CN115055699B - Device and method for manufacturing particle reinforced aluminum matrix composite material by using molten drop composite arc additive - Google Patents
Device and method for manufacturing particle reinforced aluminum matrix composite material by using molten drop composite arc additive Download PDFInfo
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Classifications
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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
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
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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
- B22F10/20—Direct sintering or melting
- B22F10/22—Direct deposition of molten metal
-
- 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
- B22F10/20—Direct sintering or melting
- B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/31—Calibration of process steps or apparatus settings, e.g. before or during manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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- 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
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- 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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- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
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- B22F12/50—Means for feeding of material, e.g. heads
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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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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0408—Light metal alloys
- C22C1/0416—Aluminium-based alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/05—Mixtures of metal powder with non-metallic powder
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Automation & Control Theory (AREA)
- Analytical Chemistry (AREA)
- Powder Metallurgy (AREA)
- Manufacture And Refinement Of Metals (AREA)
Abstract
The invention discloses a device and a method for manufacturing a particle reinforced aluminum matrix composite material molten drop composite arc additive, wherein the device comprises a molten drop generating system, a reinforced particle powder feeding device and an arc heat source, wherein the molten drop generating system comprises an air pressure driving unit, a crucible smelting unit, a labyrinth flow passage component and a graphite spray head and is used for generating controllable molten drop flow, and a flow control component based on the labyrinth flow passage ensures stable and controllable jet flow state and jet flow. The reinforced particle powder feeding device is used for directional/quantitative conveying of the particle reinforced phase, and the double-nozzle powder feeding mode is beneficial to ensuring the uniformity of particle implantation. In the forming process, the aluminum molten drops and the particle reinforced phase are jointly sent into an electric arc melting pool, and along with the movement and solidification of the electric arc melting pool, the particle reinforced phase can be dispersed in the aluminum matrix to form a composite material component in a way of stacking layer by layer, so that the high-quality, high-efficiency and low-cost additive manufacturing of the aluminum alloy/particle reinforced aluminum matrix composite material component is finally realized.
Description
Technical Field
The invention belongs to the technical field of additive manufacturing, and particularly relates to a device and a method for manufacturing a particle reinforced aluminum matrix composite material by using a molten drop composite arc additive.
Background
The additive manufacturing (also called 3D printing) technology is a non-traditional processing technology and is an advanced manufacturing technology integrating optical, electric, electromechanical, computer, numerical control and new materials into a whole, which is rising in the 90 s. The core idea is that three-dimensional parts are subjected to two-dimensional dispersion to form sheet data, discrete forming materials are gradually combined together according to layered data of a three-dimensional CAD model of the parts to form layered sections, and then the layered sections are stacked layer by layer to form solid parts, so that the parts are directly manufactured without a die, and the development period can be greatly shortened.
According to the heat source form, the main stream metal additive manufacturing method mainly comprises laser selective melting, electron beam selective melting, laser (melt) deposition and arc (melt) deposition. According to the form of raw materials, the mainstream metal additive manufacturing method can be divided into powder spreading forming, powder feeding forming, wire feeding forming and droplet forming.
The current additive manufacturing mode suitable for the rapid forming of aluminum-based components mainly comprises laser selective melting, electron beam selective melting and arc (melting) deposition. Considering the characteristic that an aluminum alloy molten pool is extremely easy to oxidize, the laser (melt) deposition technology is difficult to ensure the bonding strength between aluminum-based component layers, and solid laser (melt) deposition is not suitable for forming aluminum-based components. The special cathode cleaning function of the arc heat source, especially the variable polarity arc heat source, can break and clean the oxide film on the surface of the aluminum alloy molten pool, thereby ensuring high-quality metallurgical bonding between layers. Meanwhile, the arc heat source has high melting efficiency, and is beneficial to realizing high-efficiency additive manufacturing of aluminum-based components.
Because aluminum alloy has advantages of low density, high specific strength, high thermal conductivity coefficient, wide sources and the like, the aluminum alloy plays an extremely important role in the industrial field and the daily life field of people. However, aluminum alloys have low surface hardness and poor abrasion resistance, which makes their use in applications where wear resistance is clearly required, very limited. Therefore, the ceramic particle reinforced aluminum matrix composite technology becomes a key technical route for solving the problem of insufficient wear resistance of the aluminum alloy. The ceramic particles have extremely high hardness and thus excellent abrasion resistance.
The existing additive manufacturing schemes of the particle reinforced aluminum matrix composite material mainly comprise three types: high energy beam (laser, electron beam) selective melting additive manufacturing technology based on nanoparticle reinforced aluminum-based composite powder technology, arc additive manufacturing technology based on interlayer ceramic particle coating technology, and arc fuse additive manufacturing technology based on composite wire manufacturing technology. In the first technology (high-energy beam selective melting additive manufacturing technology based on nanoparticle reinforced aluminum-based composite powder technology), the abrasion resistance of an aluminum matrix is not remarkably improved due to the fact that the mixing proportion of the nano ceramic particles is low and the particle size of the high-hardness ceramic particles is small (nano-scale). Meanwhile, the forming efficiency of the high-energy beam selective melting additive manufacturing technology is low, so that the forming requirement of the medium-and-large-sized aluminum-based component is difficult to meet. The second technique (arc additive manufacturing technique based on interlayer ceramic particle coating technique and arc fuse additive manufacturing technique based on composite wire making technique) has limitations in that the forming efficiency is low and the reinforcing layer thickness is small. Since the inter-layer coating process requires each layer to be cooled to approximately room temperature and the next layer to be deposited should ensure thorough evaporation of the solvent components in the mixture applied to the surface of the deposited layer, the high efficiency benefits of arc deposition are greatly reduced. The third technique (arc fuse additive manufacturing technique based on composite wire making technique) is mainly limited to the preparation of special wires. Compared with the traditional welding wire, the plasticity of the aluminum-based material compounded by the ceramic particles is often obviously reduced, so that the technical difficulty of wire making is reduced.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a device and a method for manufacturing the particle reinforced aluminum matrix composite material by using a molten drop composite arc additive, which realize high-quality, high-efficiency and low-cost rapid manufacturing of the particle reinforced aluminum matrix composite material component.
