CN115091000B - Arc-assisted hot wire space support rod-free efficient additive manufacturing equipment and method - Google Patents
Arc-assisted hot wire space support rod-free efficient additive manufacturing equipment and method Download PDFInfo
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- CN115091000B CN115091000B CN202210789343.5A CN202210789343A CN115091000B CN 115091000 B CN115091000 B CN 115091000B CN 202210789343 A CN202210789343 A CN 202210789343A CN 115091000 B CN115091000 B CN 115091000B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
- B23K9/044—Built-up welding on three-dimensional surfaces
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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
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Abstract
The invention relates to an arc-assisted hot wire space support-rod-free efficient additive manufacturing device and method. The apparatus includes: the device comprises a hot wire machine, a conductive nozzle, a wire feeder, a substrate and a workbench; the wire feeder is used for feeding wires to the contact nozzle so as to manufacture a substrate without support rods on the substrate and place the substrate on the workbench; the wire material passes through the contact tube and contacts with the unsupported rod piece; the hot wire machine is electrically connected with the contact nozzle; the hot wire current provided by the hot wire machine flows through the contact nozzle, the wire, the unsupported rod piece, the substrate and the workbench to form a loop, so that resistance heat is generated, the wire is melted into a molten pool, the forming efficiency of the unsupported rod unit can be improved, the solidification speed is increased, and the appearance of a crystal grain is controlled.
Description
Technical Field
The invention relates to the field of additive manufacturing technologies, in particular to efficient additive manufacturing equipment and method without a support rod in an arc-assisted hot wire space.
Background
The lattice structure has the advantages of light weight, high specific stiffness, high specific strength and the like, and also has the functions of shock absorption, energy absorption and the like. Is the best choice for many structures for light weight, improved strength and rigidity. Due to the fact that the metal lattice space structure is complex, the traditional processing method is difficult to meet the preparation requirements in terms of process and cost, and the additive manufacturing technology greatly solves the preparation problem of the complex space lattice structure.
Additive manufacturing technology is a layer-by-layer stacking technology from bottom to top, and theoretically can prepare various structures. Although the existing powder-spreading type additive manufacturing (such as a laser selective melting technology and an electron beam selective melting technology) has a mature process and application in the aspect of preparing a lattice structure, the method has the defects of high cost, small forming size and the like and has very low forming efficiency.
The arc wire additive manufacturing (WAAM) technology includes gas metal arc welding additive manufacturing (GMAW), plasma additive manufacturing (PAW) and Gas Tungsten Arc Welding (GTAW), and has the advantages of high efficiency, low cost and the like in preparing large-size structural members, and provides a new possibility for the efficient preparation of large-size lattice structural members, but at present, the lattice structure preparation related to the arc additive manufacturing is still in the initial stage, and related researches are few.
Tn.225242450, takeyukiAbea (2019) et al, university of Jade, prepared low carbon steel support bars without support bars at an inclination angle of 90-30 ° and BCC lattice structure using GMAW technique with a deposition efficiency of 1.5mm/min. And LiYongjie et al (2020) of Huazhong science and technology university also use GMAW technology to prepare aluminum alloy support-free bar and dot matrix mechanisms with an inclination angle of 90-15 degrees. The efficiency of the GMAW technique used to produce metal bars by VA Silvestru et al, the Federal institute of technology, zurich, is approximately 1mm/min. The method for preparing the unsupported lattice structure using GMAW technology is: starting melting wire → extinguishing arc waiting for the cooling of the molten pool → starting melting wire. The method has the advantages that the arc is frequently started and extinguished, the middle part of the method needs to wait for the cooling of a molten pool, and the deposition efficiency is greatly reduced. Compared with a GMAW additive manufacturing technology, GTAW has the advantages of being more stable, less in splashing and the like, and the surface quality of parts can be improved. In addition, because the heat source is independent of the wire feeding, a hot wire device can be independently added to assist the hot wire, and further, the heat input of the electric arc is reduced. Xutian autumn et al (2021) of Beijing university of Richardson has successfully prepared 90-0 degree titanium alloy support-free rod and lattice sandwich plate by hot wire assisted GTAW additive manufacturing technology, with preparation efficiency of 15mm/min, which is 10 times of GMAW technology.
