CN114951958A - High-strength aluminum alloy powder core wire material stirring friction additive manufacturing system and method - Google Patents
High-strength aluminum alloy powder core wire material stirring friction additive manufacturing system and method Download PDFInfo
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- CN114951958A CN114951958A CN202210725989.7A CN202210725989A CN114951958A CN 114951958 A CN114951958 A CN 114951958A CN 202210725989 A CN202210725989 A CN 202210725989A CN 114951958 A CN114951958 A CN 114951958A
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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
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/1215—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding for other purposes than joining, e.g. built-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/50—Means for feeding of material, e.g. heads
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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
- B23K20/26—Auxiliary equipment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/10—Pre-treatment
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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
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Abstract
The invention belongs to the field of friction stir additive manufacturing, and particularly discloses a high-strength aluminum alloy powder core wire material friction stir additive manufacturing system and a method, wherein the system comprises a friction head, the friction head comprises a heater, a hammer ring and a friction ring which are sequentially sleeved from inside to outside: the heater is used for preheating the powder core wire fed into the middle part of the friction head, so that the powder core wire reaches the lower plate after being softened; the hammer ring can vibrate up and down and is used for fixing and extruding the powder core wires on the lower plate in real time; the friction ring can rotate and is used for generating shearing force to the powder core wires on the lower plate to realize solid phase deposition. In the stirring friction additive manufacturing process, the wire is hammered and rubbed, so that the full solid-state forming of the component is realized, the problem of defects such as air holes, cracks and the like in the melting high-strength aluminum alloy additive manufacturing process is solved, and crystal grains are refined; meanwhile, the problems that continuous and stable additive manufacturing cannot be realized, powder is easy to oxidize, space is restricted and the like in the conventional stirring friction additive manufacturing method are solved.
Description
Technical Field
The invention belongs to the field of friction stir additive manufacturing, and particularly relates to a friction stir additive manufacturing system and method for high-strength aluminum alloy powder core wires.
Background
The aluminum alloy has low density, good electrical conductivity, thermal conductivity and ductility, and can be widely applied to the fields of aerospace, automobiles, ships, mechanical manufacturing and the like. High strength aluminum alloys are widely used in aerospace due to their high strength and ease of processing.
Aluminum alloy melting additive manufacturing technologies comprise laser additive manufacturing, electron beam additive manufacturing, electric arc additive manufacturing and the like, the forming methods all have high-energy heat sources, and materials undergo melting and solidification processes in the forming process. Due to the nature of the high strength aluminum alloy itself, when melting an additive manufactured aluminum alloy member, the following problems are likely to occur, deteriorating the quality of the additive manufactured aluminum alloy member:
(1) blowholes are prone to occur in melt additive manufacturing aluminum alloy components. Because the solubility of hydrogen atoms in solid pure aluminum is only about 5 percent of that of liquid pure aluminum, the hydrogen atoms are separated out from the solid in the additive manufacturing process to form hydrogen bubbles in the liquid, but the cooling speed of the aluminum alloy is too high, and the bubbles cannot be discharged in time, so that air holes are formed. Meanwhile, high-strength aluminum alloys, such as 7-series aluminum alloys, contain elements such as Mg and Zn, which increase the partial pressure of hydrogen atoms, so that the hydrogen atoms move to a liquid state to form bubbles.
(2) Cracks are prone to occur in melting additive manufactured aluminium alloy components. High-strength aluminum alloys, such as 7-series aluminum alloys, have a large solidification range and a brittle temperature range, and meanwhile, the thermal contraction coefficients of a solid phase and a liquid phase are different, so that the solid phase contracts at a higher speed, but the solidification and cooling speeds of the aluminum alloys are too high, the hot cracking tendency in the aluminum alloys is increased, and cracks are easy to exist in the melting and additive manufacturing process of the aluminum alloys.
(3) Coarse grains can occur in the melting additive manufacturing of aluminum alloy components. In the method of melt additive manufacturing, the aluminum alloy inevitably undergoes a process of melt solidification, and the resulting bulk metal exhibits coarse grains in the as-cast state.
