CN114101855A - Electric arc additive manufacturing and testing method for duplex stainless steel - Google Patents
Electric arc additive manufacturing and testing method for duplex stainless steel Download PDFInfo
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- CN114101855A CN114101855A CN202111632211.3A CN202111632211A CN114101855A CN 114101855 A CN114101855 A CN 114101855A CN 202111632211 A CN202111632211 A CN 202111632211A CN 114101855 A CN114101855 A CN 114101855A
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- 238000012360 testing method Methods 0.000 title claims abstract description 27
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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
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
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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
- B23K9/042—Built-up welding on planar surfaces
-
- 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
- B23K9/32—Accessories
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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
本发明公开了一种双相不锈钢的电弧增材制造及测试方法，使用TIG焊枪作为增材制造过程中热源、WF‑007A型多功能送丝机以及KUKA机器人组成的增材制造实验平台；电弧增材制造熔丝采用直径为1.2 mm的ER2209双相不锈钢，焊枪采用直柄焊枪并且方向始终垂直于增材沉积方；送丝机采用脉冲送丝模式以减少残余应力的累积；TIG焊枪设定自左向右的加工路径，自左开始起弧加工进行单层沉积，到达右边后熄弧焊枪向上提高一定高度再起弧进行第二层的增材，如此往复实现单层多道的加工过程；调整焊枪的位置参数，本发明将焊道截面尺寸可以进行预测并可视化，有利于对大型构件的制造和修复进行工艺参数设计，减少再加工成本。
The invention discloses an electric arc additive manufacturing and testing method of duplex stainless steel. A TIG welding torch is used as a heat source in the additive manufacturing process, a WF-007A multifunctional wire feeder and a KUKA robot are used as an additive manufacturing experimental platform; The additive manufacturing fuse is made of ER2209 duplex stainless steel with a diameter of 1.2 mm, and the welding torch adopts a straight shank welding torch and the direction is always perpendicular to the additive deposition square; the wire feeder adopts the pulse wire feeding mode to reduce the accumulation of residual stress; TIG welding torch setting The processing path from left to right starts from the left to start the arc processing for single-layer deposition. After reaching the right, the arc-extinguishing torch is raised to a certain height, and then the arc is started to add materials for the second layer. In this way, the single-layer and multi-pass processing is realized. By adjusting the position parameters of the welding torch, the invention can predict and visualize the cross-sectional size of the welding bead, which is conducive to the design of process parameters for the manufacture and repair of large components, and reduces the reprocessing cost.
Description
The technical field is as follows:
the invention relates to the field of metal additive manufacturing of duplex stainless steel, in particular to an electric arc additive duplex stainless steel weld bead prediction and forming method.
Background art:
the duplex stainless steel has the characteristics of high strength of ferrite, good toughness and ductility of austenite and good corrosion resistance, so the duplex stainless steel is widely applied to the key fields of industry, ocean engineering, aerospace and the like; the duplex stainless steel has the yield strength which is more than twice that of the common austenitic stainless steel, has enough ductility and toughness required by forming, has excellent stress corrosion cracking resistance, and has higher stress corrosion cracking resistance than the austenitic stainless steel even with the lowest alloy content, especially in an environment containing chloride ions.
The Additive Manufacturing (AM) technology is a technology for manufacturing an entity zero by a method of scanning and accumulating three-dimensional graphic layered processing materials layer by layer through Computer Aided Design (CAD) design data, and various required complex parts can be obtained by performing rapid molding in various material forms based on the principle of the technology.
The metal additive manufacturing comprises two main types of powder and wire, and the Zhangjie of the Western-Ann transportation university uses self-made duplex stainless steel powder and carries out laser cladding experimental Laser Additive Manufacturing (LAM) technology on a 2205 duplex stainless steel substrate, so that damaged parts can be repaired, and the surface performance of the material can be enhanced; the defects are that the processing environment is strict, and the size of the part is limited; the Selective Laser Sintering (SLS) technology has high efficiency, short part construction time, low density and poor mechanical property; although the Selective Laser Melting (SLM) is suitable for processing high-precision parts, the method is complex in process parameters, high in cost, long in time consumption, easy to spheroidize, and further generates macrocracks due to porosity.
