CN114951958B - High-strength aluminum alloy powder core wire friction stir additive manufacturing system and method - Google Patents
High-strength aluminum alloy powder core wire friction stir additive manufacturing system and method Download PDFInfo
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- CN114951958B CN114951958B CN202210725989.7A CN202210725989A CN114951958B CN 114951958 B CN114951958 B CN 114951958B CN 202210725989 A CN202210725989 A CN 202210725989A CN 114951958 B CN114951958 B CN 114951958B
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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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- Y02P10/25—Process efficiency
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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 friction stir additive manufacturing system and method, wherein the friction head comprises a heater, a hammer ring and a friction ring which are sleeved in sequence from inside to outside: 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 is rotatable and is used for generating shearing force on the powder core wire on the lower plate so as to realize solid phase deposition. In the manufacturing process of friction stir additive, the wire is hammered and rubbed to realize the all-solid-state molding of the component, solve the problems of air holes, cracks and other defects in the manufacturing process of melting high-strength aluminum alloy additive, and refine grains; meanwhile, the problems that the existing friction stir additive manufacturing method cannot realize continuous and stable additive manufacturing, powder is easy to oxidize, space restriction is caused and the like 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 is widely applied to the fields of aerospace, automobiles, ships, mechanical manufacturing and the like. High-strength aluminum alloys are widely used in aerospace because of their high strength and ease of processing.
Aluminum alloy melting additive manufacturing techniques include laser additive, electron beam additive, and arc additive, among others, where the forming process has a high energy source and the material undergoes melting and solidification during the forming process. Due to the nature of the high strength aluminum alloy itself, when the additive manufactured aluminum alloy components are melted, problems are liable to occur that deteriorate the quality of the additive manufactured aluminum alloy components:
(1) Air holes are easily formed in the aluminum alloy component manufactured by melting the additive. Because the solubility of hydrogen atoms in solid pure aluminum is only about 5% of that in liquid pure aluminum, hydrogen atoms are separated out from the solid state in the additive manufacturing process, and hydrogen bubbles are formed in the liquid state, however, 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, the high-strength aluminum alloy, such as a 7-series aluminum alloy, contains Mg, zn and other elements, and the elements can increase the partial pressure of hydrogen atoms, so that the hydrogen atoms move to a liquid state to form bubbles.
(2) Cracks tend to occur in the melt additive manufacturing of aluminum alloy components. The high-strength aluminum alloy, such as 7-series aluminum alloy, has a larger solidification interval and a brittleness temperature interval, and meanwhile, the solid phase and the liquid phase have different heat shrinkage coefficients, and the solid phase contracts at a higher speed, however, the solidification and cooling speeds of the aluminum alloy are too high, so that the hot cracking tendency in the aluminum alloy is increased, and cracks are easy to exist in the aluminum alloy melting additive manufacturing.
(3) Coarse grains can occur in the manufacture of aluminum alloy components by melting the additive. In the method of melting additive manufacturing, the aluminum alloy inevitably undergoes a melting solidification process, and the resulting bulk metal exhibits coarse grains in a cast state.
As described above, in the melt additive manufacturing technology, in manufacturing a high-strength aluminum alloy member, the problem that pores, cracks and coarse grains are easily generated due to the unavoidable process of melting and solidifying is generally solved by adopting a process optimization or wire optimization method. However, once the problems of parameter fluctuation and the like occur in the manufacturing process, defects occur, and potential safety hazards exist.
Friction stir welding is used as a novel solid-phase welding technology, can avoid the defects of air holes, inclusions, cracks and the like common in the traditional fusion welding, and is widely applied to high-quality welding of various metals at present. With the rapid development of additive manufacturing technology, friction stir additive manufacturing technology based on the friction stir lap welding principle is also receiving more and more attention. For example:
patent 201710606621.8 proposes a static shoulder device for static shoulder friction stir welding and an additive manufacturing method, which solve the problem of premature fracture failure of a stirring pin caused by overlong stirring heads, large eccentric amount and friction of the inner wall of the static shoulder; the clamping difficulty problem caused by the narrow space of the static shaft shoulder is solved, and the friction stir additive manufacturing without allowance near-net forming is realized. However, friction stir additive manufacturing is still realized by adding plates layer by layer, and the stable and continuous friction stir additive manufacturing process cannot be realized in the mode, and the unresolved allowance problem cannot still exist, so that waste is caused.
Patent 201810229291.X proposes a powder feeding type friction stir additive manufacturing machine, which uses discrete powder as a raw material to solve the problem of continuous wire friction stir additive manufacturing, 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 the storage cost of the powder raw material is higher.