The GTAW technique utilizes a pulse forming technique and utilizes a base current period to rapidly cool a molten pool, thereby avoiding time waste caused by arc quenching cooling and improving the efficiency to 15mm/min. GTAW technology uses the heat generated by the arc as the primary heat input, which needs to be increased if efficiency is to be increased, and a larger arc heat input may cause the molten pool to collapse and not be shaped. Thus limiting further increases in efficiency. Meanwhile, when the forming efficiency is low, the solidification rate of a rod unit molten pool is low, crystal grains are easy to grow, the crystal grains are coarse, and the mechanical property of the rod unit is poor.
In conclusion, in the existing arc additive manufacturing technology without support rods, the manufacturing efficiency of GMAW is 1-1.5mm/min, and the manufacturing efficiency of GTAW technology is 15mm/min. In the process of preparing the large-size lattice structure, the rod piece forming efficiency is improved, and the preparation efficiency of the lattice structure can be greatly improved.
Based on this, there is a need in the art to provide a novel additive manufacturing technique, which can improve the forming efficiency of the knightless unit and increase the solidification speed, thereby controlling the morphology of the crystal grains.
Disclosure of Invention
The invention aims to provide arc auxiliary hot wire space support-rod-free efficient additive manufacturing equipment and method, which take resistance heat generated by a hot wire as main heat input in an additive manufacturing process and arc heat as auxiliary heat input to improve the forming efficiency of a support-rod-free unit, increase the solidification speed and control the morphology of grains.
In order to achieve the purpose, the invention provides the following scheme:
an arc assisted hot wire space strut-less high efficiency additive manufacturing apparatus comprising: the device comprises a hot wire machine, a conductive nozzle, a wire feeder, a substrate and a workbench;
the wire feeder is used for feeding wires to the contact nozzle so as to manufacture a support-free rod piece on the substrate; the substrate is arranged on the workbench; the wire passes through the contact nozzle to be in contact with the unsupported rod piece or the substrate; the hot wire machine is electrically connected with the contact nozzle;
preferably, the wire diameter value is 0.8-3.2mm.
Preferably, the wire feeding speed of the wire feeder is 300-3000mm/min.
The hot wire machine is used for providing hot wire current; the hot wire current forms a loop through the contact tip, the wire, the unsupported rod, the substrate, and the platen.
Preferably, the method further comprises the following steps: a welding gun, a welding machine and a numerical control system;
the numerical control system is electrically connected with the welding gun, the welding machine and the wire feeder respectively; the welding gun is electrically connected with the welding machine; the welder is for providing an arc current to the welding gun.
Preferably, the hot wire current is direct current.
Preferably, the current value of the hot wire current is 100-200A.
Preferably, the arc current is a constant current or a pulse current.
Preferably, the current value of the arc average current is 5-30A.
Preferably, the method further comprises the following steps: a gas tank;
an output gas port of the gas tank is connected with a gas inlet pipeline of the welding machine; the gas tank is used for storing protective gas.
Preferably, the protective gas is argon.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects:
according to the arc-assisted hot wire space support-rod-free efficient additive manufacturing equipment provided by the invention, resistance heat is generated by adopting a mode that hot wire current provided by a hot wire machine forms a loop through the conductive nozzle, the wire material, the support-free rod piece, the substrate and the workbench, the wire material is melted into a molten pool, the forming efficiency of a support-rod-free unit can be improved, the solidification speed can be increased, and the appearance of crystal grains can be controlled.
In addition, the invention also provides an arc auxiliary hot wire space support rod-free efficient additive manufacturing method, which comprises the following steps:
performing G code programming according to the axis of the rod piece to generate a welding gun moving track;
starting the provided arc auxiliary hot wire space support-rod-free efficient additive manufacturing equipment;
mounting a substrate or a workpiece, and moving a welding gun to an initial point;
setting manufacturing parameters; the manufacturing parameters include: peak current, base current, duty ratio, current frequency, wire feeding speed and hot wire current of the welding machine;
starting a welding machine, and preheating a substrate or a workpiece by using the hot wire current to form a molten pool;
after preheating, starting a hot wire and a wire feeder;
the wire material is sent to a molten pool, a hot wire current forms a loop, and the wire material starts to be heated and is melted into the molten pool;
the electric arc is continuous, and heat is supplied to maintain the stability of the molten pool;
the welding gun moves according to the programmed track;
moving the welding gun to the end point, and finishing the preparation of the rod piece;
and turning off the arc auxiliary hot wire space support-rod-free efficient additive manufacturing equipment.
Preferably, the size of the melt pool is the same as the size of the workpiece.