Common duplex stainless steel processing patents include the researches based on cold rolling or annealing and pickling processes of Yanglin and Hongxing iron and steel member limited companies of Beijing scientific and technology university, and the conventional metal processing method is not completely separated; the SLS and SLM additive manufacturing methods are not suitable for processing large parts and related patents are not seen to be applied to duplex stainless steel materials, since duplex stainless steel is widely applied to large components such as large-scale pressure vessels, ship storage bins, aerospace fuel tanks and the like, compared with other metal additive manufacturing methods, the duplex stainless steel electric arc additive manufacturing method has the advantages that electric arcs are used as energy carrying beams, heat input is high, forming speed is high, the method is suitable for low-cost, efficient and quick near-net forming of large-scale complex components, but has a plurality of factors influencing the quality of the welding bead and interaction, thereby meeting the requirements of manufacturing cost and reliability of the metal structure, has excellent prospect in the development direction of the manufacturing and repairing path of large mechanical workpieces, integrated special manufacturing and intelligent manufacturing, thus, the arc additive manufacturing technology has efficiency and cost advantages over other additive manufacturing technologies in the formation of large-size structural members.
Disclosure of Invention
The invention aims to provide a method for predicting and forming an electric arc additive duplex stainless steel weld bead, which takes the process parameters of a single-layer weld bead as input and the weld bead fusion width and surplus height as output and solves the problems of the prior duplex stainless steel that the selection of the process parameters is different in large parts and outdoor field repair technical paths which need to be customized.
The invention adopts the following technical scheme to realize the purpose:
the invention relates to an electric arc additive manufacturing and testing method of duplex stainless steel, which is characterized in that:
the use of the device: a TIG welding gun is used as a heat source in the additive manufacturing process, and an additive manufacturing experiment platform is composed of a WF-007A type multifunctional wire feeder and a KUKA robot; the electric arc additive manufacturing fuse wire is made of ER2209 duplex stainless steel with the diameter of 1.2 mm, a straight shank welding gun is adopted as a welding gun, and the direction of the welding gun is always vertical to an additive deposition direction; the wire feeder adopts a pulse wire feeding mode to reduce the accumulation of residual stress; setting a processing path from left to right by a TIG welding gun, starting arc striking from the left to perform single-layer deposition, raising the arc striking height upwards by an arc extinguishing welding gun after reaching the right, then striking the arc to perform second-layer material increase, and thus, repeatedly realizing a single-layer multi-channel processing process; adjusting position parameters of a welding gun, wherein the length of a tungsten wire of the TIG welding gun extending out of a nozzle is 3 mm-5 mm, the distance between a tungsten electrode and a processed substrate is kept 3 mm-4 mm, an included angle of 20-30 degrees is formed between the front end of the wire feeding and the horizontal direction, and the substrate is preheated for 10-15 seconds at 100 ℃ before processing;
the preparation method comprises the following specific steps:
1) preparing before welding:
before additive manufacturing, a substrate is polished by a polisher to expose metallic luster, then wiped by 75% absolute ethyl alcohol to remove surface oil stains and impurities, and a test is carried out within 2 hours of cleaning to avoid generation of new oxides and the like and dirt.
2) Building a test platform:
a substrate which is built up on a workbench is fixed by a clamp, the direction vertical to the substrate is taken as the advancing direction of electric arc additive manufacturing, a TIG welding gun moves from left to right in the horizontal direction, a straight shank welding gun is adopted, and the direction is always vertical to the additive deposition direction; the wire feeder adopts a pulse wire feeding mode;
3) recording and measuring the technological parameters of the single layer and single channel, and acquiring the corresponding fusion width and the corresponding extra height by using a three-dimensional scanner; based on the recorded parameter BP neural network structure, a topological structure of 3-12-1 is selected, Tansig is selected as an excitation function for a hidden layer, a Purelin function is selected for an output layer, the training times are set to be 1000, the learning rate is 0.1, and the expected error is
Substituting the parameter settings into MATLAB language programming to obtain a training result;
calculating the dimension of PSO according to the topological structure and parameter setting of the BP neural network
(ii) a The population number N is set between 10 and 50, and as an example, N =40 is selected; the initial weight and the final weight are respectively
，
(ii) a Total number of iterationsThe number G = 100; learning factor
=
=2；
Comparing the training and predicting results, and determining the optimal process parameters of 10L/min-15L/min of flow of shielding gas, 200 cm/min of wire feeding speed, 24 cm/min of welding speed and 160A of welding current through macroscopic observation.