The 201711019260.3 patent proposes a method for additive manufacturing by using a consumable friction stir tool, wherein the consumable material is used as the friction stir tool, and the material of the consumable friction stir tool is deposited layer by layer on the surface of a substrate in a solid phase manner by adopting a friction stir surfacing method, so as to prepare the required metal material. Has the advantages of low cost, high molding speed, short preparation time and the like. However, when the friction tool is replaced at intervals, continuous additive manufacturing cannot be realized, and the formed member cannot guarantee 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 upper and lower layers of the component, waste of plates and the like; the raw materials are easily oxidized during the manufacturing of the feeding type friction stir additive, so that the quality of the component is poor; the loss type friction stir additive manufacturing is limited by the diameter of the bar, the bar needs to be replaced, and the efficiency is limited.
Disclosure of Invention
In order to meet the above defects or improvement demands of the prior art, the invention provides a high-strength aluminum alloy powder core wire friction stir additive manufacturing system and a method, and aims to realize stable and continuous high-strength aluminum alloy additive manufacturing and reduce the problems of air holes, cracks and coarse grains in an aluminum alloy.
In order to achieve the above object, according to an aspect of the present invention, there is provided a high-strength aluminum alloy core wire friction stir additive manufacturing system, comprising a friction head including a heater, a hammer ring and a friction ring sleeved in sequence 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 is rotatable and is used for generating shearing force on the powder core wire on the lower plate so as to realize solid phase deposition.
As a further preferred, the wire processing assembly further comprises a wire processing assembly comprising a cored wire forming machine, a powder feeder, a roller and a reducing mill which are 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 prepared alloy powder into the U-shaped aluminum belt; 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 fed into the friction head.
As a further preferable aspect, the friction ring diameter is 3 to 4 times the diameter of the cored wire.
As a further preferable mode, the heater is a resistance heater, the hammer ring is a steel concentric ring, and the friction ring is made of hot work die steel.
As a further preferred feature, the apparatus further comprises a control assembly comprising a control mechanism, a drive mechanism and a robot, wherein the control mechanism controls the spatial displacement movement of the friction head via the robot, and the control mechanism controls the friction ring to rotate as required via the drive mechanism.
According to another aspect of the invention, there is provided a method for manufacturing a friction stir additive of a high strength aluminum alloy cored wire, which is implemented by the above system, comprising the steps of:
feeding the powder core wire into a friction head, and coaxially feeding the wire at a fixed speed; simultaneously, the friction head presses the lower plate downwards, moves according to a preset track and forms layer by layer until the aluminum alloy additive manufacturing is completed; specifically, the lower plate is a substrate after forming the first layer, and then the lower plate is a metal formed on the upper layer;
during the movement process of the friction head: the heater preheats the powder core wire material to soften and fix the powder core wire material on the lower plate; the powder core wire is driven to move by a friction belt to generate bending and is hammered and extruded by a hammer ring vibrating up and down; simultaneously, the friction ring rotates to generate shearing force on the powder core wire, and friction force can be generated on the powder core wire on the lower plate due to the integral movement of the friction head; under the combined action of a plurality of forces, the powder core wire material and the lower plate are deposited in a intergeneration Cheng Suhua way, and dynamic recrystallization is formed.
As a further preference, the friction head presses down the depth of the lower plate to 10% -15% of the diameter of the cored wire, and then the friction head starts to move.
More preferably, 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 2000r/min.
As a further preference, the friction head is moved at a speed of 100 to 250 mm/min.
As a further preferable aspect, the preparation method of the cored wire comprises the following steps: determining the components of the powder core wire, and determining the diameter of the powder core wire according to the single-channel width of the component; the prepared alloy powder is added into the U-shaped aluminum belt through a powder feeder, the U-shaped aluminum belt added with the alloy powder is closed through a roller, and then the aluminum wire is processed to the required diameter through a reducing mill.
In general, 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, the wire can be hammered and rubbed in real time in the friction stir material increase manufacturing process, so that the full solid molding of the component is realized, the defect that the traditional high-strength aluminum alloy is easy to generate air holes and cracks is overcome, and meanwhile, the grains can be thinned through friction stir. Compared with the prior art, the friction stir additive manufacturing method does not need to frequently add plates or replace friction heads, and realizes stable and continuous aluminum alloy friction stir additive manufacturing.
2. In the additive manufacturing process, the friction ring always rotates to generate 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 grains are crushed and recrystallized under the action of intense mechanical stirring to form uniform and fine equiaxed grains, so that the grains are effectively refined, the microstructure of the component is improved, and the performance of the component is improved.