The invention adopts the following technical scheme:
the particle reinforced aluminum matrix composite molten drop composite arc additive manufacturing device comprises a molten drop generating system, wherein the molten drop generating system is used for generating an aluminum melt jet flow, the particle reinforced aluminum matrix composite molten drop manufacturing device comprises a smelting crucible, the upper part of the smelting crucible is provided with a water-cooling top cover assembly, the lower part of the smelting crucible is connected with a spray head through a flow control assembly, a periodical labyrinth flow passage structure is arranged in the flow control assembly, one side of the spray head is provided with an arc heat source and an enhanced particle powder feeding device, the arc heat source is used for generating an arc molten pool, the enhanced particle powder feeding device is used for mixing gas and enhanced particles to form a powder flow, the aluminum melt jet flow is dispersed into the arc molten pool together with the powder flow after being molten drops, a particle reinforced aluminum matrix composite deposition layer is formed along with the movement and solidification of the arc molten pool, and a target particle reinforced aluminum matrix composite component is formed through gradual/gradual layer deposition.
Specifically, the water-cooling top cover assembly comprises a water-cooling top cover, a cooling water inlet, a cooling water outlet, a material adding inlet and an air inlet/outlet are formed in the water-cooling top cover, a top cover water cooling cavity is formed in the water-cooling top cover, a cooling system is arranged between the cooling water inlet and the cooling water outlet, and cooling water enters the top cover water cooling cavity through the cooling water inlet and returns to the cooling system from the cooling water outlet.
Further, a pressure sensor and a laser distance sensor are arranged on the water-cooling top cover, and the pressure sensor and the laser distance sensor are respectively connected with the air pressure driving system.
Further, a top cover radiating fin is arranged between the lower side of the water-cooling top cover and the smelting crucible, a high-temperature sealing ring is arranged between the top cover radiating fin and the smelting crucible, an induction heating coil is arranged outside the smelting crucible, and the induction heating coil is electrically connected with an induction heating power supply.
Specifically, a filtering flange is arranged at the bottom of the smelting crucible, and a ceramic filter disc is arranged between the smelting crucible and the filtering flange; the bottom of the filtering flange is provided with an adapter flange, the flow control assembly is arranged between the filtering flange and the adapter flange, the flow control assembly, the filtering flange and the smelting crucible are arranged in a lamination mode; the bottom of the adapter flange is connected with a spray head, a heating sleeve is arranged outside the spray head, and the heating sleeve is electrically connected with a temperature controller.
Specifically, be provided with the crucible temperature measurement hole on the smelting crucible, be provided with the crucible thermocouple in the crucible temperature measurement hole, be provided with shower nozzle temperature measurement hole on the shower nozzle, be provided with the shower nozzle thermocouple in the shower nozzle temperature measurement hole, crucible thermocouple and shower nozzle thermocouple are connected with the temperature control appearance electricity respectively.
Specifically, the flow control assembly comprises a flow channel inlet protection sheet and a flow channel outlet protection sheet, and a labyrinth flow control sheet is arranged between the flow channel inlet protection sheet and the flow channel outlet protection sheet; the runner inlet protection sheet is provided with a runner inlet and an inlet sedimentation tank, and the bottom surface of the inlet sedimentation tank is lower than the upper edge of the runner inlet; the labyrinth flow control sheet is provided with a flow control sheet inlet which is connected with a flow control sheet outlet through a labyrinth flow passage, and the labyrinth flow passage is provided with a labyrinth bent periodic structure; the runner outlet protection sheet is provided with a runner outlet.
Specifically, the reinforced particle powder feeding device comprises a powder feeder, wherein the powder feeder is connected with a powder feeding nozzle through a powder feeding pipe, and the powder feeding nozzle is fixed on the arc welding torch through a powder feeding nozzle clamp.
Specifically, the lower part of the spray head is provided with a substrate, and the substrate is connected with a three-dimensional motion platform.
According to another technical scheme, the manufacturing method of the particle reinforced aluminum-based composite material droplet composite arc additive comprises the following steps of:
S1, designing a three-dimensional model of a target part according to the shape and the application condition of the target part;
s2, designing a composite material according to the three-dimensional part model obtained in the step S1 and combining the functional requirements of a target part, wherein the composite material comprises matrix material type selection, reinforced particle type selection and reinforced particle implantation proportion setting of the composite material;
s3, determining a forming path file according to the three-dimensional model obtained in the step S1 and the composite material determined in the step S2, and the deposition rate, the layer height, the moving speed and the arc current process parameters, wherein the deposition rate in the forming path file is 100-300 mm 3 The layer height is 1-4 mm, the moving speed is 3-15 mm/s, and the arc current is 100-500A;
s4, calculating the amount of aluminum alloy and particle reinforcement phase required by forming according to the three-dimensional model obtained in the step S1, the composite material determined in the step S2, the planned forming path in the step S3 and the number of target parts;
s5, forming the aluminum alloy material easy to oxidize in an inert atmosphere, wherein the water and oxygen content in the atmosphere is not more than 100ppm, and filling the aluminum alloy material prepared in the step S4 into a smelting crucible and assembling a molten drop generating system;
s6, starting a cooling system, setting the final heating temperature to 650-750 ℃ and the heating rate to 10-100 ℃/min, and heating the droplet generation system in the step S5;
S7, after the droplet generation system in the step S6 is heated to a preset temperature, verifying whether the pressure detection function, the air pressure loading function and the laser liquid level measurement function of the droplet generation system are normal, verifying the jet flow state and the jet flow rate, and repeating the steps S5-S7 if the jet flow state is unstable or the flow rate error exceeds 10% or the flow rate fluctuation is greater than 5% in a preset pressure range;
s8, printing the target component according to the forming path file obtained in the step S3;
s9, performing real-time morphology monitoring in the printing process of the step S8, if the forming precision deviates from the size requirement of the part or a lap joint defect occurs, suspending forming, correcting the related data in the forming path file obtained in the step S3, and repeating the step S9 until the part manufacturing is completed;
and S10, after the printing of the target part in the step S9 is completed, removing the part which does not belong to the part to obtain the target part.