Setting a processing path from left to right by using a TIG welding gun, starting arc starting from the left to perform single-layer deposition, extinguishing the arc spot welding gun after reaching the right, raising the height upwards, then performing second-layer material increase from right to left after arc starting, and thus repeatedly realizing a single-layer multi-channel processing process; wherein the length of a tungsten wire extending out of a nozzle of the TIG welding gun is 3 mm, the distance between a tungsten electrode and a processed substrate is kept at 3 mm, an included angle of 30 degrees is formed between the front end of the wire feeding and the horizontal direction, and the substrate is preheated for 15 seconds at 100 ℃ before processing.
4) Setting technological parameters:
adopting a TIG welding gun and a KUKA robot, setting the shielding gas as argon, wherein the flow of the shielding gas is 10-15L/min, the wire feeding speed is 200 cm/min, the welding speed is 24 cm/min and the welding current is 160A;
5) test specimens were prepared by arc additive manufacturing of the resulting components: and (3) taking out a 10 mm multiplied by 10 mm square sample for detecting the corrosion resistance, comparing the corrosion resistance with the data of a duplex stainless steel casting, polishing the sample by using 600, 1000, 1500, 2000 and 3000-mesh abrasive paper in sequence to ensure that the surface has no obvious crack defects, and then carrying out test observation on the fracture appearance and observation on the surface appearance after corrosion.
Furthermore, the chemical composition ratio of the ER2209 duplex stainless steel welding wire is that C is less than or equal to 0.03, Mn is less than or equal to 2.00, P is less than or equal to 0.03, S is less than or equal to 0.03, Si is less than or equal to 0.90, Ni is 7.50-9.50, Cr is 21.50-23.50, Mo is 2.50-3.50, and N is 0.08-0.20.
Furthermore, a TIG welding gun and a wire feeding nozzle are connected at the front end of the arm of the KUKA robot through an adjustable three-dimensional clamp in the process of electric arc additive manufacturing to form a complete electric arc additive manufacturing system.
Furthermore, the formation of the single-layer weld bead is the basis of the layer-by-layer accumulation formation of the electric arc additive manufacturing, and the weld bead formation is predicted by adopting a PSO-BP neural network.
Further, through 3D scanner survey get the three-dimensional appearance of welding bead, and survey the welding bead and melt width and extra height, the horizontal and vertical direction mechanical properties of the processing wall body of next survey, horizontal and vertical direction mechanical properties index has: tensile strength, yield strength and elongation.
Compared with the prior art, the invention has the beneficial effects that:
1. the welding bead prediction and forming method for manufacturing the duplex stainless steel by the electric arc additive manufacturing process can predict and visualize the cross section size of the welding bead, is beneficial to process parameter design for manufacturing and repairing large-scale components, and reduces the reprocessing cost.
2. According to the welding bead prediction and forming method for manufacturing the duplex stainless steel by the electric arc additive manufacturing, the collapse caused by the accumulation of residual stress can be effectively reduced by waiting the arc starting point of the welding gun and processing tracks in two directions.
3. The invention relates to a weld bead prediction and forming method for manufacturing duplex stainless steel by electric arc additive manufacturing, which can realize the application of duplex stainless steel in large-scale and integrated high-end parts and repair additive manufacturing.
4. The welding bead prediction and forming method for manufacturing the duplex stainless steel by the electric arc additive manufacturing has the advantages of simple process flow, capability of saving the duplex stainless steel in a large amount, low manufacturing cost, no obvious defects of the prepared metal component and good mechanical property.
Description of the drawings:
FIG. 1 is a schematic illustration of a three-dimensional scanning STL file for a duplex stainless steel arc additive manufacturing weld bead of the present invention;
FIG. 2 is a schematic diagram of point coordinates for a duplex stainless steel arc additive manufacturing weld bead of the present invention;
FIG. 3 is a plot of model fit samples of different functions of a cross section of a duplex stainless steel arc additive manufacturing weld bead of the present invention;
FIG. 4 is a graph of the error of the fit of the different functional models of the cross section of the duplex stainless steel arc additive manufacturing weld bead of the present invention;
FIG. 5 is a graph comparing the tensile curves of a duplex stainless steel arc additive manufactured workpiece of the present invention and a 2205 cast coupon;
fig. 6 is a potential comparison of corrosion resistance of a duplex stainless steel arc additive manufactured workpiece of the present invention and a 2205 cast sample.
The specific implementation mode is as follows:
the technical solution will be further explained in conjunction with the specific implementation of the present invention.
The invention relates to a double-phase stainless steel electric arc additive manufacturing process which comprises the following steps:
And 2, programming required deposited arc starting points and arc extinguishing points of each layer on the KUKA robot demonstrator.
