CN113102861B - Arc additive manufacturing method with welding ultrasonic vibration and rolling characteristics - Google Patents
Arc additive manufacturing method with welding ultrasonic vibration and rolling characteristics Download PDFInfo
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- CN113102861B CN113102861B CN202110521112.1A CN202110521112A CN113102861B CN 113102861 B CN113102861 B CN 113102861B CN 202110521112 A CN202110521112 A CN 202110521112A CN 113102861 B CN113102861 B CN 113102861B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
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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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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Abstract
The invention discloses an electric arc additive manufacturing method with welding ultrasonic vibration and rolling characteristics, which is characterized in that an ultrasonic vibration rolling roller capable of synchronously and co-directionally moving along with an electric arc additive manufacturing welding gun is arranged behind the electric arc additive manufacturing welding gun, and during the electric arc additive manufacturing process, the ultrasonic vibration rolling roller synchronously and co-directionally moves along with the electric arc additive manufacturing welding gun, and an electric arc additive manufacturing layer in a thermoplastic stage is subjected to ultrasonic vibration and rolling to enable the electric arc additive manufacturing layer to generate plastic deformation and promote cooling of the electric arc additive manufacturing layer, and meanwhile, the ultrasonic vibration is transferred into an electric arc molten pool to enable the solidification process of the molten pool to be subjected to close ultrasonic vibration, so that the tissue and performance of the electric arc additive layer are improved by utilizing the combined action of the ultrasonic vibration rolling roller and the electric arc additive manufacturing gun. The invention has the advantages that the rolling action can be carried out on the arc additive stacking layer through the roller in the arc additive manufacturing process, and simultaneously the ultrasonic assistance is introduced, so that the ultrasonic action effect is improved, and the tissue and mechanical properties of the arc additive manufacturing material or part are improved.
Description
Technical Field
The invention relates to the field of additive manufacturing, in particular to an arc additive manufacturing method with ultrasonic vibration and rolling characteristics.
Background
In recent years, under the background of resource conservation and efficient manufacturing, additive manufacturing technology based on an addition processing mode has wide application prospect in manufacturing of thin-wall parts with complex shapes. Along with itIn the key technical fields of aerospace, national defense, military industry, rail traffic and the like, the requirements on the performance, precision, manufacturing cost and period of compact metal parts are becoming severe, and related researches are needed to break through and master the direct forming technology of the metal parts. The arc additive manufacturing mainly adopts the electric arcs such as consumable electrode inert gas (MIG), tungsten Inert Gas (TIG) and plasma welding (PA) as heat sources, adds wires, gradually forms metal parts from a line-surface-body according to a three-dimensional digital model under the control of a program, and is mainly characterized by high deposition efficiency and wire utilization rate, short integral manufacturing period (the deposition rate can reach 1 kg/h), low cost, and in-situ composite manufacturing and the capability of forming large-size parts (the manufacturing can reach as large as lm) 3 Is a workpiece). However, with the increase of the number of layers, the heat accumulation of the layers is serious, the heat dissipation condition is poor, the problems of overheating of a molten pool, coarse grains of a solidified structure of a build-up layer and the like are easy to occur, common fusion welding defects (such as air holes, inclusions, hot cracks and the like) are also likely to occur, and high-performance additive manufacturing materials or parts are difficult to obtain.
In order to solve the problems, two patents with publication numbers of CN106363173A and CN111215843A respectively disclose an ultrasonic-assisted laser welding additive manufacturing device, an application method thereof and a manufacturing method and device for hot rolling of arc additive manufacturing, which reduce air hole defects to a certain extent and improve weld quality. There are still the following problems: the laser welding equipment has complex structure, complex process flow and operation steps and higher cost; the hot rolling equipment adopts multiple rolling after welding, and does not consider that the welding line is rolled when being in thermoplasticity, and the cooling problem of the additive stacking layer can not be solved.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to solve the technical problems that: how to provide an arc additive manufacturing method with ultrasonic vibration and rolling characteristics along with welding, which can better introduce ultrasonic assistance in the arc additive manufacturing process, improve the ultrasonic effect, effectively improve the structure and performance of the arc additive manufacturing stacking layer, and cool the arc additive manufacturing stacking layer to a certain extent.
In order to solve the technical problems, the invention adopts the following technical scheme:
an electric arc additive manufacturing method with the characteristics of ultrasonic vibration and rolling along with welding is characterized in that an ultrasonic vibration rolling roller capable of synchronously moving along with the electric arc additive manufacturing welding gun in the same direction is arranged behind the electric arc additive manufacturing welding gun, during the electric arc additive manufacturing process, the electric arc additive manufacturing welding gun firstly starts an arc and moves horizontally, the electric arc additive manufacturing is realized through melting and solidification of welding materials, the ultrasonic vibration rolling roller synchronously moves along with the electric arc additive manufacturing welding gun in the same direction, ultrasonic vibration and rolling are carried out on an electric arc additive manufacturing layer in a thermoplastic stage, plastic deformation is carried out, cooling is promoted, meanwhile, ultrasonic vibration is transmitted into an electric arc molten pool through the electric arc additive manufacturing layer and a base parent metal through plane vibration combined up and down, the solidification process of the molten pool is subjected to close ultrasonic vibration, and the tissue and performance of the electric arc additive layer are improved through the comprehensive effect of the two.