Compared with the prior art, the invention has at least the following beneficial effects:
the device for manufacturing the molten drop composite arc additive of the particle reinforced aluminum-based composite material can realize high-quality, high-efficiency and low-cost additive manufacturing of aluminum alloy and particle reinforced aluminum-based composite materials. The droplet composite arc additive manufacturing system replaces a wire feeding mechanism in the traditional arc fuse additive manufacturing system by an independent droplet generation system, so that a material adding link and a heat input ring in the arc additive manufacturing process can be independently regulated and controlled. The introduction of the molten drop generating system can overcome the inherent defect of strong wire-arc coupling of the traditional arc fuse additive manufacturing technology, and has important significance for further improving the arc additive manufacturing efficiency and quality. Meanwhile, the particle reinforced aluminum matrix composite molten drop composite arc additive manufacturing device provided by the invention is introduced with the reinforced particle powder feeding device, and the device can implant reinforced particles into an arc melting pool in an air-borne powder mode, so that the particle reinforced aluminum matrix composite arc additive manufacturing is realized. The invention improves the inherent defects of arc additive manufacturing to a certain extent, and is a supplement to the arc additive manufacturing technology; meanwhile, the invention can realize the additive manufacturing of the particle reinforced aluminum matrix composite material and provides a new mode for the arc additive manufacturing of the particle reinforced metal matrix composite material.
Furthermore, the molten drop generating system is designed with a water-cooling top cover, a cooling water inlet and a cooling water outlet are arranged on the water-cooling top cover, and a top cover water-cooling cavity capable of communicating water is arranged in the top cover. The water cooling design can ensure that the sensor arranged on the water cooling top cover is at a safe working temperature; the water-cooling top cover is provided with an air inlet/outlet which can charge or discharge air into the molten drop generating system so as to achieve the aim of pressurization or depressurization; the water-cooling top cover is provided with a material adding inlet, and metal materials can be added into the molten drop generating system in the forming process, wherein the added materials comprise, but are not limited to, small-size blocks, small-size bars, wires and powdery materials, so that the requirement of continuous forming of medium-and-large-size parts or the requirement of adjustment of chemical components of the materials in the forming process can be met.
Further, the water-cooling top cover is provided with a pressure sensor and a laser distance sensor so as to realize real-time measurement of the air pressure in the crucible and the melt level in the crucible, and real-time data is fed back to the air pressure driving system. After the air pressure driving system receives the air pressure information and the melt level information, the pressure of the melt at the bottom of the crucible can be further calculated, so that the air pressure driving system can accurately control the pressure at the bottom of the crucible.
Further, a top cover radiating fin is arranged between the lower part of the water-cooling top cover and the smelting crucible, and a high-temperature sealing ring is arranged between the top cover radiating fin and the smelting crucible. The arrangement of the top cover radiating fins can prevent excessive heat from being taken away through the water-cooling top cover. When the temperature of the crucible is increased, the screw thread connection between the smelting crucible and the radiating fins can be loosened due to the difference of the thermal expansion coefficients of materials, and the high-temperature sealing ring has the function of generating axial expansion after the temperature of the high-temperature sealing ring is increased, so that the reliable high-temperature sealing between the top cover radiating fins and the smelting crucible is realized. An induction heating coil is arranged on the periphery of the smelting crucible and used for realizing induction heating of metal materials in the smelting crucible.
Further, a filtering flange is arranged at the bottom of the smelting crucible, and a ceramic filter disc is arranged between the smelting crucible and the filtering flange. The ceramic filter sheet has the function of filtering out the surface oxide film of the aluminum alloy melt and the solid impurities inside. The bottom of the filter flange is provided with an adapter flange, a flow control assembly is arranged between the filter flange and the adapter flange, the flow control assembly, the filter flange and the smelting crucible are arranged in a laminated mode. The advantage of the laminated arrangement is that it ensures that the sealing surfaces between the components can achieve a similar pre-tightening force, the seal is reliable, the assembly is simple and convenient and it is advantageous to supplement the tightening of the sealing surfaces in a high temperature state. The bottom of the adapter flange is connected with a spray head, a heating sleeve is arranged outside the spray head, and the heating sleeve is electrically connected with the temperature controller. The function of the adapter flange is to realize the conversion of the connection mode, the upper part of the adapter flange is in bolted connection (so that the smelting crucible, the filtering flange, the flow control assembly and the adapter flange form a whole), and the lower part of the adapter flange is in threaded connection, so that the spray head is convenient to install and replace. The heating jacket aims at realizing the heating of the spray head, and the temperature controller is used for controlling the heating process.
Further, a crucible temperature measuring hole is formed in the smelting crucible, and a crucible thermocouple is arranged in the crucible temperature measuring hole; a nozzle temperature measuring hole is formed in the nozzle at the bottom of the smelting crucible, and a nozzle thermocouple is arranged in the nozzle temperature measuring hole; the crucible thermocouple and the spray nozzle thermocouple are electrically connected with the temperature controller. The design of the temperature measuring hole is used for measuring the temperature of the smelting crucible and the nozzle, and the thermocouple is not required to be contacted with the aluminum alloy melt in the smelting crucible in the temperature measuring process, so that the pollution of the aluminum alloy melt and the corrosion of a temperature measuring element (thermocouple) caused by temperature measurement are avoided. The temperature controller collects thermoelectric voltage differences from the crucible thermocouple and the spray nozzle thermocouple in real time and converts the thermoelectric voltage differences into temperature information, so that the heating process control of the induction heater and the heating sleeve is realized.
Further, the flow control assembly comprises a flow channel inlet protection sheet and a flow channel outlet protection sheet, and a labyrinth flow control sheet is arranged between the flow channel inlet protection sheet and the flow channel outlet protection sheet. The flow channel inlet protection sheet, the flow channel outlet protection sheet and the labyrinth flow control sheet are arranged in a lamination mode, and a flow channel enclosed by the flow channel inlet protection sheet, the flow channel outlet protection sheet and the labyrinth flow control sheet is the labyrinth flow channel. The labyrinth flow passage has a periodically bent flow passage structure, so that friction energy consumption in viscous fluid (aluminum alloy melt) can be obviously increased, and further, smaller jet flow can be obtained under the same driving pressure, or the driving pressure can be obviously increased under the same jet flow. At the same time, the labyrinth flow passage has the effect of maintaining stable flow. In the melt jet process, small holes at the tail end of the spray head are easy to be blocked, when the flow is reduced due to the blocking of impurities, the flow rate of the melt in the labyrinth flow channel is reduced, and the lost kinetic energy of the flow field is converted into static pressure energy, so that the melt in the small holes at the tail end of the spray head is forced to flow in an accelerating way. The melt moving is accelerated, so that the blocking object adhered to the hole wall is taken away, and the jet flow is recovered to a normal value.
Further, an inlet sedimentation tank is arranged on the runner inlet protection sheet, and the bottom surface of the inlet sedimentation tank is obviously lower than the upper edge of the runner inlet. The inlet sedimentation tank is used for accommodating indissolvable particulate impurities with density larger than that of the aluminum alloy melt, and preventing excessive particulate impurities from entering the labyrinth runner through the runner inlet.