As described above, when manufacturing a high-strength aluminum alloy component, the melting additive manufacturing technology inevitably undergoes a melting solidification process, and is prone to generate pores, cracks and coarse grains, and is generally solved by adopting a process optimization or wire optimization manner. However, once the problems of parameter fluctuation and the like occur in the manufacturing process, defects can occur, and potential safety hazards exist.
Friction stir welding, as a novel solid phase welding technique, can avoid the defects of air holes, inclusions, cracks and the like which are common in the traditional fusion welding, and is widely applied to the high-quality welding of various metals at present. With the rapid development of additive manufacturing technology, friction stir additive manufacturing technology based on friction stir lap welding principle is receiving more and more attention. For example:
patent 201710606621.8 proposes a static shoulder device for static shoulder friction stir welding and a material increase manufacturing method, which solves the problem of premature breakage and failure of a stirring pin caused by overlong stirring head, large eccentricity and friction with the inner wall of the static shoulder; the problem of clamping difficulty caused by narrow space of the static shaft shoulder is solved, and zero-allowance near-net-shape friction stir additive manufacturing is realized. However, the friction stir additive manufacturing is still realized by adding the plates layer by layer, and this way cannot realize a stable and continuous friction stir additive manufacturing process, and cannot solve the problem of residual amount, which causes waste.
Patent 201810229291.X proposes a powder-feeding type friction stir additive manufacturing machine, which can solve the problem of continuous wire material friction stir additive manufacturing by using discrete powder as a raw material, but the powder is easy to form more oxides, the quality of the formed component is unstable, and the powder such as magnesium powder is easy to explode when being contacted with air, so that the storage cost of the powder raw material is high.
Patent 201711019260.3 proposes a method for additive manufacturing of consumable friction stir tools, which uses consumable materials as friction stir tools and adopts a friction stir welding method to make the materials of the consumable friction stir tools solid-phase build up layer by layer on the surface of a substrate, thereby preparing the required metal materials. Has the advantages of low cost, high forming speed, short preparation time and the like. However, the friction tool is replaced at intervals, continuous additive manufacturing cannot be achieved, and the formed component cannot ensure stable quality.
Therefore, the existing friction stir additive manufacturing has different problems, and the plate feeding type friction stir additive manufacturing has the problems of uneven structure between the upper layer and the lower layer, plate waste and the like; the feeding type stirring friction additive manufacturing is easy to oxidize raw materials, so that the quality of a component is poor; the loss-type friction stir additive manufacturing is limited by the diameter of the bar, and the bar needs to be replaced, limiting efficiency.
Disclosure of Invention
Aiming at the defects or improvement requirements of the prior art, the invention provides a high-strength aluminum alloy powder core wire material stirring friction additive manufacturing system and method, and aims to realize stable and continuous high-strength aluminum alloy additive manufacturing and reduce the problems of air holes, cracks and large crystal grains in aluminum alloy.
To achieve the above object, according to an aspect of the present invention, there is provided a high strength aluminum alloy powder core wire material stirring friction additive manufacturing system, including a friction head, the friction head including a heater, a hammer ring and a friction ring, which are sequentially sleeved from inside to outside, wherein:
the heater is used for preheating the powder core wires fed into the middle part of the friction head, so that the powder core wires reach the lower plate after being softened; the hammer ring can vibrate up and down and is used for fixing and extruding the powder core wires on the lower plate in real time; the friction ring can rotate and is used for generating shearing force on the powder core wires on the lower plate to realize solid-phase deposition.
As further preferred, still include the silk material processing subassembly, this silk material processing subassembly is including the powder core silk material make-up machine, powder feeder, roll and the reducing mill that set gradually, wherein:
the powder core wire forming machine is used for processing the flat aluminum strip into a U-shaped aluminum strip; the powder feeder is used for adding the blended alloy powder into the U-shaped aluminum strip; the roller is used for closing the U-shaped aluminum strip added with the alloy powder to form an initial powder core wire with a fixed diameter; the reducing mill is used for reducing the initial powder core wire to a required diameter to form the powder core wire which can be sent into a friction head.