In this way, the technical scheme provided by the invention organically combines ultrasonic vibration and rolling on the steel roller which can synchronously move in the same direction along with the welding gun, and the roller implements ultrasonic vibration and rolling when the arc additive stacking layer is just solidified and is still in a thermoplastic state, so that the arc additive stacking layer generates plastic deformation. The beneficial effects are as follows: firstly, the coupling effect of ultrasonic vibration and rolling can greatly improve the plasticity of the material, so that the material can obtain larger plastic deformation modification and better tissue performance improvement effect; and secondly, ultrasonic vibration rolling is carried out when the arc additive stacking layer is still in a thermoplastic state, so that waste heat is utilized, compared with a subsequent reheating rolling method, the method is more energy-saving, simpler and easier to implement, and the roller is utilized to carry out certain forced cooling on the arc additive stacking layer, thereby being beneficial to reducing the interlayer waiting time of arc additive manufacturing and improving the efficiency.
Further, the ultrasonic vibration rolling roller is made of steel, and the side surface of the ultrasonic vibration rolling roller is concave arc-shaped which is suitable for the cross section shape of the arc additive manufacturing layer.
Thus, the arc-shaped pressing surface in the steel roller has the function of increasing the contact area with the additive layer, transmitting more ultrasonic energy into a molten pool, and simultaneously increasing the cooling effect of the roller on the arc additive manufacturing layer. In practice, the rollers may be 20mm-50mm in diameter.
Further, the average pressing force of the ultrasonic vibration rolling roller on the arc additive manufacturing layer is 0.5-2.5KN, and the ultrasonic vibration power is 50-250W.
The parameter range can better ensure the ultrasonic rolling effect. When in use, the roller and the welding gun are arranged adjacent to each other by 5-15 mm.
Further, the method is realized by means of arc additive and ultrasonic rolling combined manufacturing equipment, the arc additive and ultrasonic rolling combined manufacturing equipment comprises an arc additive manufacturing welding gun, the arc additive manufacturing welding gun is arranged on a retainer which is integrally arranged horizontally, one end of a welding head is downward, a roller rolling device is further arranged on the retainer, the roller rolling device comprises a pressing device, a telescopic arm of the pressing device is vertically downward, a steel ultrasonic vibration rolling roller is arranged at the lower end of the telescopic arm, the side surface of the ultrasonic vibration rolling roller is arranged towards the arc additive manufacturing welding gun and is an inward concave arc which is suitable for the cross section shape of an arc additive manufacturing layer, and the roller rolling device further comprises an ultrasonic vibrator for the roller, and the ultrasonic vibrator and the pressing device are relatively fixedly connected and provide ultrasonic vibration for the roller.
Therefore, the roller rolling device can keep the roller to apply pressure to the arc additive manufacturing layer by means of the pressing device, and can apply ultrasonic vibration by means of the ultrasonic vibrator for the roller to achieve the ultrasonic rolling effect. The roller rolling device and the arc additive manufacturing welding gun are arranged on the same retainer, so that synchronous follow-up can be better ensured.
Further, the arc additive manufacturing welding gun is mounted on a welding gun mounting sleeve which is vertically rotatably mounted on the holding frame by a welding gun mounting sleeve rotation adjusting handle.
Therefore, the inclination angle of the welding gun mounting sleeve in the vertical direction can be rotationally adjusted by unscrewing the welding gun mounting sleeve rotating adjusting handle, further the angle of the butt welding gun can be adjusted according to the requirement, and the welding gun mounting sleeve can be fixed by screwing the welding gun mounting sleeve rotating adjusting handle after being adjusted in place. The structure that relates to adjustment handle specifically realizes adjusting fastening among the scheme belongs to ripe prior art, can set up a bolt on adjustment handle and pass welder installation cover and with the screw cooperation that corresponds on the holder can realize, specific structure is not detailed here.
Further, the arc additive manufacturing welding gun can be axially and slidably arranged on the welding gun mounting sleeve, and the welding gun mounting sleeve is also penetratingly screwed with a welding gun fastening bolt to fix the arc additive manufacturing welding gun.
Therefore, the height of the welding gun can be conveniently adjusted after the inclination adjustment, so that the welding gun can keep enough depth of a molten pool and adjust the relative position matched with the stirring needle.
Further, the retainer is in a long strip shape with the same upper and lower widths, the roller rolling device comprises a sliding sleeve which is horizontally sleeved on the retainer in a sliding mode, a sliding sleeve fastening bolt is further arranged on the sliding sleeve in a penetrating and rotating mode to fix the sliding sleeve, the pressing device is fixedly arranged at the lower end of the sliding sleeve, and the roller is fixedly arranged at the upper end of the sliding barrel through the ultrasonic vibrator.
In this way, the relative distance between the roller and the welding gun can be better adjusted as desired.
Further, during arc additive manufacturing, a stirring pin with a reciprocating ultrasonic vibration characteristic is inserted into an additive manufacturing molten pool, and moves synchronously with the molten pool, ultrasonic vibration and stirring are directly implemented in the solidification process of molten pool metal, and solidification structure and mechanical properties of the molten pool metal are improved.
In this way, during the arc additive manufacturing, a stirring pin in a vibration state is further inserted into the molten pool, ultrasonic vibration is introduced to the molten pool through stirring, so that cavitation effect and vibration effect of ultrasonic vibration can be better utilized, welding pores are reduced, grains are refined, bonding strength of the edge of the molten pool in a welding area and a non-welding area in a crystallization process is improved, and solidification structure and mechanical property of molten pool metal are improved. Compared with other ultrasonic vibration modes, such as loading on a base material of a substrate or loading through an electric arc, the ultrasonic vibration loading mode of the invention has more direct ultrasonic vibration on a molten pool, has a good mechanical stirring effect, and has better effect of improving solidification structure and mechanical property of molten pool metal.
Preferably, the stirring pin is made of tungsten or tungsten alloy.
In this way, it is better ensured that the pin does not react with the bath metal.
As optimization, the vibration direction of the stirring pin is along the axial direction of the stirring pin.