And 3, the tungsten electrode of the TIG welding gun extends for 3 mm, the welding gun is always vertical to the processed surface, and the wire feeding nozzle is connected with the welding gun by using a wire feeding three-dimensional clamp and forms a 30-degree angle with the horizontal plane.
And 4, setting technological parameters including wire feeding speed of 200 cm/min, welding speed of 24 cm/min, welding current of 160A and shielding gas argon flow of 10L/min-15L/min.
And 5, calling an expert mode and an AUTO mode of the robot demonstrator based on the completely compiled code command, clicking an operation button, driving a welding gun to move by the front end of a robot arm, and feeding the wire into a molten pool by a wire feeder to be melted to form a layer of cladding layer combined with the surface of the substrate.
And 6, cutting the single-layer weld bead obtained by cladding by using a M340 wire-cut electric discharge machine of Suzhou New spark Co., Ltd, and observing the section by using an OPLENIC metallographic microscope.
And 7, coating a reflecting material on the surfaces of the substrate and the welding bead, and scanning and collecting the welding bead by using a national acute three-dimensional scanner produced by the national acute and Chinese electro-optical limited company of Fujian nations to form an STL file.
And 8, inputting MATLAB software to the three-dimensional topography acquired under different process parameters to obtain the average size of the section, and taking the top point, the left side and the right side of the section as coordinate points.
And 9, inputting the coordinates into a fitting module of MATLAB software, fitting a semicircular function model, a parabolic function model and a cosine function model, and calculating different model errors.
And step 10, collecting 87 groups of data of the different process parameters, taking the process parameters as input, taking the weld bead fusion width and the weld bead reinforcement height as output, and taking 72 groups of the data as a training set and 15 groups of the data as a test set in the BP neural network algorithm.
And step 11, performing weight and threshold value of particle swarm optimization error transmission by using the BP neural network algorithm, so that the optimal parameters can be found more quickly, and the BP neural network algorithm has the accurate generalization capability and convergence speed under more complicated working conditions.
And 12, inputting the two different algorithms in the step 10 and the step 1 into different process parameters of the test set and the test set to obtain weld bead weld width excess height data and carrying out experimental verification.
And step 13, based on the optimized technological parameters, adopting a single-channel cross machining path and direction, namely programming required deposition arc starting points and arc extinguishing points of each layer to be machined on the KUKA robot demonstrator, and raising the height of the big arm back to the set arc starting points to lift the welding gun for a certain height and corresponding machining thickness of each layer, wherein the welding gun is machined in a reciprocating mode according to the instruction of the demonstrator, and cladding and depositing materials layer by layer to obtain the expected duplex stainless steel geometric component.
And step 14, carrying out solution treatment on the wall body which is subjected to the duplex stainless steel arc additive manufacturing at 1050 ℃ for 2 hours in a heat treatment furnace.
The invention relates to an experimental substrate material of 2205 duplex stainless steel, the specification of which is 160 mm multiplied by 5 mm, an electric arc additive manufacturing fuse wire adopts ER2209 duplex stainless steel with the diameter of 1.2 mm, a single-channel multilayer electric arc additive manufacturing test is carried out on the duplex stainless steel plate with the thickness of 5 mm by adopting a direct current TIG process, the optimal process parameters are searched for in the process parameter exploration stage of the previous stage to obtain the optimal deposition layer, a TIG 250PAC/DC welding machine of RILAND (RILAND) company is selected as the experimental welding machine, the process parameters are used as input based on MATLB language programming and a three-dimensional scanner, the weld bead fusion width and the weld bead height are used as output, the prediction is carried out through a BP neural network algorithm and a PSO-BP neural network algorithm, the accuracy and the convergence rate are obviously improved, wherein the maximum absolute error is reduced from 0.2067 to 0.1162, the size parameters of the tensile sample are transversely and longitudinally sampled by a wire cutting machine to obtain tensile data in different directions, and the sampling of the workpiece is used for detecting the corrosion resistance and comparing the corrosion resistance with the performance of common 2205 duplex stainless steel castings.
The method mainly comprises the following steps:
1) preparing before welding:
before additive manufacturing, a substrate is polished by a polisher to expose metallic luster, then wiped by 75% absolute ethyl alcohol to remove surface oil stains and impurities, and a test is carried out within 2 hours of cleaning to avoid generation of new oxides and the like and dirt.