More preferably, the diameter of the friction ring is 3-4 times of that of the powder core wire.
Preferably, the heater is a resistance heater, the hammer ring is a concentric steel ring, and the friction ring is made of hot-work die steel.
Preferably, the friction ring further comprises a control assembly, the control assembly comprises a control mechanism, a driving mechanism and a robot, the control mechanism controls the spatial displacement motion of the friction head through the robot, and meanwhile, the control mechanism controls the friction ring to rotate as required through the driving mechanism.
According to another aspect of the invention, a friction stir additive manufacturing method for a high-strength aluminum alloy powder core wire is provided, which is realized by adopting the system, and comprises the following steps:
feeding the cored wire into a friction head, and coaxially feeding the cored wire at a fixed speed; meanwhile, the friction head downwards extrudes the lower plate, moves according to a preset track, and forms layer by layer until the additive manufacturing of the aluminum alloy is completed; specifically, the lower plate refers to the substrate when the first layer is formed, and the lower plate refers to the upper layer of formed metal later;
during the moving process of the friction head: preheating the powder core wire by a heater, softening the powder core wire and fixing the powder core wire on a lower plate; the powder core wire is driven by the friction head to move to bend and is hammered and extruded by the hammer ring which vibrates up and down; meanwhile, the friction ring rotates to generate shearing force on the powder core wires, and the friction force can be generated on the powder core wires on the lower plate due to the integral movement of the friction head; under the combined action of a plurality of forces, plasticizing deposition is generated between the powder core wire and the lower plate, and dynamic recrystallization is formed.
Further preferably, the friction head presses the lower plate downward to a depth of 10% to 15% of the diameter of the powder core wire, and then the friction head starts moving.
More preferably, the temperature of the heater is 250-350 ℃, the vibration frequency of the hammer ring is 15-25 Hz, and the rotation speed of the friction ring is 1500-2000 r/min.
More preferably, the rubbing head is moved at a speed of 100 to 250 mm/min.
Further preferably, the preparation method of the powder core wire material is as follows: determining the composition of the cored wire and determining the diameter of the cored wire according to the single-pass width of the member; adding the prepared alloy powder into the U-shaped aluminum strip through the powder feeding machine, closing the U-shaped aluminum strip added with the alloy powder through the roller, and further processing the aluminum wire to the required diameter through the reducing mill.
Generally, compared with the prior art, the above technical solution conceived by the present invention mainly has the following technical advantages:
1. according to the invention, through the design of the friction head, in the process of manufacturing the stirring friction additive, the wire can be hammered and rubbed in real time, so that the full solid-state forming of the member is realized, the defect that the conventional high-strength aluminum alloy is easy to generate pores and cracks is overcome, and meanwhile, the crystal grains can be refined through stirring friction. Compared with the prior art, the friction stir additive manufacturing method provided by the invention has the advantages that the frequent addition of plates or the replacement of friction heads is not needed, and the stable and continuous aluminum alloy friction stir additive manufacturing is realized.
2. In the additive manufacturing process, the friction ring always rotates to generate a shearing force on the powder core wire in real time, so that the component is always in a dynamic recrystallization state in the plastic forming process, and originally coarse and uneven crystal grains are crushed and recrystallized under the action of violent mechanical stirring to form uniform and fine isometric crystals, thereby effectively refining the crystal grains, improving the microstructure of the component and improving the performance of the component.
3. The liquid phase is inevitably generated in the melting high-strength aluminum alloy additive manufacturing process, but the stirring friction additive manufacturing process is all solid, and the generation of air holes caused by the difference of the solubility of hydrogen atoms in the solid phase and the liquid phase is avoided.
4. Because the manufacturing process is all solid, the coefficient of thermal contraction of the component in the forming process can not generate large change, and cracks effectively avoided in the melting and solidifying process are not generated in the additive manufacturing process. Meanwhile, the friction head has the effects of extrusion force, shearing force and friction force, and cracks in the component are greatly reduced.