In this way, the stirring pin acts on the molten pool to drive liquid metal in the molten pool to do high-frequency reciprocating vibration within a certain area, and the stirring pin generates a stirring-like effect (stirring in a conventional sense is not actually performed) on the molten pool by means of vibration, so that welding pores are reduced, the bonding compactness of a molecular-level welding material is improved, the mechanical property of a welding area is further improved, and the welding effect is improved.
As optimization, the vibration frequency of the stirring pin is 20-100KHZ, and the amplitude is 0.2-1mm. The vibration in the range can better ensure that the vibration has benign influence on metal crystallization, avoid the influence on crystallization caused by overlarge vibration and reduce welding quality.
Alternatively, during welding, the arc additive manufacturing welding gun is arranged along the direction perpendicular to the plane of a product where the molten pool is located, and the stirring needle is obliquely inserted downwards from the front or the rear of the travelling direction of the arc additive manufacturing welding gun to the lower part of the middle part of the molten pool so as to realize ultrasonic vibration.
Therefore, the mode can be implemented by directly increasing the ultrasonic vibration introduced by the stirring pin on the basis of the control process of the conventional arc additive manufacturing process because the welding gun is arranged along the direction perpendicular to the plane of the product during the conventional arc additive manufacturing process, and the control program of the arc additive manufacturing welding gun is not required to be adjusted again, so that the implementation and the application are convenient.
Alternatively, the arc additive manufacturing welding gun is arranged with the upper end obliquely arranged along the front of the travelling direction of the arc additive manufacturing welding gun during welding, and the stirring needle is arranged behind the arc additive manufacturing welding gun and vertically downwards inserted into the middle part of the additive manufacturing molten pool to realize ultrasonic vibration.
Therefore, the upper end of the arc additive manufacturing welding gun is inclined along the advancing direction, the to-be-processed area in front of the molten pool can be better preheated, meanwhile, a space which is vertically arranged along the middle position of the molten pool can be reserved for the stirring pin, after the stirring pin is vertically arranged at the middle position of the molten pool, ultrasonic vibration of the stirring pin can be very uniformly transmitted to the whole molten pool, the influence on the metal crystallization fusion effect caused by uneven transmission of the ultrasonic vibration in the molten pool is avoided, and the product forming quality is greatly improved.
After the step of directly carrying out ultrasonic vibration stirring on a molten pool by stirring is added, the method can be realized by adopting equipment, namely, on the basis of the electric arc material adding and ultrasonic rolling combined manufacturing equipment, a vibration stirring device is further arranged on the retainer and comprises an ultrasonic vibrator for a stirring needle, the lower end of the ultrasonic vibrator for the stirring needle is downwards provided with the stirring needle, and the ultrasonic vibrator for the stirring needle can provide axial vibration for the stirring needle.
Like this, welder and vibration agitating unit install on same holder, can guarantee better that the stirring needle follows welder and realizes vibration stirring in step.
Further, the stirring pin is vertically arranged on a vibrator installation sleeve by an ultrasonic vibrator, the vibrator installation sleeve is vertically rotatably arranged on a sliding sleeve by a vibrator installation sleeve vibration adjusting handle, and the sliding sleeve is horizontally slidably arranged on the holding frame.
Therefore, the inclination angle of the stirring needle can be conveniently adjusted according to the requirement, so that the stirring needle is arranged perpendicular to the direction of the molten pool, or is obliquely arranged, and the front-back distance of the stirring needle relative to the welding gun can be conveniently adjusted, so that the lower end of the stirring needle can be better positioned in the middle of the molten pool. The adjusting structure of the vibrator mounting sleeve vibration adjusting handle can be consistent with the welding gun mounting sleeve rotation adjusting handle, and is not described in detail herein.
Further, the retainer is in a strip shape with the same upper and lower widths, the sliding sleeve can be horizontally and slidably sleeved on the retainer, and the sliding sleeve is also rotatably connected with a bolt for fastening the sliding sleeve in a penetrating manner to fix the sliding sleeve.
Thus, the front and back positions of the stirring needle are more convenient to adjust and fix.
Further, the ultrasonic vibrator for the stirring pin is arranged on the vibrator mounting sleeve through a vibration absorbing spring.
Thus, the vibration-absorbing spring acts between the ultrasonic vibrator for the stirring pin and the vibrator mounting sleeve, and ultrasonic vibration can be prevented from being transmitted to the retainer through the vibrator mounting sleeve, so that vibration of the welding gun is caused. The working stability of the welding gun can be better kept.
Further, the ultrasonic vibrator for the stirring pin is an ultrasonic vibrator for a pneumatic stirring pin.
The method has the advantages of stable effect, convenience in control, and small influence of ultrasonic vibration on the reaction of the retainer. And the pneumatic ultrasonic vibration source has much higher tolerance to heat and high temperature, and is more suitable for the high temperature working condition of arc additive manufacturing.
Further, the holder is fixedly mounted on a mechanical arm of the arc additive manufacturing dedicated robot.
Thus, automatic arc additive manufacturing of products is conveniently realized through control of a robot computer.
Further, the lower end of the stirring pin is provided with a circle of horizontally convex bulges.
Therefore, when the stirring pin vibrates up and down along the axial direction, the bulge can play a role in greatly amplifying vibration of the molten pool, and the ultrasonic vibration effect is improved. In specific implementation, the protruding distance should not be too large, and can be controlled within three times of the diameter of the stirring pin, and the specific size can be obtained according to test verification.
Further, the protrusions are uniformly distributed circumferentially, and the upper surface and the lower surface of each protrusion are respectively provided with an inclined surface or a spiral blade surface which are reversely symmetrical.