Further, the reinforced particle powder feeding device comprises a powder feeder, wherein the powder feeder is connected with a powder feeding nozzle through a powder feeding pipe, and the powder feeding nozzle is fixed on a ceramic protection nozzle of the arc welding torch through a powder feeding nozzle clamp. The main function of the reinforced particle powder feeding device is to drive reinforced particles into an electric arc melting pool in an air-borne powder mode to form a particle reinforced aluminum matrix composite material deposition layer, and then the additive manufacturing of the target part is completed in a layer-by-layer deposition mode.
Further, a three-dimensional motion platform is arranged below the molten drop generating system, and a substrate is arranged on a movable sliding table of the three-dimensional motion platform. The three-dimensional motion platform is used for realizing a set motion path to finish forming of a target part; the substrate surface is used to shape the target part and conduct away excess heat in a thermally conductive and convective manner.
The invention provides a manufacturing method of a particle reinforced aluminum matrix composite molten drop composite arc additive, which comprises a part/material/path design planning stage, a material/equipment preparation stage, a forming and process monitoring stage and a post-treatment and quality detection stage. A composite design step is added between the model design and the forming path planning for determining the selection of matrix materials and reinforcing particles and the implantation proportion of reinforcing particles in the composite during the design planning stage. In the forming preparation step, the forming environment requirement is included, and for the manufacturing of the easily-oxidized material molten drop composite arc additive, the forming process needs to be ensured to be in an inert atmosphere environment with low water and low oxygen. Meanwhile, in the forming preparation step, the tightness detection after the raw material filling and molten drop generating system is assembled is standardized. In the two steps of heating and function verification of the droplet generation system, the heating parameters and the flow of each function verification of the droplet generation system after heating to a preset temperature are standardized, and the flow verification comprises basic function verification such as pressure detection, air pressure loading, laser liquid level measurement and the like, and function verification of jet flow state and jet flow, and is used for ensuring that the key system droplet generation system can normally operate in the later forming stage. The main object of process monitoring is normalized in the forming process monitoring step: macroscopic shape and lap joint defects, the former is used for ensuring the forming precision, and the latter is used for ensuring the lap joint quality on the macroscopic scale. After the forming and post-treatment steps are completed, a quality detection step is added subsequently, and the detection link comprises dimensional accuracy, density, internal defects, microstructure and mechanical properties and is used for ensuring that the delivered part meets the manufacturing accuracy and quality requirements.
In summary, the invention uses the variable-polarity gas tungsten arc as a heat source to realize high-quality interlayer metallurgical bonding; the independent molten drop generating system is used for replacing a wire feeding mechanism in the traditional arc fuse additive manufacturing system, so that the substrate material adding process is hardly influenced by an arc state, and the process adaptability is remarkably improved; the particle reinforced phase is synchronously implanted into an arc melting pool in a gas-borne powder mode through an independent powder feeding system, so that additive manufacturing of the particle reinforced aluminum matrix composite is realized.
The technical scheme of the invention is further described in detail through the drawings and the embodiments.
Drawings
FIG. 1 is a schematic diagram of a droplet-based composite arc additive manufacturing apparatus of the particle-reinforced aluminum-based composite of the present invention;
FIG. 2 is a schematic diagram of an aluminum alloy melt flow control assembly based on a labyrinth flow channel according to the present invention, wherein (a) is the labyrinth flow channel flow control assembly and (b) is the labyrinth flow control sheet;
FIG. 3 is an SEM image of an exemplary microstructure of a particle-reinforced aluminum-based composite material of the present invention;
FIG. 4 is a flow chart of a droplet-based composite arc additive manufacturing process for a particle-reinforced aluminum-based composite component of the present invention;
fig. 5 is an enlarged view of a portion a in fig. 1.
Wherein: 1. water-cooling the top cover; 1-1, a top cover water cooling cavity; 1-2, top cover radiating fins; 2. a cooling water inlet; 3. a pressure sensor; 4. a laser distance sensor; 5. a cooling water outlet; 6. a cooling system; 7. a material addition inlet; 8. an air inlet/outlet port; 9. a pneumatic drive system; 10. a high-temperature sealing ring; 11. smelting a crucible; 11-1, measuring temperature holes of a crucible; 12. an aluminum alloy melt; 13. ceramic filter sheets; 14. a filter flange; 15. a flow control assembly; 15-1, a runner inlet protection sheet; 15-1-1. Flow channel inlet; 15-1-2, an inlet sedimentation tank; 15-2, labyrinth type flow control sheets; 15-2-1. A flow control plate inlet; 15-2-2. Maze flow channel; 15-2-3. A flow control sheet outlet; 15-3, a runner outlet protection sheet; 15-3-1, a runner outlet; 16. an adapter flange; 17. a spray head; 17-1, a nozzle temperature measuring hole; 17-2, jet nozzles; 17-3, end faces of the spray heads; 18. a heating jacket; 19. a crucible thermocouple; 20. a nozzle thermocouple; 21. a temperature controller; 22. an induction heating coil; 23. an induction heating power supply; 24. an arc welding torch; 25. a welding power supply; 26. a powder feeding pipe; 27. a powder feeder; 28. a particle reinforced aluminum matrix composite member; 29. a substrate; 30. a three-dimensional motion platform; 31. a jet of aluminum melt; 32. dripping; 33. a powder flow; 34. an arc melt pool; 35. an arc; 36. a tungsten electrode; 37. a tungsten electrode protection nozzle; 38. a powder feeding nozzle; 39. a powder feeding nozzle clamp; 40. an aluminum base; 41. a particulate reinforcing phase.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are some, but not all embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "one side", "one end", "one side", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are merely for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present invention. Furthermore, in the description of the present invention, unless otherwise indicated, the meaning of "a plurality" is two or more.
In the description of the present invention, it should be noted that, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
It should be understood that the terms "comprises" and "comprising," when used in this specification and the appended claims, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
It is also to be understood that the terminology used in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used in this specification and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.
It should be further understood that the term "and/or" as used in the present specification and the appended claims refers to any and all possible combinations of one or more of the associated listed items, and includes such combinations.
Various structural schematic diagrams according to the disclosed embodiments of the present invention are shown in the accompanying drawings. The figures are not drawn to scale, wherein certain details are exaggerated for clarity of presentation and may have been omitted. The shapes of the various regions, layers and their relative sizes, positional relationships shown in the drawings are merely exemplary, may in practice deviate due to manufacturing tolerances or technical limitations, and one skilled in the art may additionally design regions/layers having different shapes, sizes, relative positions as actually required.
