CN114182246A - Method for producing free-formed part based on low-temperature supersonic spraying and application - Google Patents
Method for producing free-formed part based on low-temperature supersonic spraying and application Download PDFInfo
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
-
- 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
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
-
- 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
- B33Y80/00—Products made by additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64C—AEROPLANES; HELICOPTERS
- B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Aviation & Aerospace Engineering (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
The invention provides a method for producing a free-form part based on low-temperature supersonic spraying and application thereof. The method comprises the following steps: (1) spraying a release film layer: spraying a demoulding layer on the supporting surface by using a low-temperature supersonic spraying device; (2) planning a path: planning a spraying path; (3) manufacturing a component: spraying materials on the supporting surface layer by using a low-temperature supersonic spraying method and an edge compensation spraying process to form a component; (4) demolding: and putting the part and the supporting surface into a heating device, and melting the demolding layer to separate the part from the supporting surface. By the method, the die can be repeatedly used, and the production cost of the part is reduced.
Description
Technical Field
The invention relates to the technical field of supersonic spraying, in particular to a method for producing a free-form part based on low-temperature supersonic spraying and application thereof.
Background
Compared with additive manufacturing technologies such as high-speed oxygen fuel thermal spraying and direct metal laser sintering, the low-temperature supersonic spraying technology belongs to a low-temperature process, and the working temperature of the low-temperature supersonic spraying technology is lower than the melting point of a spraying material. The low-temperature supersonic spraying technology is more suitable for manufacturing parts with larger volume, because the technology has high forming efficiency and low working temperature, and the phase change can not occur during spraying, the porosity of the parts is greatly reduced, the material oxidation is reduced, and the problem of uneven crystallization in the parts is solved. However, with this technique, the distribution and velocity of the material particles at the nozzle outlet is not even, resulting in a distribution of particles on the substrate that is approximately gaussian. Referring to FIG. 1, many studies have shown that when using cryogenic supersonic spray techniques, such as axisymmetric Laval nozzles with higher scan speeds or fewer iterations, the coating profile may exhibit a symmetrical normal Gaussian distribution curve. In a normal gaussian distribution curve, μ is the center position of the peak top of the peak, which is also the mean value of the distribution curve, and σ is the standard deviation of the distribution curve. When the axisymmetric laval nozzle scans at a lower speed or repeats at a higher number of times, the coating will form a triangular profile, so that subsequent material particles are difficult to deposit. Referring to fig. 2, continuous spraying gradually changes the single pass coating profile from a thin coating with higher stacking efficiency at the beginning to a triangular coating with lower stacking efficiency. During the spraying process, the particle velocity in the center of the nozzle is generally higher than in the edge region. In addition, the number of particles deposited in the center of the track is larger than that at the edge, and the size of the particles is larger than that at the edge. Thus, the thickness in the middle increases significantly, causing the angle of incidence of the particles to decrease progressively beyond the centerline. When the low-temperature supersonic spraying technology is used, the material particles need to reach the critical speed to generate plastic deformation to form the coating, so the technology is sensitive to the spraying incident angle. An incidence angle of 90 degrees ensures that the velocity component normal to the deposition surface is maximized, thereby achieving maximum stack efficiency. Particles with a small incident angle are bounced and dissipated and cannot be deposited on the surface because the velocity component perpendicular to the deposition surface does not reach the critical velocity. Thus, the intermediate slowly rising coating profile is detrimental to the deposition of subsequent particles, especially particles outside the centerline, whose incidence angle decreases rapidly, resulting in a sharp decrease in stacking efficiency. Only the particles at the centre line gradually have a vertical velocity component above the critical velocity, and can continue to deposit on the surface, which further increases the difficulty of subsequent particle deposition, and finally the effective area in which particles can be deposited is also continuously reduced, so that a triangular monorail profile is formed.
Therefore, while cryogenic supersonic spray techniques are capable of rapidly forming three-dimensional volumes, their triangular, single-track profile has significant limitations for forming complex three-dimensional shapes, and their triangular, single-track profile makes it impossible to form three-dimensional shapes in a layer-by-layer stack-up fashion, as with other additive manufacturing techniques, such that this technique cannot be effectively applied to the manufacture of parts. Currently, in order to form a part using cryogenic supersonic spray techniques, a large amount of excess material must be sprayed and then the shape of the part cut by subtractive processing. Spraying a large amount of excess material can prolong the production time and waste the sprayed material, and subsequent material reduction machining processes, including wire-cut electrical discharge machining and milling, can change the characteristics of the surface of the component, such as oxidizing and roughening the surface, which in turn affects the performance of the component. Subsequent processing steps also increase production costs and limit the design of the part shape.
