CN117564469A - Environment-adjustable plasma arc-laser composite additive manufacturing system and working method - Google Patents
Environment-adjustable plasma arc-laser composite additive manufacturing system and working method Download PDFInfo
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- CN117564469A CN117564469A CN202410052976.7A CN202410052976A CN117564469A CN 117564469 A CN117564469 A CN 117564469A CN 202410052976 A CN202410052976 A CN 202410052976A CN 117564469 A CN117564469 A CN 117564469A
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- 238000000034 method Methods 0.000 title claims abstract description 37
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- 239000002131 composite material Substances 0.000 title claims abstract description 24
- 239000007921 spray Substances 0.000 claims abstract description 101
- 238000010276 construction Methods 0.000 claims abstract description 38
- 230000008021 deposition Effects 0.000 claims abstract description 21
- 239000007789 gas Substances 0.000 claims description 293
- 239000007788 liquid Substances 0.000 claims description 118
- 239000000843 powder Substances 0.000 claims description 86
- 239000000463 material Substances 0.000 claims description 58
- 239000000758 substrate Substances 0.000 claims description 56
- 238000005507 spraying Methods 0.000 claims description 27
- 229910052751 metal Inorganic materials 0.000 claims description 24
- 239000002184 metal Substances 0.000 claims description 24
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Classifications
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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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/346—Working by laser beam, e.g. welding, cutting or boring in combination with welding or cutting covered by groups B23K5/00 - B23K25/00, e.g. in combination with resistance welding
-
- 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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/08—Devices involving relative movement between laser beam and workpiece
- B23K26/0869—Devices involving movement of the laser head in at least one axial direction
-
- 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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/14—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
-
- 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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/34—Laser welding for purposes other than joining
- B23K26/342—Build-up welding
-
- 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
-
- 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
-
- 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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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Plasma Technology (AREA)
Abstract
The invention discloses an environment-adjustable plasma arc-laser composite additive manufacturing system and a working method, wherein the whole system comprises a high-pressure cabin unit, an air supply unit, a solution environment construction unit, a dry area unit and a micro vacuum module, the dry area unit comprises a laser and a plasma arc spray gun, and the whole system can operate in different high-pressure solution media to provide a device foundation for additive manufacturing in different solution media environments; the system and the working method thereof can realize the combination of laser and low ionization energy gas, greatly improve the stability of arc striking, reduce the manufacturing cost in a high-pressure environment, and greatly improve the surface quality of components in the plasma arc-laser combined operation. By adopting the system and the working method, the underwater plasma arc additive manufacturing can be realized by using the low-ionization-energy gas mixed ion gas, the use ratio of the low-ionization-energy gas is reduced, the manufacturing cost of a workpiece is reduced, and meanwhile, the deposition quality of the workpiece is improved by combining the laser with the low-ionization-energy gas.
Description
Technical Field
The invention belongs to the technical field of plasma arc-laser composite additive manufacturing systems and processing technologies, and particularly relates to an environment-adjustable plasma arc-laser composite additive manufacturing system and a working method.
Background
Along with the continuous breakthrough of the technical field of additive manufacturing, the improvement of the deposition quality of the additive manufactured components under different environments is a necessary means for improving the service life of the workpiece. Aiming at the problems of high pressure in the ocean environment, difference of pH values of the ocean environment, capability of changing the solubility of beneficial elements by special solution and the like, the development and repair of components are difficult to a certain extent in high-pressure environments such as deep sea and the like.
Although plasma arc additive manufacturing has lower manufacturing cost than laser additive manufacturing in a marine high-pressure environment, the problem of weaker stability exists in the arc striking of the plasma arc in the high-pressure environment. Regarding the technical problem, patent CN 115922029A proposes that 50% -90% of low ionization energy gas mixed ion gas is used for underwater plasma arc welding, and the method can improve the arc striking effect of the plasma arc in a high-pressure environment to a certain extent, but the low ionization energy gas used in the method has high ratio, high consumption cost and is unfavorable for long-time underwater operation. Therefore, the design of a system and a method for carrying out underwater plasma arc additive manufacturing by using low-ionization-energy gas mixed ion gas, reducing the use proportion of the low-ionization-energy gas and improving the arc striking stability is a very valuable research subject.
Disclosure of Invention
The invention provides an environment-adjustable high-performance plasma arc-laser composite additive manufacturing system and method, which can use low-ionization-energy gas mixture to perform underwater plasma arc additive manufacturing, reduce the use proportion of the low-ionization-energy gas, save the cost and improve the stability of arc striking.