Referring to fig. 1, the invention provides a droplet composite arc additive manufacturing device for a particle reinforced aluminum matrix composite material, which comprises a droplet generation system, an arc heat source, a reinforced particle powder feeding device and a three-dimensional motion platform. The droplet generation system cooperates with the arc heat source and the enhanced particle powder feeder, respectively, to form a particle-enhanced aluminum-based composite member 28 on a three-dimensional motion platform.
The molten drop generating system comprises a water-cooling top cover assembly, an air pressure driving system 9, a crucible smelting unit, a flow control assembly 15 and a spray head 17; the water-cooling top cover assembly is arranged above the smelting crucible 11 in the crucible smelting unit, the air pressure driving system 9 is connected with the crucible smelting unit through the water-cooling top cover assembly, the flow control assembly 15 is arranged at the lower part of the crucible smelting unit, and the spray head 17 is arranged at the bottom of the crucible smelting unit.
The water-cooling top cover assembly comprises a water-cooling top cover 1, wherein a cooling water inlet 2, a cooling water outlet 5, a pressure sensor 3, a laser distance sensor 4, a material adding inlet 7 and an air inlet/outlet 8 are respectively arranged on the water-cooling top cover 1, a top cover water-cooling cavity 1-1 is arranged in the water-cooling top cover 1, and a top cover cooling fin 1-2 is arranged between the lower side of the water-cooling top cover 1 and a smelting crucible 11.
Wherein, a cooling system 6 is arranged between the cooling water inlet 2 and the cooling water outlet 5, cooling water enters the top cover water cooling cavity 1-1 through the cooling water inlet 2, returns to the cooling system 6 from the cooling water outlet 5 and flows through the top cover water cooling cavity 1-1 in a circulating manner, so that the pressure sensor 3 and the laser distance sensor 4 are ensured to work in a proper temperature range.
The air pressure driving system 9 is respectively connected with the pressure sensor 3 and the laser distance sensor 4, the air pressure driving system 9 respectively receives real-time air pressure signals in the crucible measured by the pressure sensor 3 and liquid level signals of the aluminum alloy melt 12 in the smelting crucible 11 measured by the laser distance sensor 4, and applies proper air pressure to the aluminum alloy melt 12 in the smelting crucible 11 through the air inlet/outlet 8, so that the flow rate of the molten drop generating system (namely, the flow rate of the aluminum melt jet 31) is ensured to meet the requirement of additive manufacturing of the particle reinforced aluminum matrix composite material.
The smelting crucible 11 is arranged below the water-cooling top cover 1, the water-cooling top cover 1 is connected with the smelting crucible 11 through threads, the top cover cooling fin 1-2 is arranged at the threaded end of the bottom of the water-cooling top cover 1, and the top cover cooling fin 1-2 can reduce heat transferred from the bottom smelting crucible 11 to the water-cooling top cover 1.
The high-temperature sealing ring 10 is arranged between the water-cooling top cover 1 and the smelting crucible 11, and the high-temperature sealing ring 10 has a thermal expansion characteristic, so that a sealing gap caused by the difference of thermal expansion coefficients of matched threads between the water-cooling top cover 1 and the smelting crucible 11 in a heating process can be made up.
A filtering flange 14 is arranged at the bottom of the smelting crucible 11, and a ceramic filter disc 13 is arranged between the smelting crucible 11 and the filtering flange 14; the ceramic filter 13 is foamed ceramic or honeycomb ceramic, or other high-temperature resistant and metal melt corrosion resistant materials with porous structures.
The bottom of the filter flange 14 is provided with an adapter flange 16, and a flow control assembly 15 is arranged between the filter flange 14 and the adapter flange 16; the adapter flange 16, the flow control assembly 15, the filter flange 14 and the melting crucible 11 are arranged in a stacked manner, and the contact surfaces are sealed with plane surfaces and locked by screws or studs.
The fastening screw or the stud is made of metal or ceramic materials with low thermal expansion coefficients, so that the screw or the stud is effectively pre-tightened at high temperature, and further reliable plane sealing is realized.
Referring to fig. 2, the flow control assembly 15 includes a flow channel inlet protection sheet 15-1, a labyrinth flow control sheet 15-2, and a flow channel outlet protection sheet 15-3, wherein the labyrinth flow control sheet 15-2 is disposed between the flow channel inlet protection sheet 15-1 and the flow channel outlet protection sheet 15-3.
Referring to fig. 2 (a), the runner inlet protection sheet 15-1 is designed with a runner inlet 15-1-1 and an inlet sedimentation tank 15-1-2, the bottom surface of the inlet sedimentation tank 15-1-2 is lower than the upper edge of the runner inlet 15-1-1, and the function of the inlet sedimentation tank 15-1-2 is to store insoluble impurities with a density higher than that of the aluminum alloy melt 12, so that the risk of the flow control assembly 15 being blocked by the insoluble impurities is effectively reduced.
Referring to fig. 2 (b), a labyrinth flow control plate inlet 15-2-1, a labyrinth flow passage 15-2-2 and a flow control plate outlet 15-2-3 are designed on the labyrinth flow control plate 15-2, and the flow control plate inlet 15-2-1 is connected with the flow control plate outlet 15-2-3 through the labyrinth flow passage 15-2-2; the labyrinth flow passage 15-2-2 has a labyrinth curved periodic structure, and any periodic flow passage structure with obvious fluid energy consumption effect belongs to the labyrinth flow passage.
The flow passage outlet protection sheet 15-3 is designed with a flow passage outlet 15-3-1.
The bottom of the adapter flange 16 is connected with a spray head 17, the spray head 17 is provided with a spray head temperature measuring hole 17-1, a jet nozzle 17-2 and a spray head end face 17-3, and the jet nozzle 17-2 and the spray head end face 17-3 are made of graphite, aluminum oxide or aluminum nitride and other materials so as to ensure that the spray head end face 17-3 of the jet nozzle 17-2 is not infiltrated by the aluminum alloy melt 12 and does not generate obvious corrosion.
The periphery of the smelting crucible 11, the aluminum alloy melt 12, the ceramic filter disc 13, the filter flange 14, the flow control assembly 15 and the adapter flange 16 is provided with an induction heating coil 22, and the induction heating coil 22 is electrically connected with an induction heating power supply 23.