Thus, along with the axial reciprocating vibration of the stirring pin, the upper surface and the lower surface of the bulge can form the action effect of pushing the molten metal outwards in a circumferential reciprocating way during the reciprocating motion, and then the molten metal is vibrated in the axial direction and simultaneously the circumferential reciprocating vibration is generated, wherein the vibration in the axial direction can better act on the bottom of a molten pool, the vibration in the circumferential direction can better act on the peripheral wall of the molten pool, the double vibration forms a composite high-frequency vibration effect on the molten pool of the molten metal, the binding property of the molten pool to the metal on the peripheral wall is greatly improved, the metal crystalline structure can be better refined, the influence of the vibration on the metal crystalline fusion effect is improved, and the forming quality of products is improved.
The scheme of the invention further introduces ultrasonic vibration stirring in the arc additive manufacturing, on one hand, the method can break up growing columnar crystals, refine and homogenize crystal grains, on the other hand, the method can promote gas overflow in a molten pool, reduce the porosity, and the combined action of the two greatly improves the mechanical properties of arc additive manufacturing materials or parts.
In summary, the invention has the advantages that the roller can roll the arc additive stacking layer in the arc additive manufacturing process, and simultaneously ultrasonic assistance is introduced to improve the ultrasonic effect so as to improve the tissue and mechanical properties of the arc additive manufacturing material or part.
Drawings
Fig. 1 is a schematic structural diagram of an arc additive and ultrasonic rolling combined manufacturing apparatus used in a first embodiment of the present invention.
Fig. 2 is a schematic view of the structure of the single ultrasonic vibration grinding roller in fig. 1.
Fig. 3 is a schematic structural diagram of an arc additive and ultrasonic rolling combined manufacturing apparatus used in the second embodiment of the present invention.
Fig. 4 is a schematic view of the lower end protrusion of the single stirring pin in fig. 3.
Detailed Description
The present invention will be described in further detail with reference to the following embodiments.
The first embodiment is as follows: an electric arc additive manufacturing method with ultrasonic vibration and rolling characteristics along with welding is characterized in that an ultrasonic vibration rolling roller capable of synchronously moving in the same direction along with the electric arc additive manufacturing welding gun is arranged behind the electric arc additive manufacturing welding gun, when the electric arc additive manufacturing process is carried out, the electric arc additive manufacturing welding gun firstly starts an arc and moves horizontally, electric arc additive manufacturing is realized through welding material melting and solidification, the ultrasonic vibration rolling roller synchronously moves in the same direction along with the electric arc additive manufacturing welding gun, ultrasonic vibration and rolling are carried out on an electric arc additive manufacturing layer in a thermoplastic stage, plastic deformation is carried out, cooling is promoted, meanwhile, ultrasonic vibration is transmitted into an electric arc molten pool through the electric arc additive manufacturing layer and a base parent metal through plane vibration combined up and down and front and back, the solidification process of the molten pool is subjected to close ultrasonic vibration, and the tissue and performance of the electric arc additive layer are improved through the comprehensive effect of the ultrasonic vibration.
In this way, the scheme organically combines ultrasonic vibration and rolling on the steel roller which can synchronously move in the same direction along with the welding gun, and the roller implements ultrasonic vibration and rolling when the arc additive stacking layer is just solidified and is still in a thermoplastic state, so that the arc additive stacking layer generates plastic deformation. The beneficial effects are as follows: firstly, the coupling effect of ultrasonic vibration and rolling can greatly improve the plasticity of the material, so that the material can obtain larger plastic deformation modification and better tissue performance improvement effect; and secondly, ultrasonic vibration rolling is carried out when the arc additive stacking layer is still in a thermoplastic state, so that waste heat is utilized, compared with a subsequent reheating rolling method, the method is more energy-saving, simpler and easier to implement, and the roller is utilized to carry out certain forced cooling on the arc additive stacking layer, thereby being beneficial to reducing the interlayer waiting time of arc additive manufacturing and improving the efficiency.
Wherein, referring to fig. 2, the ultrasonic vibration rolling roller is a steel ultrasonic vibration rolling roller, and the side surface of the ultrasonic vibration rolling roller is a concave arc adapting to the cross section shape of the arc additive manufacturing layer.
Thus, the arc-shaped pressing surface in the steel roller has the function of increasing the contact area with the additive layer, transmitting more ultrasonic energy into a molten pool, and simultaneously increasing the cooling effect of the roller on the arc additive manufacturing layer. In practice, the rollers may be 20mm-50mm in diameter.
The average pressing force of the ultrasonic vibration rolling roller on the arc additive manufacturing layer is 0.5-2.5KN, and the ultrasonic vibration power is 50-250W.
The parameter range can better ensure the ultrasonic rolling effect. When in use, the roller and the welding gun are arranged adjacent to each other by 5-15 mm.
The arc additive and ultrasonic rolling combined manufacturing equipment is realized by means of the arc additive and ultrasonic rolling combined manufacturing equipment shown in fig. 1-2, the arc additive and ultrasonic rolling combined manufacturing equipment comprises an arc additive manufacturing welding gun 1, the arc additive manufacturing welding gun 1 is arranged on a retainer 4 which is integrally arranged horizontally and one end of a welding head is downward, a roller rolling device is further arranged on the retainer, the roller rolling device comprises a pressing device 13, a telescopic arm 14 of the pressing device 13 is vertically arranged downwards, a steel ultrasonic vibration rolling roller 15 is arranged at the lower end of the telescopic arm, the side surface of the ultrasonic vibration rolling roller 15 is arranged towards the arc additive manufacturing welding gun direction and is an inward concave arc which is suitable for the cross section shape of an arc additive manufacturing layer, and the roller rolling device further comprises an ultrasonic vibrator 16 for the roller, and the roller is relatively fixedly connected with the ultrasonic vibrator 16 and provides ultrasonic vibration for the pressing device.