If a complex-shaped component is to be produced by cryogenic supersonic spray techniques without relying on subtractive machining, it is necessary to be able to spray upright thick walls and then form the complex three-dimensional shape by stacking layer by layer. At present, manufacturers use a triangular spraying process to spray vertical thick walls for layer-by-layer stacking. Referring to fig. 3, the process is to spray the current coating vertically on the inclined surface of the previous track by tilting the nozzle. However, with this process, a typical triangular monorail profile is first sprayed. As previously mentioned, the vertical velocity component of the material particles does not reach the critical velocity due to the decreasing angle of incidence, resulting in a typical triangular single-rail profile that affects the overall stacking efficiency. In addition, the high and sharp triangular monorail profile causes a velocity component of the material particles parallel to the deposition surface, thereby creating a pulling force on the deposition surface parallel to the deposition surface, which reduces the bond strength between the material particles and the previously sprayed coating, and the porosity increases, resulting in a reduced strength of the overall part. In view of the above, the "delta spray technique" is not a good solution for producing high quality parts by low temperature supersonic spray techniques.
At present, manufacturers also use low-temperature supersonic spraying technology to spray material on a mold to produce a component. However, since the sprayed material is tightly bonded to the mold base, the mold must be broken in the mold-releasing step to smoothly remove the part. This means that when this method is used, the mold is a disposable consumable and cannot be reused, which increases the production cost. Therefore, it is highly desirable to find a more convenient low-temperature supersonic spraying technique.
Disclosure of Invention
In order to solve the above technical problem, it is an object of the present invention to provide a method for producing a free-form part based on low-temperature supersonic spraying. The method can ensure that the die can be repeatedly used, and reduce the production cost of the part.
Another object of the invention is to provide the use of the method for producing a free-form part based on low-temperature supersonic spraying.
To achieve the above object, in one aspect, the present invention provides a method for producing a free-form part based on low-temperature supersonic spraying, comprising the steps of: (1) spraying a release film layer: spraying a demoulding layer on the supporting surface by using a low-temperature supersonic spraying device; (2) planning a path: planning a spraying path; (3) manufacturing a component: spraying materials on the supporting surface layer by using a low-temperature supersonic spraying method and an edge compensation spraying process, stacking the sections of all layers, and forming a component layer by layer; (4) demolding: and putting the part and the supporting surface into a heating device, and melting the demolding layer to separate the part from the supporting surface.
According to some embodiments of the invention, the low temperature supersonic spray device is selected from a low temperature supersonic spray gun; preferably, the spraying speed of the low-temperature supersonic spraying gun is Mach 1-4; further preferably, the working gas in the low-temperature supersonic spray gun is selected from one of air, nitrogen and inert gas; further preferably, the temperature of the working gas in the low-temperature supersonic spraying gun is lower than that of the release layer; further preferably, the temperature of the working gas in the low-temperature supersonic spraying gun is 180-1000 ℃; further preferably, the pressure of the working gas in the low-temperature supersonic spray gun is 5.5 to 55 bar.
According to some embodiments of the invention, the support surface is made of a hard material selected from one of a metal, a ceramic and a composite material.
According to some embodiments of the invention, the release layer is made of a material selected from one of a metal and a composite material.
According to some embodiments of the invention, the path of the spray is planned by software.
According to some embodiments of the present invention, the sprayed path is a path plan for planning additive manufacturing of the component by slicing a computer aided design file of the component to form a series of cross sections by using hierarchical slicing computer software, and generating control instructions for low-temperature supersonic spraying according to contour characteristics of the component by the software.
According to some embodiments of the invention, the material of the component is selected from one of metal, plastic, ceramic and composite material.
According to some embodiments of the invention, the component is free-form, having a non-fixed cross-section.
According to some embodiments of the invention, the edge compensation coating process can be used to compensate for differences in thickness between the middle and the edge of the coated coating profile, preferably using an inclined nozzle.