The heating jacket 18 is provided outside the shower head 17 to heat the shower head 17, and the heating jacket 18 is resistance-heated or induction-heated.
The smelting crucible 11 is provided with a crucible temperature measuring hole 11-1, a crucible thermocouple 19 is arranged in the crucible temperature measuring hole 11-1, a nozzle temperature measuring hole 17-1 is arranged on the nozzle 17, a nozzle thermocouple 20 is arranged in the nozzle temperature measuring hole 17-1, the crucible thermocouple 19 and the nozzle thermocouple 20 are respectively and electrically connected with a temperature controller 21, and the temperature controller 21 is respectively and electrically connected with an induction heating power supply 23 and a heating sleeve 18; the temperature controller 21 collects temperature signals from the crucible thermocouple 19 and the shower nozzle thermocouple 20, and regulates the heating process of the induction heating power supply 23 and the heating jacket 18.
Wherein, the crucible thermocouple 19 and the nozzle thermocouple 20 are thermocouples or other devices with temperature measuring function.
The arc heat source comprises an arc welding torch 24 and a welding power supply 25, wherein the arc welding torch 24 is provided with a tungsten electrode 36, the tungsten electrode 36 is electrically connected with the welding power supply 25, when the welding power supply 25 works, the tail end of the tungsten electrode 36 generates an arc 35, the arc 35 acts on a substrate 29 or a formed deposition layer to generate an arc melting pool 34, and a tungsten electrode protection nozzle 37 is arranged outside the tungsten electrode 36.
The reinforcing particle powder feeding device includes a powder feeding nozzle 38, a powder feeding nozzle holder 39, a powder feeding tube 26, and a powder feeder 27. The powder feeder 27 is connected to one end of the powder feeding pipe 26, the other end of the powder feeding pipe 26 is connected to the powder feeding nozzle 38, the powder feeding nozzle 38 is fixed to the powder feeding nozzle fixture 39, the tungsten electrode protection nozzle 37 is also fixed to the powder feeding nozzle fixture 39, and the powder feeder 27 is to feed the mixture of gas and reinforcing particles in the form of gas-borne powder in the form of powder flow 33 through the powder feeding pipe 26 and the powder feeding nozzle 38.
Referring to fig. 5, the jet nozzle 17-2 of the nozzle 17 extends to the nozzle end face 17-3 to satisfy the requirement of continuous forming; the molten aluminum jet 31 generated by the droplet generation system, after exiting through the jet nozzle 17-2, is dispersed into droplets 32 that enter the arc pool 34 formed by the arc 35 generated by the tungsten electrode 36 along with the powder stream 33 from the powder feed nozzle 38.
Wherein the discrete process of droplets 32 is naturally occurring, and may also be controlled by introducing a disturbance of a certain frequency.
A base plate 29 is arranged below the spray head 17, and the base plate 29 is arranged on a movable slipway of a three-dimensional movement platform 30 and moves along with the slipway, and moves according to a planned path under the control of a computer.
Wherein the substrate 29 is part of the target member or is not contained within the target member.
In the droplet-composite arc additive manufacturing process, droplets 32 and powder flow 33 are synchronously fed into an arc bath 34, and along with the relative movement of an arc 35 and a substrate 29, the particulate phases contained in the powder flow will be dispersed in the aluminum matrix along with the movement and solidification of the arc bath 34 to form a particulate reinforced aluminum matrix composite deposit layer, which is deposited channel by channel/layer by layer under the control of a computer to form a target particulate reinforced aluminum matrix composite member 28 until a prescribed manufacturing task is completed.
The droplet-composite arc additive manufacturing system may be operated in an inert atmosphere environment to improve the stability of the manufacturing process, the manufacturing quality and mechanical properties of the component 28.
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. The components of the embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the invention, as presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to FIG. 3, an SEM image of an exemplary microstructure of a particle-reinforced aluminum matrix composite material is shown, wherein the black background is an aluminum matrix 40 and the gray-white globular phase is a particle-reinforced phase 41.
The aluminum substrate 40 is pure aluminum or other aluminum alloys with weldability, including but not limited to, grades a356, 2219, 4043, 4047, 5356, 6061, etc.
The particle-reinforced phase 41 is a metal particle, a ceramic particle, or a metal-ceramic composite particle, including but not limited to a pure metal particle, an alloy particle, a carbide ceramic particle, a nitride ceramic particle, or the like.
Referring to fig. 4, the method for manufacturing the droplet composite arc additive of the particle reinforced aluminum matrix composite material comprises the following steps:
s1, model design
And designing a three-dimensional model of the target part by adopting CAD software according to the shape and the application condition of the target part.
S2, composite design
Designing a composite material according to the three-dimensional model obtained in the step S1 and combining the functional requirements of the target part; design considerations include, but are not limited to, matrix material selection, reinforcement particle selection, and reinforcement particle implantation ratio setting.
S3, forming path planning
And (3) determining a forming path file (wherein the forming path file comprises coordinate information of each layer, interpolation movement mode information between coordinate points, movement speed information, layer height information, layer number information, deposition rate information and current value information of an arc heat source) according to the three-dimensional model obtained in the step (1) and the composite material determined in the step (2) and technological parameters such as deposition rate, layer height, moving speed and arc current. The deposition rate is 100-300 mm 3 And/s, the layer height is 1-4 mm, the moving speed is 3-15 mm/s, and the arc current is 100-500A.
S4, raw material preparation
And calculating the amount of aluminum alloy and particle reinforcement phase required by forming according to the three-dimensional model obtained in S1, the composite material determined in S2, the planned forming path in S3 and the number of target parts, and preparing the required raw materials. The method comprises the steps of removing dirt and thicker oxide films on the surface of the raw material, cleaning the raw material with absolute ethyl alcohol, and finally removing residual moisture on the surface of the raw material by adopting a heating drying or (and) vacuumizing mode.