Therefore, the roller rolling device can keep the roller to apply pressure to the arc additive manufacturing layer by means of the pressing device, and can apply ultrasonic vibration by means of the ultrasonic vibrator for the roller to achieve the ultrasonic rolling effect. The roller rolling device and the arc additive manufacturing welding gun are arranged on the same retainer, so that synchronous follow-up can be better ensured. When the pressure applying device is implemented, the pressure applying device can be realized by adopting an electric push rod, so that the pressure is conveniently and accurately controlled.
Wherein, arc additive manufacturing welder 1 is installed on a welder installation cover 5, and welder installation cover 5 is installed on holder 4 through a welder installation cover rotation adjustment handle 6 vertically rotatablely.
Therefore, the inclination angle of the welding gun mounting sleeve in the vertical direction can be rotationally adjusted by unscrewing the welding gun mounting sleeve rotating adjusting handle, further the angle of the butt welding gun can be adjusted according to the requirement, and the welding gun mounting sleeve can be fixed by screwing the welding gun mounting sleeve rotating adjusting handle after being adjusted in place. The structure that relates to adjustment handle specifically realizes adjusting fastening among the scheme belongs to ripe prior art, can set up a bolt on adjustment handle and pass welder installation cover and with the screw cooperation that corresponds on the holder can realize, specific structure is not detailed here.
The arc additive manufacturing welding gun 1 is axially slidably mounted on the welding gun mounting sleeve 5, and a welding gun fastening bolt 10 is also rotatably connected to the welding gun mounting sleeve in a penetrating manner to fix the arc additive manufacturing welding gun.
Therefore, the height of the welding gun can be conveniently adjusted after the inclination adjustment, so that the welding gun can keep enough depth of a molten pool and adjust the relative position matched with the stirring needle.
The retainer 4 is in a strip shape with the same vertical width, the roller rolling device comprises a sliding sleeve 17 which is horizontally sleeved on the retainer in a sliding mode, a sliding sleeve fastening bolt 18 is further arranged on the sliding sleeve 17 in a penetrating and screwing mode to fix the sliding sleeve, the pressing device is fixedly arranged at the lower end of the sliding sleeve 17, and the roller is fixedly arranged at the upper end of the sliding cylinder through an ultrasonic vibrator.
In this way, the relative distance between the roller and the welding gun can be better adjusted as desired.
The holder 4 is fixedly mounted on a mechanical arm of a robot special for arc additive manufacturing (the robot special for arc additive manufacturing is a mature existing product, and can control a travel path of a welding gun by computer programming to realize additive welding manufacturing, so the robot is not shown in the figure).
The second embodiment is as follows: in the specific embodiment, a step of stirring the molten pool by ultrasonic vibration by adopting the stirring needle 2 is added on the basis of the first embodiment, namely, when the arc additive is manufactured in the first embodiment, the stirring needle with the reciprocating ultrasonic vibration characteristic is simultaneously inserted into the additive manufacturing molten pool and synchronously moves along with the molten pool, and ultrasonic vibration and stirring are directly implemented in the solidification process of molten pool metal, so that solidification structure and mechanical property of the molten pool metal are improved.
In this way, a stirring pin in a vibration state is further inserted into the molten pool, ultrasonic vibration is introduced to the molten pool through stirring, so that cavitation effect and vibration effect of ultrasonic vibration can be better utilized, welding air holes are reduced, grains are refined, bonding strength of the edge of the molten pool in a welding area and a non-welding area in a crystallization process is improved, and solidification structure and mechanical property of molten pool metal are improved. Compared with other ultrasonic vibration modes, such as loading on a base material of a substrate or loading through an electric arc, the ultrasonic vibration loading mode of the invention has more direct ultrasonic vibration on a molten pool, has a good mechanical stirring effect, and has better effect of improving solidification structure and mechanical property of molten pool metal.
Wherein, the stirring pin adopts tungsten or tungsten alloy.
In this way, it is better ensured that the pin does not react with the bath metal.
Wherein, the stirring pin vibration direction is along self axial.
In this way, the stirring pin acts on the molten pool to drive liquid metal in the molten pool to do high-frequency reciprocating vibration within a certain area, and the stirring pin generates a stirring-like effect (stirring in a conventional sense is not actually performed) on the molten pool by means of vibration, so that welding pores are reduced, the bonding compactness of a molecular-level welding material is improved, the mechanical property of a welding area is further improved, and the welding effect is improved.
Wherein the vibration frequency of the stirring pin is 20-100KHZ, and the amplitude is 0.2-1mm. The vibration in the range can better ensure that the vibration has benign influence on metal crystallization, avoid the influence on crystallization caused by overlarge vibration and reduce welding quality.
Alternatively, during welding, the arc additive manufacturing welding gun is arranged along the direction perpendicular to the plane of a product where the molten pool is located, and the stirring needle is obliquely inserted downwards from the front or the rear of the travelling direction of the arc additive manufacturing welding gun to the lower part of the middle part of the molten pool so as to realize ultrasonic vibration.
Therefore, the mode can be implemented by directly increasing the ultrasonic vibration introduced by the stirring pin on the basis of the control process of the conventional arc additive manufacturing process because the welding gun is arranged along the direction perpendicular to the plane of the product during the conventional arc additive manufacturing process, and the control program of the arc additive manufacturing welding gun is not required to be adjusted again, so that the implementation and the application are convenient.
Alternatively, the arc additive manufacturing welding gun is arranged with the upper end obliquely arranged along the front of the travelling direction of the arc additive manufacturing welding gun during welding, and the stirring needle is arranged behind the arc additive manufacturing welding gun and vertically downwards inserted into the middle part of the additive manufacturing molten pool to realize ultrasonic vibration.