According to some embodiments of the invention, the parameters of the edge compensation spray process include: spraying incident angle, nozzle path deviation, nozzle layer retreating distance, nozzle scanning speed and path track;
preferably, the spraying incident angle is 30 degrees;
further preferably, the nozzle row path offset is from 1 to 5 mm;
further preferably, the nozzle recedes by a distance of 0.1 to 0.5 mm per layer;
further preferably, the nozzle scan speed is from 10 to 300 mm per second;
further preferably, the path trajectory includes: each layer consists of a middle first coating track, a left second coating track, and a right third coating track.
According to some embodiments of the invention, the heating device has a temperature above the melting point of the release layer and below the melting point of the part.
In another aspect, the invention provides the use of the above method for the manufacture of a component having a non-fixed cross-section.
The invention further describes the "edge compensation spraying process" as follows:
in order to apply cryogenic supersonic spraying techniques to produce high quality complex shaped parts, it is desirable to avoid deposition of material particles into the triangular track profile, which can lead to high porosity and low strength problems in the part. Many studies have shown that when using cryogenic supersonic spray techniques, such as axially symmetric laval nozzles with higher scan speeds or with fewer repeated scans, the coating profile can appear as a symmetrical normal gaussian distribution curve. Referring to fig. 1, in a normal gaussian distribution curve, μ is the center position of the peak top of the peak, i.e., the average value of the distribution curve, and σ is the standard deviation of the distribution curve. When the coating profile was approximately normal gaussian, 68% of the total particles were deposited in the region one standard deviation from the peak top left and right, i.e., it means that only 32% of the total particles were deposited in the region one standard deviation from the peak top. It can be seen that the deposited material particles are concentrated too much in the central region. If the component is to be produced in a layer-by-layer stack, complementary coatings must be applied to the edge regions on either side of the central region to produce a thick, upright wall for each layer of the stack. In the edge compensation spraying process, the spraying incidence angle of the Laval nozzle can change the symmetry of the track profile, so that the gravity center of the sprayed coating moves towards the incidence direction of particles. Therefore, by tilting the nozzle, the distribution of the deposited particles per coating can be made uniform.
Unlike the "triangular spray process" used by existing manufacturers, this spray process does not produce a triangular-like monorail profile prior to tilting the nozzle. In the "edge compensated spray process", the oblique spray is to compensate for the thickness difference between the middle and the edge of the coating profile. Referring to fig. 4, in the "edge compensated spray coating process", there are three main parameters for controlling the deposition profile: theta is a spraying incident angle so as to supplement particle deposits on the edge; s is the deviation of the nozzle line path, and the track width of the coating can be adjusted; d is the retreating distance of each layer of the nozzle, so that the spraying distance between the top end of the coating and the outlet of the nozzle can be ensured to be consistent in the spraying process. In addition to the three process parameters, the process is also matched with a suitable nozzle scanning speed to avoid the triangular coating profile, and the scanning speed is determined according to the material of the spraying material. In addition, when each layer is sprayed, the process needs to match the following spraying path tracks: referring to fig. 4, each layer is composed of a middle first coating track, a left second coating track, and a right third coating track. Before coating tracks on the left side and the right side are sprayed, a first coating track in the middle is controlled, and a track outline similar to a triangle is avoided in the middle. After the left and right coating tracks are sprayed, the current coating can form a plane before the next coating is sprayed, and the effective particle deposition area reaches the maximum.
Therefore, in the 'edge compensation spraying process', the next coating can be effectively deposited on the previous coating, the problem of edge thinning caused by too few incident angles is avoided, the low-temperature supersonic spraying technology can produce the component in a layer-by-layer stacking mode, a triangular coating profile which is harmful to the quality of the component cannot be generated in the process, material particles can be approximately vertically deposited on the previous coating, the stacking efficiency of the material particles is increased, the tension generated on the surface of the coating is reduced, the bonding strength between the material particles and the coating is increased, the porosity of the coating is reduced, and the strength of the whole component is improved. At the same time, the spraying process is also suitable for producing thick coatings, by first spraying the surface of a specific area in a vertical manner and then spraying the edge by means of an inclined nozzle, compensating for the difference in thickness of the edge. In addition, referring to fig. 5, the spraying process can also be applied to manufacture free-form parts, and the symmetry of the track profile is changed by tilting the nozzle and adjusting the deviation of the nozzle path, so that the gravity center of the sprayed coating moves towards the incident direction of the particles, and then the deposition direction of the next coating is changed, and the deposition direction of each coating is gradually tilted and is not perpendicular to the original spraying plane, thereby manufacturing the free-form shape.