3. Liquid phase is inevitably generated in the process of manufacturing the molten high-strength aluminum alloy additive, but the process of manufacturing the friction stir additive is all solid, and air holes are not generated due to different solubilities of hydrogen atoms in the solid phase and the liquid phase.
4. Because the manufacturing process is all solid, the thermal contraction coefficient of the component does not change greatly in the forming process, and no cracks are effectively avoided in the melting and solidification process in the additive manufacturing process. Meanwhile, the friction head has the functions of extrusion force, shearing force and friction force, so that the occurrence of cracks in the component is greatly reduced.
5. According to the invention, the powder core wire is obtained through processing of the wire processing assembly, and the manufacturing of the powder core wire and the friction stir additive manufacturing are combined together; the aluminum strip is used for wrapping alloy powder, the alloy powder can be deposited simultaneously during additive manufacturing, and the problems that the powder is easy to oxidize and the like are avoided.
6. When the friction head presses 10% -15% downwards, the friction head moves, so that an original interface (wire) bends towards a lower plate (a base plate or stacked metal) and stretches into the lower plate to form interface migration. If the extrusion amount is too small, interface migration can not occur, and additive manufacturing can not be realized; if the extrusion amount is too large, interface migration occurs between the advancing end (i.e., the end of the friction ring in the advancing direction from which the wire enters) and the return end, and the drug-resistant wire cannot be sufficiently mixed; when 10% -15% of the material is extruded, only the return end is subjected to interface migration, so that the requirement of additive manufacturing is met.
Drawings
FIG. 1 is a schematic diagram of a high-strength aluminum alloy cored wire friction stir additive manufacturing system in accordance with 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 method for friction stir additive manufacturing of high strength aluminum alloy cored wires according to an embodiment of the invention.
The same reference numbers are used throughout the drawings to reference 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-powder core wire, 10-heater, 11-hammer ring, 12-friction ring.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention. In addition, the technical features of the embodiments of the present invention described below may be combined with each other as long as they do not collide with each other.
The embodiment of the invention provides a high-strength aluminum alloy powder core wire friction stir additive manufacturing system, which is shown in fig. 1 and comprises a wire processing assembly, a control assembly and a friction head 8.
The wire processing assembly comprises a forming machine 1, a powder feeder 2, a roller 3 and a reducing mill 4, wherein:
the forming machine 1 is positioned at the beginning of the system and is used for processing the flat aluminum strip into a U-shaped aluminum strip, so that the powder feeder 2 can conveniently add alloy powder in the subsequent process.
The powder feeder 2 is positioned between the forming machine 1 and the roller 3 and is used for adding the prepared 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 belt added with the alloy powder to form a powder core wire with a fixed diameter.
A reducing mill 4 is connected to the rolls 3 for processing the fixed diameter cored wire into the desired diameter, more than one reducing mill being used, in order to achieve the desired diameter and to ensure the quality of the cored wire, it is common to pass through a plurality of reducing processes to form a cored wire 9 which is finally fed into the friction head 8.
The control assembly comprises a control mechanism 5, a robot 6 and a driving mechanism 7, wherein:
and the control mechanism 5 is connected with the robot 6 and is used for generating a robot motion instruction according to a robot control code, sending the robot motion instruction to the robot and controlling the space 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 comprises spatial displacement path information of the 6 th shaft end part of the robot 6 and speed information during moving 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 according to the requirements 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 carry out machining operation according to the motion command.
The friction head 8 is connected with the driving mechanism 7 and is positioned at the terminal end of the system 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:
the heater 10 is positioned at the innermost layer of the friction head and is a resistance heater, and the main component of the heater is graphite; for preheating the cored wire and providing a portion of the energy.
The hammer ring 11, which is located on the second layer of the friction head, is a steel concentric ring capable of realizing vibration hammering, and vibrates up and down according to a certain frequency, and is used for fixing the powder core wire and providing a downward extrusion force.
And the friction ring 12 is positioned on the outermost layer of the friction head and made of hot work die steel and is used for realizing 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, as shown in fig. 3, comprises the following steps:
the first step: the components of the powder core wire are determined, the diameter of the powder core wire is determined according to the single-channel width of the component, the alloy powder with the proportion is added into an aluminum belt through a powder feeder, and the aluminum wire is processed to the required diameter through a reducing mill.
Specifically, the preparation method of the cored wire comprises the following steps: forming a U-shaped aluminum strip 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 the required diameter is obtained by a reducing mill.