Therefore, the upper end of the arc additive manufacturing welding gun is inclined along the advancing direction, the to-be-processed area in front of the molten pool can be better preheated, meanwhile, a space which is vertically arranged along the middle position of the molten pool can be reserved for the stirring pin, after the stirring pin is vertically arranged at the middle position of the molten pool, ultrasonic vibration of the stirring pin can be very uniformly transmitted to the whole molten pool, the influence on the metal crystallization fusion effect caused by uneven transmission of the ultrasonic vibration in the molten pool is avoided, and the product forming quality is greatly improved.
In the second embodiment, after the step of directly performing ultrasonic vibration stirring on the molten pool by stirring is added, the step can be realized by adopting equipment shown in fig. 3-4, namely, on the basis of the electric arc material adding and ultrasonic rolling combined manufacturing equipment, a vibration stirring device is additionally arranged on the retainer, the vibration stirring device comprises an ultrasonic vibrator 3 for a stirring needle, the lower end of the ultrasonic vibrator 3 for the stirring needle is downwards provided with a stirring needle 2, and the ultrasonic vibrator 3 for the stirring needle can provide axial vibration for the stirring needle 2.
Like this, welder and vibration agitating unit install on same holder, can guarantee better that the stirring needle follows welder and realizes vibration stirring in step.
Wherein, ultrasonic vibrator 3 for the stirring needle is installed on a vibrator installation cover 7 vertically, and vibrator installation cover 7 is installed on a slip cap 8 through a vibrator installation cover vibration adjustment handle 9 can vertically rotate, and the slip cap can install on the holder with horizontal slip.
Therefore, the inclination angle of the stirring needle can be conveniently adjusted according to the requirement, so that the stirring needle is arranged perpendicular to the direction of the molten pool, or is obliquely arranged, and the front-back distance of the stirring needle relative to the welding gun can be conveniently adjusted, so that the lower end of the stirring needle can be better positioned in the middle of the molten pool. The adjusting structure of the vibrator mounting sleeve vibration adjusting handle can be consistent with the welding gun mounting sleeve rotation adjusting handle, and is not described in detail herein.
The retainer 4 is in a strip shape with the same vertical width, the sliding sleeve 8 is horizontally sleeved on the retainer in a sliding manner, and a bolt 11 for fastening the sliding sleeve is also arranged on the sliding sleeve in a penetrating and screwing manner to fix the sliding sleeve 8.
Thus, the front and back positions of the stirring needle are more convenient to adjust and fix.
Wherein, the ultrasonic vibrator 3 for the stirring needle is arranged on the vibrator installation sleeve through a vibration absorption spring.
Thus, the vibration-absorbing spring acts between the ultrasonic vibrator for the stirring pin and the vibrator mounting sleeve, and ultrasonic vibration can be prevented from being transmitted to the retainer through the vibrator mounting sleeve, so that vibration of the welding gun is caused. The working stability of the welding gun can be better kept.
Wherein, ultrasonic vibrator 3 for the stirring needle is an ultrasonic vibrator for a pneumatic stirring needle.
The method has the advantages of stable effect, convenience in control, and small influence of ultrasonic vibration on the reaction of the retainer. And the pneumatic ultrasonic vibration source has much higher tolerance to heat and high temperature, and is more suitable for the high temperature working condition of arc additive manufacturing.
The holder 4 is fixedly mounted on a mechanical arm of a robot special for arc additive manufacturing (the robot special for arc additive manufacturing is a mature existing product, and can control a travel path of a welding gun by computer programming to realize additive welding manufacturing, so the robot is not shown in the figure).
Thus, automatic arc additive manufacturing of products is conveniently realized through control of a robot computer.
Wherein, the lower end of the stirring pin 2 is provided with a circle of horizontally and externally convex bulges 12.
Therefore, when the stirring pin vibrates up and down along the axial direction, the bulge can play a role in greatly amplifying vibration of the molten pool, and the ultrasonic vibration effect is improved. In specific implementation, the protruding distance should not be too large, and can be controlled within three times of the diameter of the stirring pin, and the specific size can be obtained according to test verification.
The protrusions are uniformly distributed in the circumferential direction, and the upper surface and the lower surface of each protrusion are respectively provided with an inclined surface or a spiral blade surface which are reversely symmetrical.
Thus, along with the axial reciprocating vibration of the stirring pin, the upper surface and the lower surface of the bulge can form the action effect of pushing the molten metal outwards in a circumferential reciprocating way during the reciprocating motion, and then the molten metal is vibrated in the axial direction and simultaneously the circumferential reciprocating vibration is generated, wherein the vibration in the axial direction can better act on the bottom of a molten pool, the vibration in the circumferential direction can better act on the peripheral wall of the molten pool, the double vibration forms a composite high-frequency vibration effect on the molten pool of the molten metal, the binding property of the molten pool to the metal on the peripheral wall is greatly improved, the metal crystalline structure can be better refined, the influence of the vibration on the metal crystalline fusion effect is improved, and the forming quality of products is improved.
In order to further verify the effect, the applicant further performs a plurality of groups of comparison experiments to verify that the parameters in each experimental example are consistent: the geometric dimension of the base plate is 100 multiplied by 50 multiplied by 10mm, an MIG (consumable electrode argon arc welding) welding machine is adopted, and the technological parameters of arc additive manufacturing are as follows: the welding current is 80A, the voltage is 19.8V, the diameter of a welding wire is 1.6mm, the wire feeding speed is 120cm/min, the welding speed (the moving speed of a welding gun) is 200mm/min, the shielding gas is 99.99% of argon, and the gas flow is 15L/min. The arc additive manufacturing stacking layer passes are 4, each pass is separated by two minutes, 3 samples are welded in each embodiment, three positions before, during and after each sample is taken, testing is carried out, and the average value is obtained after performance testing.
