and the like, and is widely applied to the fields of aviation, ships and warships and the like. However, the aluminum alloy has the defects of low hardness, poor strength, large friction coefficient and the like, and further development of the aluminum alloy in the field of high-precision manufacturing is limited. Under the influence of traditional concepts, the mechanical properties are adjusted mostly by changing components, and as a result, materials with similar properties have different chemical components, especially in the special fields of aerospace and ocean-going navigation. On one hand, the method is unfavorable for production, increases the consumption of manpower and material resources, on the other hand, the inherent potential of the alloy elements is not fully exerted, and a plurality of strengthening mechanisms are ignored. Therefore, the preparation process of the intensive aluminum alloy powder with high strength and high toughness is very important, has reduced components, realizes the purpose of intensive production of 'one aluminum with multiple purposes', and fully exerts the positive effects of the intensive production in production and manufacturing. The preparation of the intensified powder improves the application range, meets the requirements of repairing and remanufacturing of most products, and particularly meets the emergency situations of damage of various parts and the like in ocean navigation.
In recent years, scholars at home and abroad have studied a lot of heat treatment after aluminum alloy forming, and a lot of data show that the heat treatment after forming has great influence on the performance, corrosion resistance, hardness and the like of an aluminum alloy forming structure. The post-forming heat treatment is a heating or cooling treatment for improving the strength and hardness of the alloy. Compared with steel, the aluminum alloy has unique advantages that the plasticity is increased after quenching, and meanwhile, the strength and the hardness of the aluminum alloy are increased through aging treatment.
The domestic research on the application of rare earth elements in aluminum alloys starts from the 60 th century, and although the development is carried out later, the development is fast in recent years, and domestic researchers make a lot of work from mechanism research to actual application. With the injection of rare earth elements into new lives, the development of the manufacturing industry has been unprecedented. Of course, the mechanical property, casting property, electrochemical property and the like of the aluminum alloy are also greatly improved, and the method mainly shows the aspects of purifying the solution, improving the structure, refining grains and the like.
The rare earth elements have high chemical activity and can almost act with all alloy elements in the aluminum alloy. The rare earth elements which are usually added into aluminum and aluminum alloy mainly comprise Sc, Zr, Ce and the like, and are usually added into the aluminum liquid under the action of forming crystal nuclei by using a modifier. In the current aluminum alloy casting process, a large amount of gas (mainly hydrogen and oxygen) is usually brought in, so that a casting generates a large amount of defects. Proper amount of rare earth elements are added into the aluminum alloy, so that the hardness, corrosion resistance, elongation, wear resistance and the like of the alloy can be improved.
The laser additive manufacturing technology is a novel three-dimensional forming technology, and comprises the steps of slicing and layering a three-dimensional part model by 0.8mm in thickness, converting model three-dimensional data information into a series of two-dimensional profile information, and finally stacking materials layer by layer according to the profile information by adopting a laser cladding method to finally form a three-dimensional part (as shown in figure 1). The laser additive manufacturing system mainly comprises a laser system, a powder feeding system, a spray head system, a control system and a mechanical platform.
Disclosure of Invention
The invention aims to prepare a novel aluminum alloy powder aiming at the damage and the loss of various aluminum alloy components in the fields of aviation, ships and warships and the like, and provides a preparation method, so that the replacement of various original parts can be realized by virtue of the intensive characteristics of the novel aluminum alloy powder, and simultaneously, the hardness, the strength, the toughness and the like of the novel aluminum alloy powder are improved relative to the original components.
The invention relates to an intensive alloy material for additive repair of aluminum alloy parts and a preparation method thereof, wherein the intensive alloy material comprises the following components in percentage by mass: 0.31 to 0.42 wt% of Mg; 0.15 to 0.38 wt% of Mn;
0.04-0.12 wt% of Cu; 0.015-0.025 wt% of Sc; 0.07-0.13 wt% of Zr; 0.28 to 0.32 wt% of Zn; 0.02-0.035 wt% of Ce; 0.02-0.05 wt% of Pb; 0.7 wt% of Fe; 0.007 wt% of Sn; 0.0065 wt% of Co; 0.0045 wt% of Y; 0.0015 wt% of La; the balance of Al; slicing and layering the three-dimensional part model by 0.8-1.5 mm in thickness, converting three-dimensional data information into a series of two-dimensional contour information, finally inputting an instruction to a robot demonstrator through a numerical control system, and controlling a laser head to perform additive manufacturing on the part, wherein the process parameters are as follows: the laser power is 1200W-2800W, the scanning speed is 5-10 mm/s, the powder feeding speed is 2.5-6 g/min, the spot diameter is 2-3 mm, the overlapping rate is 30-50%, the included angle between the laser beam and the normal direction of the inner wall is 10-15 degrees, the flow of argon protective gas is 15-25L/min, and an aluminum alloy coating with the thickness of 0.8-1.5 mm can be formed by single-layer overlapping.