5. The invention obtains the powder core wire material by processing the wire material processing assembly, and combines the manufacturing of the powder core wire material and the friction stir material increase manufacturing together; the aluminum strip wraps the alloy powder, so that the aluminum strip can be deposited simultaneously during additive manufacturing, and the problems that the powder is easy to oxidize and the like are solved.
6. When the friction head is pressed down by 10% -15%, the friction head moves, so that the original interface (wire) bends towards the lower plate (substrate or accumulated metal) and extends into the lower plate to form interface migration. If the extrusion amount is too small, interface migration cannot occur, and additive manufacturing cannot be realized; if the extrusion amount is too large, interface migration occurs at the advancing end (i.e. the end in the advancing direction of the friction ring, from which the wire enters) and the returning end, and the medicinal wires cannot be fully mixed; when the extrusion is carried out for 10% -15%, only the return end generates interface migration, and the requirement of additive manufacturing is met.
Drawings
FIG. 1 is a schematic structural diagram of a friction stir additive manufacturing system for high-strength aluminum alloy powder core wires according to an embodiment of the present invention;
FIG. 2 is a cross-sectional view of a friction head according to an embodiment of the present invention;
FIG. 3 is a schematic flow chart of a friction stir additive manufacturing method for high-strength aluminum alloy powder core wires according to an embodiment of the invention.
The same reference numbers will be used throughout the drawings to refer to the same or like elements or structures, wherein: 1-forming machine, 2-powder feeder, 3-roller, 4-reducing mill, 5-control mechanism, 6-robot, 7-driving mechanism, 8-friction head, 9-cored wire, 10-heater, 11-hammer ring and 12-friction ring.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
The high-strength aluminum alloy powder core wire material stirring friction additive manufacturing system provided by the embodiment of the invention comprises a wire material processing assembly, a control assembly and a friction head 8, as shown in figure 1.
The silk material processing subassembly includes make-up machine 1, powder feeder 2, roll 3 and reducing mill 4, wherein:
and the forming machine 1 is positioned at the beginning of the system and used for processing the flat aluminum strip into a U-shaped aluminum strip, so that alloy powder can be conveniently added into the powder feeder 2 in the subsequent process.
And the powder feeder 2 is positioned between the forming machine 1 and the roller 3 and used for adding the blended alloy powder into the U-shaped aluminum strip.
And the roller 3 is connected with the powder feeder 2 and is used for closing the U-shaped aluminum strip added with the alloy powder to form a powder core wire with a fixed diameter.
And the reducing mill 4 is connected with the roller 3 and is used for processing the powder core wire with a fixed diameter into a required diameter, the reducing mill is generally more than one, and in order to achieve the required diameter and ensure the quality of the powder core wire, the powder core wire 9 finally sent to the friction head 8 is generally formed through multiple times of reducing.
The control assembly comprises a control mechanism 5, a robot 6 and a drive mechanism 7, wherein:
and the control mechanism 5 is connected with the robot 6 and used for generating a robot motion instruction according to a robot control code, sending the robot motion instruction to the robot and controlling the spatial displacement motion of the friction head.
Specifically, a stacking path file during friction stir additive manufacturing is generated in a robot motion planning software package, and the control code includes spatial displacement path information of the 6 th shaft end of the robot 6 and speed information during movement on each path.
And the driving mechanism 7 is connected with the control mechanism 5 and the friction head 8 and is used for controlling the friction head to rotate as required according to the processing parameters transmitted by the control mechanism and setting the rotating speed of the friction ring and the moving speed of the friction head.
And the robot 6 is connected with the friction head 8 and is used for controlling the friction head 8 to perform machining operation according to the motion instruction.
And the friction head 8 is connected with the driving mechanism 7, is positioned at the terminal of the system and is used for realizing friction stir additive manufacturing. As shown in fig. 2, the friction head includes a heater 10, a hammer ring 11, and a friction ring 13, wherein:
a heater 10, which is a resistance heater and mainly comprises graphite, is positioned at the innermost layer of the friction head; used for preheating the powder core wire and providing a part of energy.