2) Building a test platform:
a substrate which is built up on a workbench is fixed by a clamp, the direction vertical to the substrate is taken as the advancing direction of electric arc additive manufacturing, a TIG welding gun moves from left to right in the horizontal direction, a straight shank welding gun is adopted, and the direction is always vertical to the additive deposition direction; the wire feeder adopts a pulse wire feeding mode, so that the accumulation of residual stress can be effectively reduced.
Recording the technological parameters of the single layer and the single channel, and acquiring the corresponding fusion width and the corresponding extra height by using a three-dimensional scanner; based on the recorded parameter BP neural network structure, a topological structure of 3-12-1 is selected, Tansig is selected as an excitation function for a hidden layer, a Purelin function is selected for an output layer, the training times are set to be 1000, the learning rate is 0.1, and the expected error is
And substituting the parameter settings into MATLAB language programming to obtain a training result.
According to the topology and parameter setting of the BP neural network,calculating dimensions of PSO
(ii) a The population number N is set between 10 and 50, and as an example, N =40 is selected; the initial weight and the final weight are respectively
，
(ii) a The total number of iterations is G = 100; learning factor
=
=2。
Comparing the training and predicting results, and determining the optimal process parameters of 10L/min-15L/min of flow of shielding gas, 200 cm/min of wire feeding speed, 24 cm/min of welding speed and 160A of welding current through macroscopic observation.
Setting a processing path from left to right by using a TIG welding gun, starting arc starting from the left to perform single-layer deposition, extinguishing the arc spot welding gun after reaching the right, raising the height upwards, then performing second-layer material increase from right to left after arc starting, and thus repeatedly realizing a single-layer multi-channel processing process; wherein the length of a tungsten wire extending out of a nozzle of the TIG welding gun is 3 mm, the distance between a tungsten electrode and a processed substrate is kept at 3 mm, an included angle of 30 degrees is formed between the front end of the wire feeding and the horizontal direction, and the substrate is preheated for 15 seconds at 100 ℃ before processing.
3) Setting technological parameters:
a TIG welding gun and a KUKA robot are adopted, argon is set as shielding gas, the flow of the shielding gas is 10L/min-15L/min, the wire feeding speed is 200 cm/min, the welding speed is 24 cm/min, and the welding current is 160A.
The method comprises the steps of preparing a test sample through a component obtained through electric arc additive manufacturing, taking out a 10 mm multiplied by 10 mm cube sample at the same time of sampling a tensile sample, detecting the corrosion resistance, comparing with data of a duplex stainless steel casting, polishing the sample by using 600, 1000, 1500, 2000 and 3000-mesh abrasive paper in sequence to enable the surface to have no obvious defects such as cracks and the like, and then testing and observing the fracture appearance and the surface appearance after corrosion.
Wherein fig. 3 is a plot of model fit samples of different functions of a cross section of a duplex stainless steel arc additive manufacturing weld bead of the present invention; FIG. 4 is a graph of the fitting error of different functional models of the cross section of a duplex stainless steel arc additive manufacturing weld bead of the present invention; FIG. 5 is a graph comparing the tensile curves of a duplex stainless steel arc additive manufactured workpiece of the present invention and a 2205 cast coupon; fig. 6 is a potential comparison of corrosion resistance of duplex stainless steel arc additive manufactured workpieces of the present invention versus 2205 cast specimens.
The above figures illustrate that the two-phase stainless steel electric arc additive manufacturing wall has smooth two side surfaces, high precision and no obvious defects; by sampling in the transverse and longitudinal directions, performing tensile mechanical test by using an E45.105 type microcomputer controlled electronic universal testing machine of Meitess Industrial systems (China) company at a tensile speed of 2 mm/min, respectively measuring transverse and longitudinal tensile strengths of 685.3 MPa and 805.7 MPa by tensile test, having anisotropy, ductile fracture in cross section, elongation after fracture of 24.79 percent and 28.57 percent, good corrosion resistance, and corrosion current density of 24.79 percent and 28.57 percent
The tensile strength of the cast 2205 duplex stainless steel is 622.72 MPa at 1050 ℃ after solution treatment, the elongation after fracture is 29.89 percent and the corrosion current density is
The performance is obviously improved; the components printed by a direct-reading spectrometer are as follows: 0.02 percent of C, 1.57 percent of Mn, 0.02 percent of P, 0.01 percent of S, 0.57 percent of Si, 8.90 percent of Ni, 23.10 percent of Cr, 3.06 percent of Mo and 0.18 percent of N.
The experimental data show that the arc additive manufacturing workpiece obtained by the method has good mechanical property and can actually meet service conditions.
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