Because the technical effect achieved by the arc-assisted hot wire space support-rod-free efficient additive manufacturing method provided by the invention is the same as the technical effect achieved by the arc-assisted hot wire space support-rod-free efficient additive manufacturing equipment provided by the invention, the details are not repeated herein.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
FIG. 1 is a schematic structural diagram of an arc-assisted hot-wire space support-rod-free high-efficiency additive manufacturing apparatus according to the present invention;
FIG. 2 is a flow chart of an arc assisted hot wire space support rod-free high-efficiency additive manufacturing method provided by the invention;
FIG. 3 is a graphical representation of the effects of weld pool topography with different efficiencies provided by embodiments of the present invention; wherein, part of the graph in FIG. 3 (a) is a molten pool shape effect graph of 12 mm/min; FIG. 3 (b) is a diagram of the effect of the topography of the molten pool at 24 mm/min; FIG. 3 (c) is a view of the effect of the topography of the molten pool at 36 mm/min; FIG. 3 (d) is a diagram showing the effect of the topography of the molten pool at 48mm/min;
FIG. 4 is a microstructure topography of a 316L stainless steel rod element formation of varying efficiencies provided by an embodiment of the present invention; wherein, FIG. 4 (a) is a microstructure topography of a 12mm/min 316L stainless steel rod unit forming; FIG. 4 (b) is a microstructure profile of a formed 316L stainless steel rod element of 24 mm/min; FIG. 4 (c) is a microstructure topography of 36mm/min 316L stainless steel rod element formation; FIG. 4 (d) is a microstructure topography of a 48mm/min 316L stainless steel rod element formation;
FIG. 5 is a photograph of samples of unsupported rods prepared with different efficiencies provided by embodiments of the invention; wherein the preparation efficiency from left to right along the page is 12mm/min, 24mm/min, 36mm/min and 48mm/min in sequence;
fig. 6 is a schematic diagram of the current carrying rate at different wire feeding speeds when the rod diameter is 8mm according to an embodiment of the present invention.
Description of the symbols:
1-hot wire machine, 2-contact nozzle, 3-wire feeder, 4-numerical control system, 5-welding machine, 6-welding gun, 7-gas tank, 8-unsupported rod piece, 9-base plate and 10-workbench.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
The invention aims to provide an arc-assisted hot wire space support-rod-free efficient additive manufacturing device and method, which can improve the forming efficiency of a support-rod-free unit to increase the solidification speed so as to control the morphology of crystal grains.
In order to make the aforementioned objects, features and advantages of the present invention more comprehensible, the present invention is described in detail with reference to the accompanying drawings and the detailed description thereof.
As shown in fig. 1, the arc-assisted hot-wire space support-rod-free high-efficiency additive manufacturing apparatus provided by the present invention comprises: hot-wire machine 1, contact tip 2, wire feeder 3, base plate 9 and workbench 10.
The wire feeder 3 is used to feed the wire to the contact tip 2 to prepare the unsupported rod member 8 on the base plate 9. The substrate 9 is placed on a table 10. The wire passes through the contact tip 2 to contact the substrate 9 or the unsupported rod 8. The hot wire machine 1 is electrically connected with the contact tip 2. The wire feeding speed of the wire feeder is preferably 300-3000mm/min
The hot wire machine 1 is used for supplying hot wire current. The hot wire current forms a loop through the contact nozzle 2, the wire material, the unsupported rod 8, the substrate 9 and the workbench 10, and the wire material has a very large resistance due to the very small diameter (0.8-3.2 mm), so that a large amount of resistance heat can be generated to heat and melt the wire material. The current of the hot wire may be direct current, and the current value may be 100-200A, but is not limited thereto. In the present invention, the base plate 9 may be another part that requires the fabrication of the unsupported beam 8. The table 10 may also be used to hold workpieces and form a ground.
Further, in order to keep the temperature of the molten pool formed on the unsupported rod 8 constant, the arc-assisted hot wire space support-rod-free high-efficiency additive manufacturing equipment provided by the invention is further provided with: a welding gun 6, a welding machine 5 and a numerical control system 4.
The numerical control system 4 is electrically connected with the welding gun 6, the welding machine 5 and the wire feeder 3 respectively, so as to control the wire feeding speed by adopting the numerical control system 4. The welding gun 6 is electrically connected with the welding machine 5, and the welding gun 6 can also be connected with a multi-shaft mechanical arm or a machine tool and is controlled by the numerical control system 4 to move. The welder 5 generates an electric arc between the wire and the unsupported rod 8 by means of a welding torch 6, melting and connecting the wire to the unsupported rod 8. In the present invention, the arc current is a constant current or a pulse current, and the current value thereof may be 5 to 30A.