The hammer ring 11 is a steel concentric ring which can realize vibration hammering and vibrates up and down according to a certain frequency and is positioned on the second layer of the friction head and used for fixing the powder core wires and providing a downward extrusion force.
And the friction ring 12 is positioned on the outermost layer of the friction head, is made of hot-work die steel and is used for realizing the solid-phase deposition of the powder core wire.
Preferably, the diameter of the friction head (namely the diameter of the friction ring) is 3-4 times of the diameter of the powder core wire.
A friction stir additive manufacturing method of a high-strength aluminum alloy powder core wire material is shown in figure 3 and comprises the following steps:
the first step is as follows: determining the components of the cored wires, determining the diameters of the cored wires according to the single-pass width of the component, adding alloy powder in a prepared proportion into an aluminum strip through a powder feeder, and processing the aluminum wire to the required diameter through a reducing mill.
Specifically, the manufacturing method of the powder core wire comprises the following steps: forming the flat aluminum strip into a U shape by a forming machine, adding alloy powder such as 7-series aluminum alloy by a powder feeder, and adding Zn powder, Al-Mg powder and electrolytic copper powder in proportion to introduce required elements into the aluminum alloy; then the U-shaped aluminum strip is closed by a forming machine and then passes through a reducing mill to obtain the required diameter.
The second step is that: determining the material of a friction ring according to the components of the cored wire, determining the diameter of a friction head according to the diameter of the cored wire, processing to obtain the friction head, and mounting the friction head on a driving mechanism;
the third step: generating a robot control code according to the stacking path of the stirring friction additive manufacturing, and sending the robot control code to the control system;
the robot control code can control the robot to move at a speed of 100-250 mm/min on a metal stacking path, so that the friction head driven by the robot can also perform friction stir material increase manufacturing at a speed of 100-250 mm/min;
the fourth step: the control mechanism generates a robot motion instruction according to the robot control code;
the fifth step: the following parameters are preset in the control mechanism: the temperature of the heater is 300 ℃, the vibration frequency of the hammer ring is 15-25 Hz, and the rotation speed of the friction ring is 1500-2000 r/min.
And a sixth step: the control mechanism sends a processing parameter instruction to the driving mechanism, and the powder core wire is sent into the friction head at a fixed speed; the friction ring starts to rotate and maintains the set rotational speed. When the friction head presses the powder core wire down by 10% -15%, the driving mechanism starts to drive the friction head to move according to a set track, and additive manufacturing of a layer of component is completed.
Specifically, the physical mechanism of friction stir additive manufacturing is as follows:
after the powder core aluminum wire is processed, the powder core aluminum wire is sent into a friction head through a guide wheel, and coaxial wire feeding is carried out at a fixed speed. When the powder core aluminum wire enters the friction head, the resistance heater starts to work to preheat the powder core aluminum wire so that the aluminum wire is softened and can be fixed on the lower plate; the lower plate is in particular a substrate or a formed additive manufacturing component.
The robot moves according to a designed track, the aluminum wire is bent under the drive of the robot and is fixed by the hammer ring, the friction head extrudes 10% -15% downwards to give downward pressure to the cored wire, then the height of the friction head is fixed, the friction head starts to move forwards under the drive of the driving mechanism, and when the friction head moves, the friction head generates further friction force opposite to the moving direction to the aluminum wire.
In the moving process of the robot, the hammer ring vibrates and hammers the powder core wire material at a fixed frequency all the time; meanwhile, the friction ring rotates at a fixed rotating speed, and the rotation of the friction ring generates a shearing force on the aluminum wire and an extrusion force of the friction head to jointly generate a friction heat effect.
From the above, in the friction stir additive manufacturing process, the heater gives an initial amount of heat to the powder core wire; the whole friction head, particularly the hammer ring, can provide extrusion force for the powder core wire; the friction ring can generate shearing force on the wire when rotating; when the whole friction head moves, friction force is generated on the wire; these factors work together to create a plasticized deposit between the cored aluminum wire and the additive manufactured component, and under the combined action of these forces, a dynamic recrystallization is formed such that:
(1) the friction stir additive manufacturing process is all solid, a liquid phase is inevitably generated in the melting high-strength aluminum alloy additive manufacturing process, and air holes cannot be generated due to the fact that the hydrogen atoms are different in solubility in the solid phase and the liquid phase.