The invention has the beneficial effects that:
the method of the invention can smoothly take out the part without damaging the mould during demoulding, and can not generate serious loss to the mould in the process. Therefore, the mould of the part can be reused, the disposable mould does not need to be produced in large quantity, and the mould production is saved.
The edge compensation spraying process provided by the invention has the advantages that the triangular coating outline which is harmful to the quality of the component can not appear, so that the stacking efficiency is increased, the porosity of the component is reduced, the strength of the component is increased, and the product quality is improved. In addition, the spraying process can produce the freely formed complex part shape on a mould or a supporting plane by controlling specific process parameters, so that the sprayed part has higher dimensional accuracy, the subsequent required material reducing processing procedures are reduced, and the product design freedom is greatly improved. The reduction of the production of the mold and the subsequent processing procedures, the increase of the stacking efficiency, the reduction of the waste materials, the reduction of the production cost of the component, the reduction of the time required by the production of the component and the competitive power of the component on the market.
Drawings
FIG. 1 is a schematic representation of a normal Gaussian distribution curve of a prior art coating profile.
FIG. 2 is a schematic diagram of particle impact of materials with high and low stack efficiency for a cryogenic supersonic spray technique.
FIG. 3 is a schematic view of a "triangular spraying process" in the prior art of low-temperature supersonic spraying.
FIG. 4 is a schematic diagram of three main control parameters of the "edge compensated spray process" process in the method of the present invention for producing a large number of free-form parts by cryogenic supersonic spray.
FIG. 5 is a schematic illustration of the fabrication of free-form parts by an "edge compensated spray process" in the method of the present invention for producing a plurality of free-form parts by cryogenic supersonic spray.
FIG. 6 is a flow chart of a method of the present invention for producing a plurality of free-form parts by cryogenic supersonic spraying.
Detailed Description
The present invention is further illustrated by the following specific examples so that those skilled in the art can better understand the present invention and can practice it, but the examples are not to be construed as limiting the present invention.
Referring to fig. 6, the present invention provides a method for producing a large number of free-form parts based on low temperature supersonic spray coating, comprising: step S101, spraying a layer of low-melting-point material on a mold or a supporting plane as a demolding layer by using a low-temperature supersonic spraying technology; step S102, slicing the computer aided design file of the component by utilizing layered slicing computer software to form a series of sections, generating a control instruction of low-temperature supersonic spraying according to the contour characteristics of the component by the software, and planning the path planning of the additive manufacturing of the component; step S103, spraying materials on a mold or a support plane layer by using a low-temperature supersonic spraying technology and an edge compensation spraying process, and stacking sections of all layers to form a part with a complex shape layer by layer; step S104, the part and the mould or the support are placed in a heating device, the demoulding layer is melted, and the part is separated from the mould or the support plane, so that the demoulding procedure is carried out.
Example 1
The present invention is illustrated below by making helmets on a mold as a specific example, and the method for producing a large number of free-form parts by low-temperature supersonic spraying of the present invention specifically comprises the following four steps:
the method comprises the following steps: spraying a low-melting-point demolding layer:
the mold is made of a hard material, typically selected from metal, ceramic or composite materials. The material of the helmet female die in this embodiment is die steel H11. Before spraying the low-melting-point demolding layer, a powder storage tank of a low-temperature supersonic spraying gun is filled with a low-melting-point material, wherein the low-melting-point material is generally selected from metal or composite materials. In the present embodiment, the low melting point material is a low melting point alloy containing tin (Sn). Then, a layer of low melting point material is sprayed on the mould to be used as a demoulding layer. In this embodiment, the working gas for spraying the low-melting-point release layer is dehumidified pressurized air, and the working temperature is 180 ℃ to 225 ℃ and the air pressure is 6 bar to 8 bar. In this embodiment, the release layer is no more than 1 mm thick to preserve details on the helmet mold. In this example, the spray incidence angle of the low-melting-point release layer was fixed at 90 degrees, i.e., a laval nozzle perpendicular to the mold surface; the nozzle line offset is 1 to 5 mm, the nozzle scanning speed is 10 to 300 mm per second, the powder feed rate is fixed at 12 to 25 g per minute, and the distance between the nozzle and the mold surface is 10 to 25 mm. The low melting point material needs to uniformly cover the mold surface or support plane to ensure that the mold surface or support plane does not come into direct contact with the part material as the part is sprayed.