Further, in order to improve the oxidation resistance of the equipment in the wire manufacturing process, the air tank 7 is also arranged in the equipment provided by the invention. The gas outlet and gas inlet of the gas tank 7 are connected to the gas inlet pipe of the welding machine 5 so that the molten metal is protected from the atmosphere by the welding machine 5 to the welding gun 6. The gas tank 7 is used for storing protective gas, and the protective gas is generally argon.
Based on the equipment structure provided by the invention, the energization time of the additive can be prolonged by increasing the wire feeding speed, so that the aim of improving the heat input is fulfilled. Resistance heat generated by the wire is used for melting the wire to a molten pool, and arc heat assists the hot wire to generate resistance heat to maintain the stability of the molten pool, so that the preparation of the unsupported rod 8 is realized. In addition, in the additive manufacturing process, the wire forms a loop when contacting with the rod piece, resistance heat is generated, the wire is fused into a molten pool, and the electric arc only provides a small amount of heat source to assist the resistance heat to maintain the stability of the molten pool.
The heat input is the key for preparing the support-free rod, the heat input mainly comprises 2 parts, namely, the arc heat input and the hot wire heat input, and the heat input in unit time can be calculated by the following formula:
H i =H a +H w
H a =I a ×V a ×η
wherein H i For heat input per unit time of the bath, H a Heat input and H for arc w For heat input from the heater, I a Is the average current of the arc, V a Is the arc average voltage, η is the welder efficiency, I w Is the current of the wire, R w The resistance of the wire (the resistance of the wire from the contact nozzle to the molten pool), omega the hot wire electrifying rate and zeta the hot wire efficiency.
As shown in fig. 2, the arc-assisted hot wire space support rod-free high-efficiency additive manufacturing method provided by the invention comprises the following specific processes:
performing G code programming according to the axis of the rod piece to generate a welding gun moving track;
and starting the arc auxiliary hot wire space support-rod-free efficient additive manufacturing equipment. Comprises a hot wire machine, a machine tool, a numerical control system, a welding machine, a wire feeder and the like;
mounting a substrate or a workpiece, and moving a welding gun to an initial point;
manufacturing parameters are set. Manufacturing parameters comprise peak current, base current, duty ratio, current frequency, wire feeding speed and hot wire current of the welding machine;
starting a welding machine, and preheating the substrate or the workpiece by using large current to form a rod diameter molten pool;
after preheating, starting a hot wire and a wire feeder;
feeding the wire material to a molten pool, forming a loop by hot wire current, starting heating the wire material, and melting the wire material into the molten pool;
the electric arc is continuous, and partial heat is provided to maintain the stability of a molten pool;
the welding gun moves according to a programmed track;
moving the welding gun to the end point, and finishing the preparation of the rod piece;
closing the wire feeding, the hot wire and the arc extinguishing;
the devices were shut down.
The following describes a process of additive manufacturing by using the arc-assisted hot wire space support-rod-free high-efficiency additive manufacturing equipment provided above, taking 316L stainless steel as an example.
The manufacturing parameters of 316L stainless steel are shown in fig. 1. The 316L stainless steel preparation mode takes electric arc as the main part and hot wire as the auxiliary part, and the gradual transition mostly takes the hot wire as the main part and the electric arc as the auxiliary part.
Wherein, under the condition that the preparation efficiency is 12mm/min, if the electric arc heat input is large, the melting of the wire material mainly depends on the electric arc heat input, and the hot wire heats the wire material in an auxiliary way, as shown in part 3 (a). The time for the hot wire to directly contact with the molten pool is short, and the energizing rate is only 0.28, which is the hot wire auxiliary arc additive manufacturing technology used at present.