And a second step of: determining the material of a friction ring according to the components of the powder core wire, determining the diameter of a friction head according to the diameter of the powder core wire, processing to obtain the friction head, and mounting the friction head on a driving mechanism;
and a third step of: generating a robot control code according to a stacking path of friction stir additive manufacturing, and sending the robot control code to the control system;
the robot control code can control the robot to displace at the speed of 100-250 mm/min on the metal stacking path, so that the friction head driven by the robot also performs friction stir additive manufacturing at the speed of 100-250 mm/min;
fourth step: the control mechanism generates a robot motion instruction according to the robot control code;
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.
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 rotation speed. When the friction head presses down the powder core wire 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 components 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 the 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, and the powder core aluminum wire is preheated to soften the aluminum wire and can be fixed on the lower plate; the lower plate is in particular a base plate or a shaped additive manufactured member.
The robot moves according to the designed track, the aluminum wire is bent and fixed by the hammer ring under the drive of the robot, the friction head extrudes downwards by 10% -15%, the powder core wire is given a downward pressure, 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 on the aluminum wire.
In the moving process of the robot, the hammer ring always shakes and hammers the powder core wire at a fixed frequency; meanwhile, the friction ring can rotate at a fixed rotating speed, and the shearing force generated by the rotation of the friction ring on the aluminum wire and the extrusion force of the friction head jointly generate friction heat.
From the above, the heater gives an initial heat to the cored wire during the friction stir additive manufacturing process; the whole friction head, particularly the hammer ring, can give extrusion force to the powder core wire; the friction ring can generate shearing force on the wire when rotating; friction force is generated on the wire when the whole friction head moves; these factors act 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 created such that:
(1) The friction stir additive manufacturing process is all solid, and liquid phase is inevitably generated in the process of melting the high-strength aluminum alloy additive manufacturing, so that air holes are not generated due to different solubilities of hydrogen atoms in the solid phase and the liquid phase.
(2) Meanwhile, the heat shrinkage rate of the aluminum alloy is not changed basically because of the full solid state, and meanwhile, the occurrence of cracks in the component is greatly reduced under the action of extrusion force, shearing force and friction force.
(3) In the whole additive manufacturing process, the aluminum alloy is always in a dynamic recrystallization process, and originally coarse and uneven grains are crushed and recrystallized under the action of intense mechanical stirring to form uniform and fine equiaxed grains, so that the microstructure of the material is improved, and the performance of the material is improved.
The following are specific examples:
example 1
The wires used in the friction stir additive manufacturing process are aluminum and aluminum alloy welding wires, in the embodiment, the prepared wires are ER2319 aluminum alloy welding wires, the used substrate is 2219 aluminum alloy substrate, and alloy powder is prepared according to a certain proportion for adding various required elements into the powder core wires.
Specifically, the ingredients of the cored wire after the addition are shown in table 1:
TABLE 1 powder cored wire composition
| 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 the embodiment, the diameter of the friction head is 5mm, and the friction ring is made of H13 steel. The diameter of the aluminum wire processed by the powder feeding machine is 5mm; the closed aluminum wire processed by the roller 3 can reach the required diameter of 1.2mm after reducing for a plurality of times.
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 20Hz.
Example 2
The method for manufacturing the high-strength aluminum alloy cored wire friction stir additive comprises the following steps:
s1: the components of the powder core wire are determined, the diameter of the powder core wire is determined according to the single-channel width of the component, the alloy powder with the proportion is added into an aluminum belt through a powder feeder, and the aluminum wire is processed to the required diameter through a reducing mill.
Specifically, 7075 aluminum alloy powder core wires with the diameter of 1.2mm are prepared, and 7075 aluminum alloy plates are selected as the base plates.
S2: determining the material of a friction ring according to the components of the powder core wire, determining the diameter of a friction head according to the diameter of the powder core 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 friction ring is made of H15 steel.
S3: generating a robot control code according to a stacking path of friction stir additive manufacturing, and sending the robot control code to the control system;
specifically, the moving speed of the friction head was set to 150mm/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 was 300 ℃, the vibration frequency of the hammer ring was 20Hz, and the rotation speed of the friction ring was 2000r/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 maintained. When the friction head presses down the powder core wire 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 components is completed.
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 readily appreciated by those skilled in the art that the foregoing description is merely a preferred embodiment of the invention and is not intended to limit the invention, but any modifications, equivalents, improvements or alternatives falling within the spirit and principles of the invention are intended to be included within the scope of the invention.