Step two: the process of planning the spraying path through software:
after the demolding layer is sprayed, a computer aided design file of the part is sliced by using layered slicing computer software to form a series of sections, and control instructions of low-temperature supersonic spraying are generated according to the contour characteristics of the part by the software to plan the path of additive manufacturing of the part. In this embodiment, the CAD file of the helmet is an STL file. Because the helmet and the concave die thereof are approximately in the shape of a hemisphere rather than a plane, a spraying path of low-temperature supersonic spraying must be accurately planned by means of computer software, so that the helmet can form a required shape on the concave die in a mode of stacking coatings of all layers, and the thickness difference of each coating cannot occur in the process.
Step three: process for manufacturing a part by an "edge compensation spray process":
after step two, the process of manufacturing the component can be started. The powder reservoir of the cryogenic supersonic spray gun is filled with the part material, which is typically selected to be metal, plastic or composite, prior to spraying the part material. In this embodiment, the component material is an aluminum alloy, which comprises aluminum, magnesium, silicon and copper. Then, using low-temperature supersonic spraying technology, spraying materials layer by layer on a mould or a support plane by using an edge compensation spraying process, and stacking the sections of all layers to form a part with a complex shape layer by layer. In the edge compensation spraying process, the spraying incidence angle of the Laval nozzle can change the symmetry of the track profile, so that the gravity center of the sprayed coating moves towards the incidence direction of particles. Therefore, by tilting the nozzle to compensate for the difference in thickness between the middle and the edge of the coating profile, the deposited particles of each coating can be uniformly distributed, the next coating can be effectively deposited on the previous coating without the problem of edge thinning caused by too few incident angles, thus enabling the cryogenic supersonic spray technique to produce parts in a layer-by-layer stack. In the "edge compensated coating process", apart from controlling the incident angle of the coating, attention must be paid to the deviation of the nozzle path, the retreat distance of each layer of the nozzle, the scanning speed of the nozzle and the path trajectory so as to coat the coating with an average thickness and stack the coating layer by layer.
In the present embodiment, the working gas for spraying the helmet material is dehumidified pressurized air, the working temperature is 450 to 500 degrees celsius, and the air pressure is 31 to 35 bar. In this embodiment, the path trajectory of each layer is as follows: firstly, spraying a large area on the surface of a helmet female die at a 90-degree spraying incident angle, namely a Laval nozzle is vertical to the surface of the die, wherein the line path deviation of the nozzle is 1-5 mm, the nozzle scanning speed is 10-200 mm per second, the powder feeding amount is 12-25 g per minute, and the distance between the nozzle and the surface of the die is 10-25 mm; then, the edge of the coating is sprayed by an inclined nozzle to compensate the thickness difference of the coating edge, wherein the spraying incident angle is fixed at 30 degrees, the line path deviation of the nozzle is fixed at 2 mm, the nozzle scanning speed is 10-200 mm per second, the powder feeding amount is 12-50 g per minute, and the distance between the nozzle and the surface of the coating edge is 10-40 mm; and then, after the single-layer spraying is finished, moving the nozzle backwards, and continuing to spray the next layer of coating until the retreat distance of the whole nozzle reaches 8 mm, wherein the retreat distance of each layer of the middle nozzle is fixed to be 0.1 mm. In this example, the nozzle travel offset was fixed at 2 mm and the nozzle retreat distance was fixed at 0.1 mm for each layer when compensating for the coating edge since the two standard deviations 2 σ of the gaussian profile were measured to be 2 mm and the center peak height was 0.1 mm after a single pass of coating.