(2) Meanwhile, because the aluminum alloy is all solid, the heat shrinkage rate of the aluminum alloy is basically not changed, and the aluminum alloy has the effects of extrusion force, shearing force and friction force, so that the occurrence of cracks in the component is greatly reduced.
(3) In the whole additive manufacturing process, the aluminum alloy is always in a dynamic recrystallization process, and originally thick and uneven crystal grains are crushed and recrystallized under the action of violent mechanical stirring to form even and fine isometric crystals, so that the microstructure of the material is improved, and the performance of the material is improved.
The following are specific examples:
example 1
In the embodiment, the prepared wire is an ER2319 aluminum alloy welding wire, the used substrate is a 2219 aluminum alloy substrate, and alloy powder is prepared according to a certain proportion and used for adding various required elements into the powder core wire.
Specifically, the compositions of the cored wires after the addition are shown in Table 1:
TABLE 1 composition of powder core wire
| Element(s) | Al | Cu | Mn | Fe | Ti | Zr | Mg | Si | V |
| ER2319 aluminum alloy welding wire | Bal. | 6.06 | 0.31 | 0.16 | 0.12 | 0.15 | 0.09 | 0.19 | 0.06 |
| 2219 aluminum alloy substrate | Bal. | 5.8-6.8 | 0.2-0.4 | ≤0.3 | ≤0.3 | 0.1-0.25 | ≤0.2 | ≤0.2 | 0.1-0.15 |
In this embodiment, the diameter of the friction head is 5mm, and the material of the friction ring is H13 steel. The diameter of the aluminum wire processed by the powder feeder is 5 mm; the closed aluminum wire processed by the roller 3 can be reduced for a plurality of times to reach the required diameter of 1.2 mm.
In the additive manufacturing process, the rotating speed of the friction ring is 1500r/min, the moving speed of the friction head is 200mm/min, and the vibration frequency of the hammer ring is 20 Hz.
Example 2
The friction stir additive manufacturing method for the high-strength aluminum alloy powder core wire provided by the embodiment comprises the following steps of:
s1: determining the components of the cored wires, determining the diameters of the cored wires according to the single-pass width of the component, adding alloy powder in a prepared proportion into an aluminum strip through a powder feeder, and processing the aluminum wire to the required diameter through a reducing mill.
Specifically, a 7075 aluminum alloy powder core wire material is prepared, the diameter is 1.2mm, and a 7075 aluminum alloy plate is selected as a substrate.
S2: determining the material of a friction ring according to the components of the cored wire, determining the diameter of a friction head according to the diameter of the cored wire, processing to obtain the friction head, and mounting the friction head on a driving mechanism;
specifically, the diameter of the friction head is 5.5mm, and the material of the friction ring is H15 steel.
S3: generating a robot control code according to the stacking path of the stirring friction additive manufacturing, and sending the robot control code to the control system;
specifically, the moving speed of the friction head is set to 150 mm/min.
S4: the control mechanism generates a robot motion instruction according to the robot control code;
s5: the following parameters are preset in the control mechanism: the temperature of the heater is 300 ℃, the vibration frequency of the hammer ring is 20Hz, and the rotation speed of the friction ring is 2000 r/min.
S6: the control mechanism sends a processing parameter instruction to the driving mechanism, the powder core wire is sent into the friction head, the wire feeding speed is 2000mm/min, the friction ring starts to rotate, and the set rotating speed is kept. When the friction head presses the powder core wire down by 12%, the driving mechanism starts to drive the friction head to move according to a set track, and additive manufacturing of a layer of component is completed.
And S7, repeating the step S6 until the high-strength aluminum alloy additive manufacturing is completed.