Claims (10)
1. The utility model provides a high-strength aluminum alloy powder core wire friction stir material manufacturing system which characterized in that, includes the friction head, and this friction head includes heater, hammer ring and the friction ring that establishes from interior to outside cover in proper order, 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 is rotatable and is used for generating shearing force on the powder core wire on the lower plate so as to realize solid phase deposition;
when the friction head is used, the friction head presses the lower plate downwards and moves according to a preset track, and the friction head moves in the process: the heater preheats the powder core wire material to soften and fix the powder core wire material on the lower plate; the powder core wire is driven to move by a friction belt to generate bending and is hammered and extruded by a hammer ring vibrating up and down; simultaneously, the friction ring rotates to generate shearing force on the powder core wire, and friction force can be generated on the powder core wire on the lower plate due to the integral movement of the friction head; under the combined action of a plurality of forces, the powder core wire material and the lower plate are deposited in a intergeneration Cheng Suhua way, and dynamic recrystallization is formed.
2. The high strength aluminum alloy cored wire friction stir additive manufacturing system of claim 1 further comprising a wire processing assembly comprising a cored wire former, a powder feeder, a roller, and a reducer disposed 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 prepared alloy powder into the U-shaped aluminum belt; 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 fed into the friction head.
3. The high strength aluminum alloy cored wire friction stir additive manufacturing system of claim 1 wherein the friction ring diameter is 3-4 times the cored wire diameter.
4. The high strength aluminum alloy cored wire friction stir additive manufacturing system of claim 1 wherein the heater is a resistive heater, the hammer ring is a concentric ring of steel, and the friction ring is hot work die steel.
5. The high strength aluminum alloy core wire friction stir additive manufacturing system of any of claims 1-4 further comprising a control assembly including a control mechanism, a drive mechanism and a robot, the control mechanism controlling the spatial displacement movement of the friction head via the robot while the control mechanism controlling the friction ring to rotate as desired via the drive mechanism.
6. A method for manufacturing a high-strength aluminum alloy cored wire friction stir additive, which is realized by adopting the system as recited in any one of claims 1-5, and is characterized by comprising the following steps:
feeding the powder core wire into a friction head, and coaxially feeding the wire at a fixed speed; simultaneously, the friction head presses the lower plate downwards, moves according to a preset track and forms layer by layer until the aluminum alloy additive manufacturing is completed; specifically, the lower plate is a substrate after forming the first layer, and then the lower plate is a metal formed on the upper layer;
during the movement process of the friction head: the heater preheats the powder core wire material to soften and fix the powder core wire material on the lower plate; the powder core wire is driven to move by a friction belt to generate bending and is hammered and extruded by a hammer ring vibrating up and down; simultaneously, the friction ring rotates to generate shearing force on the powder core wire, and friction force can be generated on the powder core wire on the lower plate due to the integral movement of the friction head; under the combined action of a plurality of forces, the powder core wire material and the lower plate are deposited in a intergeneration Cheng Suhua way, and dynamic recrystallization is formed.
7. The method for manufacturing the high-strength aluminum alloy cored wire friction stir additive of claim 6 wherein the depth of the lower plate is reduced by the friction head to 10% -15% of the diameter of the cored wire and then the friction head starts to move.
8. The method for manufacturing the high-strength aluminum alloy powder core wire friction stir additive according to claim 6, wherein 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.
9. The method for manufacturing a high-strength aluminum alloy core wire friction stir additive according to claim 8, wherein the friction head moves at a speed of 100 to 250 mm/min.
10. The method for manufacturing the high-strength aluminum alloy cored wire friction stir additive according to any one of claims 6 to 9, wherein the method for manufacturing the cored wire comprises the following steps: determining the components of the powder core wire, and determining the diameter of the powder core wire according to the single-channel width of the component; the prepared alloy powder is added into the U-shaped aluminum belt through a powder feeder, the U-shaped aluminum belt added with the alloy powder is closed through a roller, and then the aluminum wire is processed to the required diameter through a reducing mill.
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| CN115647569B (en) * | 2022-11-15 | 2023-04-14 | 哈尔滨工业大学 | Robot continuous wire feeding friction stir material increasing device and curved surface material increasing method |
| CN117139814B (en) * | 2023-08-04 | 2024-07-12 | 哈尔滨工业大学 | Friction stir additive manufacturing device and method with accurate regulation and control of intelligent temperature control tissue |
| CN117144174B (en) * | 2023-11-01 | 2024-02-13 | 北京索德瀚智能科技有限公司 | Alloy preparation method and system |
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