Comparative example 1: the welding wire is AZ31 magnesium alloy, and ultrasonic vibration and rolling are not added during arc additive manufacturing. Experimental results: the average tensile strength was 222.34MPa.
Comparative example 2: the welding wire is ER5356 aluminum alloy, and ultrasonic vibration and rolling are not added during arc additive manufacturing. Experimental results: the average tensile strength was 251.4MPa.
Experimental example 1: the test was performed using the apparatus and procedure of embodiment one, with the welding wire being AZ31 magnesium alloy. The roller was 5mm from the gun. During arc additive manufacturing, follow-up ultrasonic vibration and rolling are applied to each thermal-state additive accumulation layer, the ultrasonic vibration power is 100W, and the rolling pressure of the roller is 2.4KN.
Experimental results: the average tensile strength of the arc additive manufacturing stacking layer is 228.14MPa, and compared with comparative example 1, the arc additive manufacturing stacking layer has more compact structure and finer grains.
Experimental example 2: the test was performed using the apparatus and procedure of embodiment one, with the welding wire being AZ31 magnesium alloy. The roller was 10mm from the gun. During arc additive manufacturing, follow-up ultrasonic vibration and rolling are applied to each thermal-state additive accumulation layer, the ultrasonic vibration power is 175W, and the rolling pressure of the roller is 1.6KN.
Experimental results: the average tensile strength of the arc additive manufacturing stacking layer is 235.41MPa, and compared with comparative example 1, the arc additive manufacturing stacking layer has more compact structure and finer grains.
Experimental example 3: the test was performed using the apparatus and procedure of embodiment one, with the welding wire being AZ31 magnesium alloy. The roller was 15mm from the gun. During arc additive manufacturing, follow-up ultrasonic vibration and rolling are applied to each thermal-state additive accumulation layer, the ultrasonic vibration power is 250W, and the rolling pressure of the roller is 0.8KN.
Experimental results: the average tensile strength of the arc additive manufacturing stacking layer is 230.14MPa, and compared with comparative example 1, the arc additive manufacturing stacking layer has more compact structure and finer grains.
Experimental example 4: the test was performed using the apparatus and procedure of embodiment two, with the welding wire being AZ31 magnesium alloy. The roller was 15mm from the gun. During arc additive manufacturing, follow-up ultrasonic vibration and rolling are applied to each thermal-state additive accumulation layer, the ultrasonic vibration power is 250W, and the rolling pressure of the roller is 0.8KN.
Experimental results: the average tensile strength of the arc additive manufacturing stacking layer is 237.55MPa, and compared with comparative example 1, the arc additive manufacturing stacking layer has more compact structure and finer grains.
Experimental example 5: the test was performed using the apparatus and procedure of embodiment one, with the welding wire being ER5356 aluminum alloy welding wire. The roller was 5mm from the gun. During arc additive manufacturing, follow-up ultrasonic vibration and rolling are applied to each thermal-state additive accumulation layer, the ultrasonic vibration power is 50W, and the rolling pressure of the roller is 2.4KN.
Experimental results: the average tensile strength of the arc additive manufacturing stacking layer is 269.05MPa, and compared with comparative example 2, the arc additive manufacturing stacking layer has more compact structure and finer grains.
Experimental example 6: the test was performed using the apparatus and procedure of embodiment one, with the welding wire being ER5356 alloy welding wire. The roller was 10mm from the gun. During arc additive manufacturing, follow-up ultrasonic vibration and rolling are applied to each thermal-state additive accumulation layer, the ultrasonic vibration power is 125W, and the rolling pressure of the roller is 1.6KN.
Experimental results: the average tensile strength of the arc additive manufacturing stacking layer is 266.30MPa, and compared with comparative example 2, the arc additive manufacturing stacking layer has more compact structure and finer grains.
Experimental example 7: the test was performed using the apparatus and procedure of embodiment one, with the welding wire being ER5356 aluminum alloy welding wire. The roller was 15mm from the gun. During arc additive manufacturing, follow-up ultrasonic vibration and rolling are applied to each thermal-state additive accumulation layer, the ultrasonic vibration power is 200W, and the rolling down force of the roller is 0.8KN.
Experimental results: the average tensile strength of the arc additive manufacturing stacking layer is 264.37MPa, and compared with comparative example 2, the arc additive manufacturing stacking layer has more compact structure and finer grains.
Experimental example 8: the test was performed using the apparatus and procedure of embodiment two, the welding wire being ER5356 aluminum alloy welding wire. The roller was 15mm from the gun. During arc additive manufacturing, follow-up ultrasonic vibration and rolling are applied to each thermal-state additive accumulation layer, the ultrasonic vibration power is 200W, and the rolling down force of the roller is 0.8KN.
Experimental results: the average tensile strength of the arc additive manufacturing stacking layer is 273.42MPa, and compared with comparative example 2, the arc additive manufacturing stacking layer has more compact structure and finer grains.
Therefore, it is known from the above experimental examples that under the same parameter conditions, the strength performance of the product obtained in the second embodiment is greater than that of the product obtained in the first embodiment, and the strength performance of the product obtained in the first embodiment is greater than that of the conventional arc additive manufacturing product. Therefore, the method can effectively improve the tensile strength of the product obtained by arc additive manufacturing.