S5, preparation for forming
For the aluminum alloy material to be easily oxidized, it should be ensured that the forming environment is an argon (or other inert atmosphere) environment, and the water and oxygen content in the atmosphere does not exceed 100ppm. After raw material preparation and forming environment preparation are completed, checking functions of a cooling system, an arc heat source, a three-dimensional movement unit and a pneumatic driving system which are involved in the particle reinforced aluminum matrix composite molten drop composite arc additive manufacturing device, and ensuring that all subsystems can work normally. After this, the aluminum alloy material prepared in S4 (in whole or in part) is charged into a melting crucible and the droplet generation system is assembled. After the molten drop generating system is assembled, the tightness of the molten drop generating system needs to be detected, so that the normal loading of the air pressure can be ensured;
S6, heating
After the preparation for forming is finished, starting a cooling system, setting heating parameters of a temperature controller, wherein the heating parameters comprise final heating temperature (650-750 ℃) and heating rate (10-100 ℃/min), and then starting an induction heating power supply 23 and a nozzle heating sleeve 18;
s7, functional verification of molten drop generating system
After the droplet generation system is heated to a preset temperature, whether the functions of the droplet generation system are normal or not needs to be verified, wherein the functions comprise a pressure detection function, an air pressure loading function, a laser liquid level measurement function and the like. Then, the jet state and the jet flow rate are verified, and if the jet state is unstable or the flow rate error exceeds 10% (or the flow rate fluctuation is more than 5%) in a predetermined pressure range, the steps S5 to S7 are repeated.
S8, forming
The data file for part forming (the forming path file obtained by S3) is imported into the process control computer, the welding power supply 25 and the powder feeder 27 are turned on, and thereafter, the target member printing program is started to be executed.
S9, monitoring forming process
In the process of forming the target part, real-time morphology monitoring should be performed to determine whether the formed part meets the design requirements. The process parameters can be adjusted in real time to meet the forming requirements (including forming dimensional accuracy and lap quality), if the forming accuracy deviates significantly from the dimensional requirements of the parts or serious lap defects occur, the forming is stopped, the current parts are scrapped, and the related data in the forming path file is checked and corrected. And after the related parameters are corrected, repeating the steps S8 and S9 until the part manufacturing is completed.
S10, post-treatment
And after the target part is printed, and is cooled to the temperature capable of being manually operated, taking out the substrate and the printed part, and removing the part which does not belong to the part, wherein the process comprises the steps of removing the substrate, removing auxiliary support, removing surface-adhered powder, or removing the machining allowance of the part in a machining mode, and if the requirement exists, adding heat treatment or surface treatment of the part.
S11, quality detection
The quality detection links include, but are not limited to, size measurement, density test, CT scan, etc.; the simulation sample can be subjected to destructive testing according to requirements, including metallographic characterization, mechanical property testing, frictional wear performance testing and the like. And if the parts meet the use requirements, delivering or continuing the manufacture of the rest parts. And if the part cannot pass the quality detection, scrapping treatment is carried out.
The method of the invention provides a general flow suitable for manufacturing the molten drop composite arc additive of the aluminum alloy/particle reinforced aluminum matrix composite. The method mainly comprises a part/material/path design planning stage, a material/equipment preparation stage, a forming and process monitoring stage and a post-treatment and quality detection stage. Step S2 composite design is added between the step S1 model design and the step S3 forming path planning, and is used for determining the selection of matrix materials and reinforcing particles and the implantation proportion of the reinforcing particles in the composite material in the design planning stage. In the step S5 of forming preparation, the requirement of forming environment is included, and for the manufacturing of the easily-oxidized material molten drop composite arc additive, the forming process needs to be ensured to be in an inert atmosphere environment with low water and low oxygen. Meanwhile, in the step S5 of forming preparation, the tightness detection after the raw material filling and the droplet generation system assembly is completed is standardized, and the air pressure loading function is used for detecting the tightness of the droplet generation system. In the two steps of heating in the step S6 and verifying the functions of the droplet generation system in the step S7, the heating parameters and the verification flow of each function of the droplet generation system after heating to a preset temperature are standardized, and the verification flow comprises basic function verification such as pressure detection, air pressure loading, laser liquid level measurement and the like, and function verification of jet flow state and jet flow, and is used for ensuring that the key system droplet generation system can normally operate in the later forming (S8) stage. The main object of process monitoring is normalized in step S9 of shaping process monitoring: macroscopic shape and lap joint defects, the former is used for ensuring the forming precision, and the latter is used for ensuring the lap joint quality on the macroscopic scale. After the shaping and post-treatment steps specified in the steps S8-S10 are completed, the quality detection in the step S11 is added subsequently, and the detection links comprise dimensional accuracy, density, internal defects, microstructure and mechanical properties and are used for ensuring that the delivered parts meet the manufacturing accuracy and quality requirements.
In summary, according to the device and the method for manufacturing the particle reinforced aluminum matrix composite material by using the droplet composite arc additive, the variable-polarity gas tungsten electrode arc is used as a heat source, so that high-quality interlayer metallurgical bonding is realized; the independent molten drop generating system is used for replacing a wire feeding mechanism in the traditional arc fuse additive manufacturing system, so that the substrate material adding process is hardly influenced by an arc state, and the process adaptability is remarkably improved; the particle reinforced phase is synchronously implanted into an arc melting pool in a gas-borne powder mode through an independent powder feeding system, so that additive manufacturing of the particle reinforced aluminum matrix composite is realized.
The above is only for illustrating the technical idea of the present invention, and the protection scope of the present invention is not limited by this, and any modification made on the basis of the technical scheme according to the technical idea of the present invention falls within the protection scope of the claims of the present invention.