After the additive manufacturing is finished and the mechanical processing is carried out, the part is placed in an aluminum alloy vertical quenching furnace for quenching and aging treatment, and the heat treatment regulation and control parameters comprise: the quenching temperature is 400-450 ℃, the aging temperature is 160 ℃, and the aging time is 2 hours.
The method is mainly used for emergency replacement of damaged aluminum alloy components in the fields of aviation, ships and the like, the replaceable aluminum alloy components are quickly prepared by a laser additive manufacturing technology, and the performances of hardness, wear resistance, corrosion resistance and the like are ensured to meet service conditions.
Drawings
FIG. 1 is a schematic diagram of a laser additive manufacturing technique
FIG. 2 shows the molten pool morphology under high-definition camera monitoring
FIG. 3 is a macroscopic view of a laser additive manufactured three-dimensional structure
FIG. 4 is an interface diagram of a laser additive manufacturing three-dimensional component
FIG. 5 is a graph of the morphology of the heat-treated sample
FIG. 6 is a graph comparing polarization curves of laser additive manufacturing samples and a matrix
FIG. 7 is a graph of hardness comparison of a laser additive manufactured sample to a substrate
Detailed Description
Example 1
The method comprises the following steps:
(1) the novel intensive aluminum alloy powder is designed as follows by mass percent: 0.32 wt% of Mg;
Mn:0.21wt％；Cu:0.08wt％；Sc:0.018wt％；Zr:0.11wt％；Zn:0.28wt％；Ce:0.025wt％；
0.03 wt% of Pb; 0.7 wt% of Fe; 0.007 wt% of Sn; 0.0065 wt% of Co; 0.0045 wt% of Y; 0.0015 wt% of La; the balance of Al; weighing the single element powder in the proportion according to the mass percentage of the components, mixing the powder in a ball mill for 3 hours to obtain uniform powder;
(2) drying the powder in a drying oven for 2 hours at the drying temperature of 100 ℃ for later use;
(3) cleaning and wiping the surface of the 2024 engine bracket by using acetone until oil contamination and impurities on the surface are cleaned, moving a cladding head of the semiconductor laser to a preset starting point position to be formed of the blade, and adjusting the distance between the cladding head and the surface of the blade to 15 mm;
(4) the powder feeder filled with the novel aluminum alloy powder is connected with a laser, a program corresponding to pre-compiled model two-dimensional outline information (layered thickness is 1.0mm) is called through a demonstrator in a control platform, a laser additive manufacturing experiment is automatically executed, the process parameters are laser power 1600W, the scanning speed is 6mm/s, the powder feeding speed is 3r/min, the light spot diameter is 2mm, the lap joint rate is 40%, the included angle between a laser beam and the normal direction of the inner wall is 12 degrees, and the flow of argon protective gas is 18L/min. After the first layer is formed, suspending the procedure, measuring that the aluminum alloy coating with the thickness of 1.0mm can be formed by single-layer lap joint, and then continuing to execute the procedure;
(5) after the forming is finished, the prepared aluminum alloy member is placed in an aluminum alloy vertical quenching furnace for quenching aging treatment, and the heat treatment regulation and control parameters comprise: the quenching temperature is 400 ℃, the aging temperature is 160 ℃, and the aging time is 2 hours;
(6) and after the heat treatment is finished, machining by using a lathe, monitoring the change of the cutting force in real time, and obtaining a component with excellent surface quality and higher glossiness within the allowable range of the machining allowance.
The alloy coatings obtained in this example were subjected to various performance tests.
1. Electrochemical experiments
The composite coating is subjected to polarization curve test by using a CHI660D electrochemical workstation, the test is carried out at room temperature, a three-electrode system comprises a working electrode, an auxiliary electrode and a reference electrode, electrolyte is NaCl solution with the mass percentage concentration of 3.5%, the surface of a sample is polished to be flat by using coarse abrasive paper, and the sample is sealed by using sample embedding glue (waterproof insulation). Before testing, firstly, the scanning potential range is determined by the open-circuit potential of the sample, and then the test is carried out by Linear Scanning Voltammetry (LSV) in an electrochemical workstation, and the surface of the sample is black after corrosion. As a result, as shown in FIG. 6, the newly prepared aluminum alloy structural member has higher corrosion resistance.