Claims (5)
1. An electric arc additive manufacturing method with ultrasonic vibration and rolling characteristics along with welding is characterized in that an ultrasonic vibration rolling roller capable of synchronously moving in the same direction along with the electric arc additive manufacturing welding gun is arranged behind the electric arc additive manufacturing welding gun, when in an electric arc additive manufacturing process, the electric arc additive manufacturing welding gun firstly starts an arc and moves horizontally, electric arc additive manufacturing is realized through melting and solidification of welding materials, the ultrasonic vibration rolling roller synchronously moves in the same direction along with the electric arc additive manufacturing welding gun, ultrasonic vibration and rolling are carried out on an electric arc additive manufacturing layer in a thermoplastic stage, plastic deformation is carried out on the electric arc additive manufacturing layer, cooling is promoted, meanwhile, ultrasonic vibration is transmitted into an electric arc molten pool through the electric arc additive manufacturing layer and a base parent metal through plane vibration combined up and down and front and back, the solidification process of the molten pool is subjected to close ultrasonic vibration, and the tissue and performance of the electric arc additive layer are improved through the combined effect of the two;
the ultrasonic vibration rolling roller is made of steel, and the side surface of the ultrasonic vibration rolling roller is concave arc adapting to the cross section shape of the arc additive manufacturing layer;
during arc additive manufacturing, a stirring needle with a reciprocating ultrasonic vibration characteristic is inserted into an additive manufacturing molten pool and moves synchronously with the molten pool, ultrasonic vibration and stirring are directly carried out on the solidification process of molten pool metal, and solidification structure and mechanical property of the stirring needle are improved; the vibration direction of the stirring pin is along the axial direction of the stirring pin;
the method is realized by means of arc additive and ultrasonic rolling combined manufacturing equipment, the arc additive and ultrasonic rolling combined manufacturing equipment comprises an arc additive manufacturing welding gun, the arc additive manufacturing welding gun is arranged on a retainer which is arranged horizontally in a whole and one end of a welding head is downward, a roller rolling device is also arranged on the retainer, the roller rolling device comprises a pressing device, a telescopic arm of the pressing device is arranged vertically downward, a steel ultrasonic vibration rolling roller is arranged at the lower end of the telescopic arm, the side surface of the ultrasonic vibration rolling roller is arranged towards the arc additive manufacturing welding gun and is an inward concave arc which is suitable for the cross section shape of an arc additive manufacturing layer, and the roller rolling device also comprises an ultrasonic vibrator for the roller;
the stirring device comprises an ultrasonic vibrator for a stirring needle, the lower end of the ultrasonic vibrator for the stirring needle is provided with a stirring needle downwards, and the ultrasonic vibrator for the stirring needle can provide axial vibration for the stirring needle;
the lower end of the stirring pin is provided with a circle of horizontal convex bulges; the protrusions are uniformly distributed in the circumferential direction, and the upper surface and the lower surface of each protrusion are respectively provided with an inclined surface or a spiral blade surface which are reversely symmetrical; along with the axial reciprocating vibration of the stirring pin, the upper surface and the lower surface of the bulge can form the action effect of pushing the molten metal outwards in a circumferential reciprocating and rotary mode during the reciprocating motion, so that the molten metal can vibrate in the axial direction and simultaneously generate the circumferential reciprocating vibration, and a composite high-frequency vibration effect is formed for a molten metal pool.
2. The arc additive manufacturing method with ultrasonic vibration and compaction along with welding according to claim 1, wherein the ultrasonic vibration compaction roller achieves an average pressing force of 0.5-2.5KN and an ultrasonic vibration power of 50-250W for the arc additive manufacturing layer.
3. The arc additive manufacturing method with ultrasonic vibration and rolling characteristics along with welding according to claim 1, wherein the arc additive manufacturing welding gun is mounted on a welding gun mounting sleeve, and the welding gun mounting sleeve is vertically rotatably mounted on the holding frame through a welding gun mounting sleeve rotation adjusting handle;
the arc additive manufacturing welding gun is axially and slidably arranged on the welding gun mounting sleeve, and the welding gun mounting sleeve is also penetratingly screwed with a welding gun fastening bolt to fix the arc additive manufacturing welding gun.
4. The arc additive manufacturing method with the characteristics of ultrasonic vibration along with welding and rolling according to claim 1, wherein the retainer is in a strip shape with a uniform upper and lower width, the roller rolling device comprises a sliding sleeve which is horizontally and slidably sleeved on the retainer, a bolt for fastening the sliding sleeve is further arranged on the sliding sleeve in a penetrating and screwing mode to fix the sliding sleeve, the pressing device is fixedly arranged at the lower end of the sliding sleeve, and the roller is fixedly arranged at the upper end of the sliding sleeve by using an ultrasonic vibrator.
5. The arc additive manufacturing method with ultrasonic vibration and rolling characteristics along with welding according to claim 1, wherein the stirring pin is vertically mounted on a vibrator mounting sleeve by an ultrasonic vibrator, the vibrator mounting sleeve is vertically rotatably mounted on a sliding sleeve by a vibrator mounting sleeve vibration adjusting handle, and the sliding sleeve is horizontally slidably mounted on a holding frame;
the retainer is in a long strip shape with the same upper and lower widths, the sliding sleeve can be horizontally and slidably sleeved on the retainer, and the sliding sleeve is also rotatably connected with a bolt for fastening the sliding sleeve in a penetrating manner to fix the sliding sleeve;
the ultrasonic vibrator for the stirring needle is arranged on the vibrator installation sleeve through a vibration absorption spring.
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| CN113909678A (en) * | 2021-11-18 | 2022-01-11 | 哈焊国创(青岛)焊接工程创新中心有限公司 | Welding system for aluminum alloy laser welding and surface treatment method |
| CN114290668A (en) * | 2021-12-27 | 2022-04-08 | 南京航空航天大学 | Ultrasonic micro-rolling additive manufacturing and forming device and method for continuous fiber composite material |
| CN118060667A (en) * | 2022-11-24 | 2024-05-24 | 深圳先进技术研究院 | Arc additive manufacturing device and arc additive manufacturing method |
| CN116038349B (en) * | 2023-03-01 | 2024-07-02 | 四川航天长征装备制造有限公司 | Arc additive manufacturing rib wide-rib high-stability forming device and method |
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