Claims (7)
1. The particle reinforced aluminum matrix composite material molten drop composite arc additive manufacturing device is characterized by comprising a molten drop generating system, wherein the molten drop generating system is used for generating an aluminum melt jet flow (31), the particle reinforced aluminum matrix composite material molten drop composite arc additive manufacturing device comprises a smelting crucible (11), a water-cooling top cover assembly is arranged at the upper part of the smelting crucible (11), the lower part of the smelting crucible (11) is connected with a spray head (17) through a flow control assembly (15), a periodical labyrinth flow passage structure is arranged in the flow control assembly (15), an arc heat source and an enhanced particle powder feeding device are arranged on one side of the spray head (17), the arc heat source is used for generating an arc melting pool (34), the enhanced particle powder feeding device is used for mixing gas and enhanced particles to form a powder flow (33), the aluminum melt jet flow (31) enters the arc melting pool (34) together with the powder flow (33) after being dispersed into the molten drop (32), a particle reinforced aluminum matrix composite material deposition layer is formed along with the movement and solidification of the arc melting pool, and a target particle reinforced aluminum matrix composite material component (28) is formed through successive/layer deposition;
The water-cooling top cover assembly comprises a water-cooling top cover (1), wherein a cooling water inlet (2), a cooling water outlet (5), a material adding inlet (7) and an air inlet/outlet (8) are formed in the water-cooling top cover (1), a top cover water-cooling cavity (1-1) is formed in the water-cooling top cover (1), a cooling system (6) is arranged between the cooling water inlet (2) and the cooling water outlet (5), cooling water enters the top cover water-cooling cavity (1-1) through the cooling water inlet (2), and returns to the cooling system (6) from the cooling water outlet (5);
a filtering flange (14) is arranged at the bottom of the smelting crucible (11), and a ceramic filter disc (13) is arranged between the smelting crucible (11) and the filtering flange (14); the bottom of the filtering flange (14) is provided with an adapter flange (16), the flow control assembly (15) is arranged between the filtering flange (14) and the adapter flange (16), the flow control assembly (15), the filtering flange (14) and the smelting crucible (11) are arranged in a laminated mode; the bottom of the adapter flange (16) is connected with a spray head (17), a heating sleeve (18) is arranged outside the spray head (17), and the heating sleeve (18) is electrically connected with a temperature controller (21);
The flow control assembly (15) comprises a flow passage inlet protection sheet (15-1) and a flow passage outlet protection sheet (15-3), and a labyrinth flow control sheet (15-2) is arranged between the flow passage inlet protection sheet (15-1) and the flow passage outlet protection sheet (15-3); the runner inlet protection sheet (15-1) is provided with a runner inlet (15-1-1) and an inlet sedimentation tank (15-1-2), and the bottom surface of the inlet sedimentation tank (15-1-2) is lower than the upper edge of the runner inlet (15-1-1); a flow control sheet inlet (15-2-1) is arranged on the labyrinth flow control sheet (15-2), the flow control sheet inlet (15-2-1) is connected with a flow control sheet outlet (15-2-3) through a labyrinth flow passage (15-2), and the labyrinth flow passage (15-2-2) has a labyrinth bent periodic structure; the runner outlet protection sheet (15-3) is provided with a runner outlet (15-3-1).
2. The device for manufacturing the particle-reinforced aluminum matrix composite molten drop composite arc additive according to claim 1, wherein a pressure sensor (3) and a laser distance sensor (4) are arranged on the water-cooled top cover (1), and the pressure sensor (3) and the laser distance sensor (4) are respectively connected with a pneumatic driving system (9).
3. The particle reinforced aluminum matrix composite material molten drop composite arc additive manufacturing device according to claim 1, wherein a top cover radiating fin (1-2) is arranged between the lower side of the water-cooling top cover (1) and the smelting crucible (11), a high-temperature sealing ring (10) is arranged between the top cover radiating fin (1-2) and the smelting crucible (11), an induction heating coil (22) is arranged outside the smelting crucible (11), and the induction heating coil (22) is electrically connected with an induction heating power supply (23).
4. The particle reinforced aluminum matrix composite molten drop composite arc additive manufacturing device according to claim 1, wherein a crucible temperature measuring hole (11-1) is formed in the smelting crucible (11), a crucible thermocouple (19) is arranged in the crucible temperature measuring hole (11-1), a nozzle temperature measuring hole (17-1) is formed in the nozzle (17), a nozzle thermocouple (20) is arranged in the nozzle temperature measuring hole (17-1), and the crucible thermocouple (19) and the nozzle thermocouple (20) are respectively electrically connected with the temperature controller (21).
5. The particle-reinforced aluminum matrix composite droplet composite arc additive manufacturing device of claim 1, wherein the reinforcing particle powder feeder comprises a powder feeder (27), the powder feeder (27) is connected with a powder feeder nozzle (38) through a powder feeder tube (26), and the powder feeder nozzle (38) is fixed on the arc welding torch (24) through a powder feeder nozzle clamp (39).
6. The device for manufacturing the particle-reinforced aluminum-based composite material molten drop composite arc additive according to claim 1, wherein a substrate (29) is arranged below the spray head (17), and the substrate (29) is connected with a three-dimensional motion platform (30).
7. A method for manufacturing a droplet-based composite arc additive by using the droplet-based composite arc additive manufacturing device of the particle-reinforced aluminum-based composite material according to claim 1, comprising the following steps:
S1, designing a three-dimensional model of a target part according to the shape and the application condition of the target part;
s2, designing a composite material according to the three-dimensional part model obtained in the step S1 and combining the functional requirements of a target part, wherein the composite material comprises matrix material type selection, reinforced particle type selection and reinforced particle implantation proportion setting of the composite material;
s3, determining a forming path file according to the three-dimensional model obtained in the step S1 and the composite material determined in the step S2, and the deposition rate, the layer height, the moving speed and the arc current process parameters, wherein the deposition rate in the forming path file is 100-300 mm 3 The layer height is 1-4 mm, the moving speed is 3-15 mm/s, and the arc current is 100-500A;
s4, calculating the amount of aluminum alloy and particle reinforcement phase required by forming according to the three-dimensional model obtained in the step S1, the composite material determined in the step S2, the planned forming path in the step S3 and the number of target parts;
s5, forming the aluminum alloy material easy to oxidize in an inert atmosphere, wherein the water and oxygen content in the atmosphere is not more than 100 ppm, and filling the aluminum alloy material prepared in the step S4 into a smelting crucible and assembling a molten drop generating system;
s6, starting a cooling system, setting the final heating temperature to 650-750 ℃ and the heating rate to 10-100 ℃/min, and heating the droplet generation system in the step S5;
S7, after the droplet generation system in the step S6 is heated to a preset temperature, verifying whether a pressure detection function, an air pressure loading function and a laser liquid level measurement function of the droplet generation system are normal, verifying the jet flow state and the jet flow rate, and repeating the steps S5-S7 if the jet flow state is unstable or the flow rate error exceeds 10% or the flow rate fluctuation is greater than 5% in a preset pressure range;
s8, printing the target component according to the forming path file obtained in the step S3;
s9, performing real-time morphology monitoring in the printing process of the step S8, if the forming precision deviates from the size requirement of the part or a lap joint defect occurs, suspending forming, correcting the related data in the forming path file obtained in the step S3, and repeating the step S9 until the part manufacturing is completed;
and S10, after the printing of the target part in the step S9 is completed, removing the part which does not belong to the part to obtain the target part.
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| CN115383136B (en) * | 2022-09-19 | 2024-05-14 | 上海交通大学 | Additive preparation device and method |
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| CN118060667A (en) * | 2022-11-24 | 2024-05-24 | 深圳先进技术研究院 | Arc additive manufacturing device and arc additive manufacturing method |
| US20240189895A1 (en) * | 2022-12-07 | 2024-06-13 | Xerox Corporation | System and method for liquid metal jet printing with plasma assistance |
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