2. Microhardness
Performing hardness test by using an HV-1000 type microhardness tester, wherein the load is 50g, the loading time is 10s, performing multipoint test on the gradient composite coating and the surface of the substrate, and calculating the average value, wherein the result is shown in figure 7, and the average microhardness of the substrate material is 121.6 HV; the average microhardness of the new aluminium alloy member before heat treatment was 128.76 HV; after heat treatment, the average hardness of the new aluminium alloy member was 164.06 HV.
3. Mechanical Property measurement
The test piece is arranged in a chuck of an HT2402 type computer servo control material testing machine, the lower chuck is moved to a proper position, the lower end of the test piece is clamped, the testing machine is started to uniformly load at a low speed, the stretching speed is 1mm/min, and the rotation of a force measuring pointer, the automatic drawing condition and various phenomena of the test piece in the stretching process are observed. The testing machine is closed, and the test piece is taken down. And aligning the fractured test piece and keeping the test piece as close as possible, and measuring the length of the gauge length section and the diameter of the fracture by using a vernier caliper. The test result shows that: the tensile strength of the novel aluminum alloy member is 451Mpa, the tensile strength of the base material is 430Mpa, and the tensile strength is improved by 4.9%; the yield strength of the novel aluminum alloy member is 298Mpa, the yield strength of the base material is 275Mpa, and the yield strength is improved by 8.7%.
Example 2
The method comprises the following steps:
(1) the novel intensive aluminum alloy powder is designed as follows by mass percent: 0.38 wt% of Mg;
Mn:0.25wt％；Cu:0.10wt％；Sc:0.02wt％；Zr:0.12wt％；Zn:0.30wt％；Ce:0.03wt％；
0.04 wt% of Pb; 0.7 wt% of Fe; 0.007 wt% of Sn; 0.0065 wt% of Co; 0.0045 wt% of Y; 0.0015 wt% of La; the balance of Al; weighing the single element powder in the ratio according to the mass percent of the components, mixing the powder in a ball mill for 2.5 hours to obtain uniform powder;
(2) drying the powder in a drying oven for 3 hours at the drying temperature of 100 ℃ for later use;
(3) cleaning and wiping the surface of a 7075 aircraft wing box by using acetone until oil contamination impurities on the surface are cleaned, moving a cladding head of a semiconductor laser to a preset starting point position to be formed of a blade, and adjusting the distance between the cladding head and the surface of the blade to 15 mm;
(4) the powder feeder filled with the novel aluminum alloy powder is connected with a laser, a program corresponding to pre-programmed model two-dimensional profile information (the layering thickness is 1.2mm) is called through a demonstrator in a control platform, a laser additive manufacturing experiment is automatically executed, the process parameters are laser power 2000W, the scanning speed is 8mm/s, the powder feeding speed is 4r/min, the light spot diameter is 3mm, the lap joint rate is 50%, the included angle between a laser beam and the normal direction of the inner wall is 12 degrees, and the flow of argon gas protection gas is 20L/min. After the first layer is formed, suspending the procedure, measuring that the aluminum alloy coating with the thickness of 1.2mm can be formed by single-layer lap joint, and then continuing to execute the procedure;
(5) after the forming is finished, the prepared aluminum alloy member is placed in an aluminum alloy vertical quenching furnace for quenching aging treatment, and the heat treatment regulation and control parameters comprise: the quenching temperature is 430 ℃, the aging temperature is 160 ℃, and the aging time is 2 h;
(6) and after the heat treatment is finished, machining by using a lathe, monitoring the change of the cutting force in real time, and obtaining a component with excellent surface quality and higher glossiness within the allowable range of the machining allowance.
The alloy coatings obtained in this example were subjected to various performance tests.
1. Electrochemical experiment, the test method is the same as example 1, and the result is shown in figure 6, and the novel aluminum alloy member has higher corrosion resistance.
2. Microhardness
The test method was the same as example 1, and the results are shown in FIG. 7, in which the average microhardness of the base material was 111.68 HV; the average microhardness of the new aluminium alloy member before heat treatment was 128.41 HV; after heat treatment, the average hardness of the new aluminium alloy member was 161.74 HV.
3. Mechanical properties
The test method is the same as example 1, and the test result shows that: the tensile strength of the novel aluminum alloy member is 425MPa, the tensile strength of the base material is 375MPa, and the tensile strength is improved by 13.3%; the yield strength of the novel aluminum alloy member is 315MPa, the yield strength of the base material is 291MPa, and the yield strength is improved by 8.2%.