Step four: and (3) demolding:
and after the third step, forming the part on the mold or the supporting plane. The support plane is placed into a heating device together with the part, and the part is subjected to a part demolding process. The heating device is higher than the melting point of the low-melting-point material of the demoulding layer and lower than the melting point of the spraying material of the part. Since the high temperature environment of the heating device can simultaneously heat treat the parts, and the mechanical properties of the parts can be changed, the temperature and the heating time of the heating device need to be controlled at proper levels so as to smoothly demould the parts without causing negative influence on the mechanical properties of the parts. In this example, in order to melt the release layer formed of the low melting point alloy, the helmet was smoothly taken out from the mold, and the heating device temperature was set to 350 ℃ to 450 ℃ for 4 to 10 minutes. After heating, it is desirable to remove the part from the mold or support plane as quickly as possible while the release layer is still in a liquid state.
The embodiment of the invention achieves the following beneficial technical effects:
the application of the demoulding layer is benefited, so that the part can be smoothly taken out without damaging the mould during demoulding, and the mould is not seriously worn in the process. Therefore, the mold of the helmet can be repeatedly used, a large amount of disposable molds are not needed, and the mold production is saved. The edge compensation spraying process provided by the invention has the advantages that the triangular coating profile which is harmful to the quality of the part can not appear, so that the stacking efficiency is increased, the porosity of the part is reduced, the strength of the helmet is increased, and the product quality of the helmet is improved. In addition, the helmet shape can be directly sprayed on the die by controlling specific process parameters, so that the sprayed helmet has higher dimensional accuracy, the subsequent required material reduction processing procedures are reduced, and the design freedom of the helmet is greatly improved. The reduction of the production of the mould and the subsequent processing procedures, the increase of the stacking efficiency, the reduction of the waste materials, the reduction of the production cost of the helmet, the reduction of the time required by the helmet production and the competitive power of the helmet on the market.
The above-mentioned embodiments are merely preferred embodiments for fully illustrating the present invention, and the scope of the present invention is not limited thereto. The equivalent substitution or change made by the technical personnel in the technical field on the basis of the invention is all within the protection scope of the invention. The protection scope of the invention is subject to the claims.
Claims (10)
1. A method for producing a free-form part based on low temperature supersonic spraying, comprising the steps of:
(1) spraying a release film layer: spraying a demoulding layer on the supporting surface by using a low-temperature supersonic spraying device;
(2) planning a path: planning a spraying path;
(3) manufacturing a component: spraying materials on the supporting surface layer by using a low-temperature supersonic spraying method and an edge compensation spraying process to form a component;
(4) demolding: and putting the part and the supporting surface into a heating device, and melting the demolding layer to separate the part from the supporting surface.
2. The method of claim 1, wherein the cryogenic supersonic spray device is selected from a cryogenic supersonic spray gun;
preferably, the spraying speed of the low-temperature supersonic spraying gun is Mach 1-4;
further preferably, the working gas in the low-temperature supersonic spray gun is selected from one of air, nitrogen and inert gas;
further preferably, the temperature of the working gas in the low-temperature supersonic spraying gun is lower than that of the release layer;
further preferably, the temperature of the working gas in the low-temperature supersonic spraying gun is 180-1000 ℃;
further preferably, the pressure of the working gas in the low-temperature supersonic spray gun is 5.5 to 55 bar.
3. The method of claim 1 or 2, wherein the material of the support surface is selected from one of a metal, a ceramic and a composite material.
4. The method of claim 1, wherein the release layer is made of a material selected from one of a metal and a composite material.
5. The method of claim 1, wherein the path of the spray is planned by software.
6. The method according to any one of claims 1-5, wherein the material of the component is selected from one of metal, plastic, ceramic and composite material.
7. A method according to claim 1, characterized in that the edge compensation coating process can be used to compensate for differences in thickness between the middle and the edge of the coating profile being coated, preferably with an inclined nozzle.
8. The method of any of claims 1-7, wherein the parameters of the edge compensation spray process include: spraying incident angle, nozzle path deviation, nozzle layer retreating distance, nozzle scanning speed and path track;
preferably, the spraying incident angle is 30 degrees;
further preferably, the nozzle row path offset is from 1 to 5 mm;
further preferably, the nozzle recedes by a distance of 0.1 to 0.5 mm per layer;
further preferably, the nozzle scan speed is from 10 to 300 mm per second;
further preferably, the path trajectory includes: each layer consists of a middle first coating track, a left second coating track, and a right third coating track.
9. The method of claim 1 wherein the heating device is at a temperature above the melting point of the release layer and below the melting point of the part.
10. Use of a method according to any one of claims 1 to 9 for the preparation of a component having a non-fixed cross-section.
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