The performance index of the obtained member is shown in table 2:
TABLE 2 Performance index
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (10)
1. The high-strength aluminum alloy powder core wire material stirring friction additive manufacturing system is characterized by comprising a friction head, wherein the friction head comprises a heater, a hammer ring and a friction ring which are sequentially sleeved from inside to outside, wherein:
the heater is used for preheating the powder core wires fed into the middle part of the friction head, so that the powder core wires reach the lower plate after being softened; the hammer ring can vibrate up and down and is used for fixing and extruding the powder core wires on the lower plate in real time; the friction ring can rotate and is used for generating shearing force on the powder core wires on the lower plate to realize solid-phase deposition.
2. The high-strength aluminum alloy powder core wire friction stir additive manufacturing system of claim 1, further comprising a wire processing assembly comprising a powder core wire forming machine, a powder feeder, a roller and a reducing mill arranged in sequence, wherein:
the powder core wire forming machine is used for processing the flat aluminum strip into a U-shaped aluminum strip; the powder feeder is used for adding the blended alloy powder into the U-shaped aluminum strip; the roller is used for closing the U-shaped aluminum strip added with the alloy powder to form an initial powder core wire with a fixed diameter; the reducing mill is used for reducing the initial powder core wire to a required diameter to form the powder core wire which can be sent into a friction head.
3. The high-strength aluminum alloy powder core wire friction stir additive manufacturing system according to claim 1, wherein the diameter of the friction ring is 3 to 4 times the diameter of the powder core wire.
4. The high-strength aluminum alloy powder core wire material friction stir additive manufacturing system of claim 1, wherein the heater is a resistance heater, the hammer ring is a concentric ring made of steel, and the friction ring is made of hot-work die steel.
5. The high-strength aluminum alloy powder core wire material stirring friction additive manufacturing system of any one of claims 1 to 4, further comprising a control assembly, wherein the control assembly comprises a control mechanism, a driving mechanism and a robot, the control mechanism controls the spatial displacement motion of the friction head through the robot, and the control mechanism controls the friction ring to rotate according to requirements through the driving mechanism.
6. A friction stir additive manufacturing method of high-strength aluminum alloy powder core wire, which is realized by the system of any one of claims 1 to 5, and is characterized by comprising the following steps:
feeding the cored wire into a friction head, and coaxially feeding the cored wire at a fixed speed; meanwhile, the friction head downwards extrudes the lower plate, moves according to a preset track, and forms layer by layer until the additive manufacturing of the aluminum alloy is completed; specifically, the lower plate refers to the substrate when the first layer is formed, and the lower plate refers to the upper layer of formed metal later;
during the moving process of the friction head: preheating the powder core wire by a heater, softening the powder core wire and fixing the powder core wire on a lower plate; the powder core wire is driven by the friction head to move to bend and is hammered and extruded by the hammer ring which vibrates up and down; meanwhile, the friction ring rotates to generate shearing force on the powder core wires, and the friction force can be generated on the powder core wires on the lower plate due to the integral movement of the friction head; under the combined action of a plurality of forces, plasticizing deposition is generated between the powder core wire and the lower plate, and dynamic recrystallization is formed.
7. The friction stir additive manufacturing method of high strength aluminum alloy powder core wire according to claim 6, wherein the friction head is pressed down the lower plate to a depth of 10% to 15% of the diameter of the powder core wire, and then the friction head starts to move.
8. The friction stir additive manufacturing method of high-strength aluminum alloy powder core wire according to claim 6, wherein the temperature of the heater is 250 to 350 ℃, the vibration frequency of the hammer ring is 15 to 25Hz, and the rotation speed of the friction ring is 1500 to 2000 r/min.
9. The friction stir additive manufacturing method of a high strength aluminum alloy powder core wire according to claim 8, wherein the friction head moves at a speed of 100 to 250 mm/min.
10. The friction stir additive manufacturing method of high strength aluminum alloy powder core wire according to any one of claims 6 to 9, wherein the method for preparing the powder core wire is as follows: determining the composition of the cored wire and determining the diameter of the cored wire according to the single-pass width of the member; adding the prepared alloy powder into the U-shaped aluminum strip through the powder feeding machine, closing the U-shaped aluminum strip added with the alloy powder through the roller, and further processing the aluminum wire to the required diameter through the reducing mill.
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