Example 3
The method comprises the following steps:
(1) the novel intensive aluminum alloy powder is designed as follows by mass percent: 0.40 wt% of Mg;
Mn:0.35wt％；Cu:0.12wt％；Sc:0.025wt％；Zr:0.08wt％；Zn:0.28wt％；Ce:0.035wt％；
0.05 wt% of Pb; 0.7 wt% of Fe; 0.007 wt% of Sn; 0.0065 wt% of Co; 0.0045 wt% of Y; 0.0015 wt% of La; the balance of Al; weighing the single element powder in the proportion according to the mass percentage of the components, mixing the powder in a ball mill for 3 hours to obtain uniform powder;
(2) drying the powder in a drying oven for 3 hours at the drying temperature of 100 ℃ for later use;
(3) cleaning and wiping the surface of a 5083 ship structure part by using acetone until oil contamination and impurities on the surface are cleaned, moving a cladding head of the semiconductor laser to the position of a starting point to be formed, and adjusting the distance between the cladding head and the surface of a blade to 15 mm;
(4) the powder feeder filled with the novel aluminum alloy powder is connected with a laser, a program corresponding to pre-compiled model two-dimensional profile information (the layering thickness is 1.4mm) is called through a demonstrator in a control platform, a laser additive manufacturing experiment is automatically executed, the process parameters are laser power 2200W, the scanning speed is 10mm/s, the powder feeding speed is 5g/min, the light spot diameter is 3mm, the lap joint rate is 40%, the included angle between a laser beam and the normal direction of the inner wall is 12 degrees, and the flow of argon protective gas is 20L/min. After the first layer is formed, suspending the procedure, measuring that the aluminum alloy coating with the thickness of 1.4mm can be formed by single-layer lap joint, and then continuing to execute the procedure;
(5) after the forming is finished, the prepared aluminum alloy component is placed in an aluminum alloy vertical quenching furnace for quenching and aging treatment, and the heat treatment regulation and control parameters comprise: the quenching temperature is 450 ℃, the aging temperature is 160 ℃, and the aging time is 2 hours;
(6) and after the heat treatment is finished, machining by using a lathe, monitoring the change of the cutting force in real time, and obtaining a component with excellent surface quality and higher glossiness within the allowable range of the machining allowance.
The alloy coatings obtained in this example were subjected to various performance tests.
1. Electrochemical experiments
The results of the test method are the same as example 1, and the results are shown in fig. 6, and the corrosion resistance of the novel aluminum alloy member is higher.
2. Microhardness
The test method was the same as example 1, and the results are shown in FIG. 7, in which the average microhardness of the base material was 109.1 HV; the average microhardness of the new aluminium alloy member before heat treatment was 128.68 HV; after heat treatment, the average hardness of the new aluminium alloy member was 160.78 HV.
3. Mechanical properties
The test method is the same as example 1, and the test result shows that: the tensile strength of the novel aluminum alloy member is 413Mpa, the tensile strength of the base material is 357Mpa, and the tensile strength is improved by 15.7%; the yield strength of the novel aluminum alloy member is 275Mpa, the yield strength of the base material is 241Mpa, and the yield strength is improved by 14.1%.
Claims (1)
1. A preparation method of intensive compound alloy material for additive repair of aluminum alloy parts is characterized by comprising the following steps: the mass percentages of the components are as follows: 0.31 to 0.42 wt% of Mg; 0.15 to 0.38 wt% of Mn; 0.04-0.12 wt% of Cu; 0.015-0.025 wt% of Sc; 0.07 to 0.13 wt% of Zr; 0.28 to 0.32 wt% of Zn; 0.02-0.035 wt% of Ce; 0.02-0.05 wt% of Pb; 0.7 wt% of Fe; 0.007 wt% of Sn; 0.0065 wt% of Co; 0.0045 wt% of Y; 0.0015 wt% of La; the balance of Al;
the preparation steps are as follows:
(a) slicing and layering the three-dimensional part model by 0.8-1.5 mm in thickness, converting three-dimensional data information into a series of two-dimensional contour information, and finally inputting an instruction through a numerical control system to control a laser head to perform additive manufacturing, wherein the process parameters are as follows: the laser power is 1000W-2800W, the scanning speed is 4-15 mm/s, the powder feeding speed is 2-8 g/min, the diameter of a light spot is 1-4 mm, the overlapping rate is 30-50%, the included angle between a laser beam and the axial direction of a part processing surface is 10-15 degrees, the flow of argon protective gas is 15-25L/min, and an aluminum alloy coating with the thickness of 0.8-1.5 mm is formed by single-layer overlapping;
(b) after laser additive manufacturing is finished and machining is carried out, the part is placed in an aluminum alloy vertical quenching furnace for quenching aging treatment, and the treatment regulation and control parameters comprise: the quenching temperature is 400-450 ℃, the aging temperature is 160 ℃, and the aging time is 2 hours.
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