To improve the efficiency of rod preparation, the scanning speed needs to be increased, and the wire feeding speed needs to be increased correspondingly. With the increase of the wire feeding speed, the heat input of the electric arc cannot meet the requirement of melting wires, and if the heat input of the electric arc is increased, the molten pool is too large, so that the molten pool collapses. Therefore, there is a need to increase the heat input to the hot wire so that the hot wire melts the wire. When the wire feeding speed is increased, the arc current is properly reduced, so that the hot wire can be prevented from being fused by the arc, the time for forming a loop by the current of the hot wire can be prolonged, and the heat input of the hot wire is increased. As can be seen from fig. 3 (b) to fig. 3 (d), as the efficiency increases, the transition form of the droplet is free to transition from a droplet-like state to a liquid bridge transition and finally to a contact transition. The conduction ratios of the hot wire currents were 0.28, 0.52, 0.74, and 0.97, respectively. As shown in fig. 6, the hot-wire energization rate increases, and the resistance heat generated per unit time also increases. The preparation efficiency is improved by 4 times from 12mm/min to 48 mm/min.
The arc additive manufacturing parameters of the 316L stainless steel support-free rod under different preparation efficiencies are shown in table 1, and the microstructures of the prepared 316L stainless steel rod are shown in parts 4 (a) - (d), so that when the forming rate is low, the microstructures are columnar crystals, the crystal grains are reduced along with the increase of the forming efficiency, and when the forming rate is high, the crystal grains are converted into isometric crystals. Photo samples of unsupported rods finally prepared at different efficiencies are shown in parts (a) - (d) of fig. 5.
Table 1 electric arc additive manufacturing parameter table for 316L stainless steel support-less bars with different preparation efficiency
Based on the description, the invention uses the hot wire as the main heat input and the electric arc as the auxiliary heat input, and the unsupported rod piece is efficiently prepared, the efficiency can reach 48mm/min, which is 32 times that of GMAW technology and 3.2 times that of GTAW technology.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other.
The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to help understand the method and the core concept of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (7)
1. An arc-assisted hot wire space support rod-free additive manufacturing method is characterized by comprising the following steps:
performing G code programming according to the axis of the rod piece to generate a welding gun moving track;
starting the electric arc auxiliary hot wire space support rod-free additive manufacturing equipment;
mounting a substrate, and moving a welding gun to an initial point;
setting manufacturing parameters, the manufacturing parameters including: peak current, base current, duty ratio, current frequency, wire feeding speed and hot wire current of the welding machine;
starting a welding machine, and preheating the substrate by using arc current to form a molten pool with the size of the rod diameter;
after preheating, starting a hot wire machine and a wire feeder;
the wire material is sent to a molten pool, hot wire current forms a loop, and the wire material is melted to the molten pool by using resistance heat generated by the wire material;
the electric arc continuously provides heat to maintain the stability of the molten pool;
the welding gun moves according to the programmed track;
moving the welding gun to the end point, and finishing the preparation of the rod piece;
turning off the arc auxiliary hot wire space support rod-free additive manufacturing equipment;
wherein, the supplementary heater space of electric arc does not have bracing piece vibration material disk equipment includes: the device comprises a hot wire machine, a conductive nozzle, a wire feeder, a substrate, a workbench, a welding gun, a welding machine and a numerical control system;
the wire feeder is used for feeding wires to the contact nozzle so as to manufacture a support-free rod piece on the substrate, and the substrate is placed on the workbench; the wire passes through the contact nozzle to contact the unsupported rod piece; the hot wire machine is electrically connected with the contact nozzle;
the hot wire machine is used for providing hot wire current; the hot wire current forms a loop through the contact tip, the wire, the unsupported rod, the substrate and the worktable;
the numerical control system is electrically connected with the welding gun, the welding machine and the wire feeder respectively; the welding gun is electrically connected with the welding machine; the welder is for providing an arc current to the welding gun.
2. The arc assisted hot wire spatial support rod-less additive manufacturing method of claim 1, wherein the diameter value of the wire is 0.8-3.2mm.
3. The arc assisted hot wire spatial support rod-less additive manufacturing method of claim 1, wherein a wire feed speed of the wire feeder is 300-3000mm/min.
4. The arc assisted hot wire spatial support rod-less additive manufacturing method of claim 1, wherein the hot wire current is direct current.
5. The arc assisted hot wire space strut-less additive manufacturing method of claim 4, wherein the hot wire current has a current value of 100-200A.
6. The arc-assisted hot wire spatial strut-less additive manufacturing method of claim 1, wherein the arc-assisted hot wire spatial strut-less additive manufacturing apparatus further comprises: a gas tank;
an output gas port of the gas tank is connected with a gas inlet pipeline of the welding machine; the gas tank is used for storing protective gas.
7. The arc assisted hot wire space strut-less additive manufacturing method of claim 6, wherein the shielding gas is argon.
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