According to one aspect of the present invention, there is provided an environmentally-tunable plasma arc-laser composite additive manufacturing system comprising a hyperbaric chamber unit, an air supply unit, a solution environment construction unit, and a dry zone unit;
the high-pressure cabin unit is provided with a high-pressure cavity and an air compressor for providing high-pressure gas into the high-pressure cavity;
the gas supply unit is positioned outside the high-pressure cabin unit and comprises a gas mixing device, a powder mixing device, a protective gas cylinder, a low ionization energy gas cylinder and an ion gas cylinder, wherein the gas mixing device is provided with a plurality of gas inlet ends, a protective gas output end and a mixed gas output end, the powder mixing device is provided with a gas inlet position and a powder outlet, the low ionization energy gas cylinder, the ion gas cylinder and the protective gas cylinder are respectively communicated with the corresponding gas inlet ends of the gas mixing device through corresponding flow valves, the protective gas of the protective gas cylinder is unidirectionally output through the gas mixing device, the low ionization energy gas of the low ionization energy gas cylinder and the ion gas of the ion gas cylinder are mixed through the gas mixing device to form mixed ion gas output, the proportion of the low ionization gas in the mixed ion gas is 5% -49%, and the protective gas output end of the gas mixing device is connected with the gas inlet position of the powder mixing device through a pipeline;
The solution environment construction unit comprises a solution medium and a liquid supply assembly, wherein the liquid supply assembly is provided with a liquid supply end, the liquid supply end is communicated with the high-pressure cavity, the solution medium is nonflammable and explosive liquid, and the solution medium is input into the high-pressure cavity through the liquid supply assembly;
the dry area unit is arranged in the high-pressure cavity, a solution medium in the high-pressure cavity is not over the dry area unit, the dry area unit comprises a movable frame, a laser and a plasma arc spray gun, the bottom surface of the high-pressure cavity is used for placing substrate materials, the movable frame is arranged above the substrate materials in the high-pressure cavity, a cavity is arranged on the bottom surface of the movable frame, an air compressor simultaneously provides high-pressure environment for the high-pressure cavity and the cavity, the plasma arc spray gun and the laser are both arranged on the inner top surface of the cavity, the plasma arc spray gun is provided with an arc spraying end, an ion transmission air port and a powder outlet which are communicated uniformly, the laser is provided with a laser emission end and an air inlet end which are communicated, the laser emission end is opposite to the arc spraying end, a protective air output end of the air mixing device is communicated with an air inlet end of the laser and an air inlet position of the powder mixing device respectively, a mixed air output end of the air mixing device is communicated with the ion transmission of the plasma arc spray gun through a corresponding air inlet valve, and a powder outlet of the powder mixing device is communicated with a powder inlet of the plasma arc spray gun through a corresponding air inlet valve.
The plasma arc-laser composite additive manufacturing system with adjustable environment has the following beneficial effects: by arranging the high-pressure cabin unit and the solution environment construction unit, a high-pressure environment and a nonflammable and explosive solution medium environment are provided for the high-pressure cavity, and a better working environment is provided for the working of the plasma arc spray gun; meanwhile, by arranging the air supply unit and the dry area unit, the mixed gas equipment is used for providing the protective gas, the low ionization energy gas, the ion gas and the mixer, the proportion of the low ionization gas in the mixed ion gas is 5% -49%, the mixed gas equipment can transmit the protective gas into the laser to protect the laser, the laser emitted by the laser emitting end of the laser is used for heating and preheating the substrate material opposite to the plasma arc spray gun, and the mixed ion gas can be transmitted to the ion transmission port of the plasma arc spray gun; the laser emission end is opposite to the arc spraying end, so that the low ionization energy gas of the laser and the mixed ion gas is combined, the arc starting stability of the plasma arc spray gun during working is improved, a better solution is provided for stable arc starting of the plasma arc under a higher pressure environment, and meanwhile, the cost is reduced; after plasma arc operation, laser remelting the surface of the component reduces the waviness of the surface of the component and improves the quality of the surface of the component.
In some embodiments, the dry zone unit further comprises a robotic arm, a laser mover, a plasma arc torch mover; the mechanical arm is arranged in the high-pressure cavity, and the movable frame is arranged at the moving end of the mechanical arm; the laser moving part comprises a rotating part, a lifting part and a rotating part, the rotating part is arranged on the inner top surface of the cavity, the lifting part is arranged at the rotating end of the rotating part, the lifting part is provided with a lifting end, the rotating part is arranged at the lifting end of the lifting part, and the laser is arranged at the rotating end of the rotating part; the plasma arc spray gun moving part comprises an up-down moving part, the up-down moving part is arranged on the inner top surface of the cavity, the up-down moving part is provided with a moving end which moves up and down, and the plasma arc spray gun is arranged at the moving end.
Therefore, the mechanical arm is arranged, so that the movable frame is convenient to move, the plasma arc spray gun and the laser are moved integrally, and the deposition position on the substrate material can be adjusted; the laser moving part is arranged so as to adjust the angle of the laser in the vertical direction through the rotating part, and the rotating part rotates the laser at the same time, so that the laser emitting end of the laser is opposite to the arc spraying end of the plasma arc spray gun; by arranging the plasma arc spray gun moving part, the plasma arc spray gun and the substrate material can be adjusted to be kept within a reasonable interval range by utilizing the up-down moving part.
In some embodiments, the dry zone unit further comprises a linear lifter mounted on a side wall of the cavity, the linear lifter having a lifting end that moves up and down, and a high speed camera mounted on the lifting end, a camera window of the high speed camera facing the laser and the plasma arc torch. Therefore, the lifting movement of the high-speed camera is realized by arranging the linear lifting piece and the high-speed camera, and the arc spraying end position of the plasma arc spray gun is tracked to monitor the appearance of a molten pool and the deposition process of a component.
In some embodiments, the liquid supply assembly includes a liquid reservoir, a liquid drain reservoir, and a solution state sensor; the liquid storage container and the liquid discharge container are both positioned outside the high-pressure cabin unit, the liquid storage container is communicated with the high-pressure cavity through the liquid inlet valve, the liquid discharge container is communicated with the high-pressure cavity through the liquid discharge valve, and the solution medium is discharged into the high-pressure cavity through the liquid inlet valve and is discharged into the liquid discharge container through the liquid discharge valve at the same time so as to adjust the liquid level of the solution medium in the high-pressure cavity; the solution state sensor is arranged in the high-pressure cavity to monitor the liquid level pressure, the solution temperature, the solution pH value and the solution state parameters of the oxygen content of the solution in the high-pressure cavity. Therefore, the liquid storage container, the liquid discharge container, the liquid inlet valve and the liquid discharge valve are arranged, so that the liquid inlet valve and the liquid discharge valve are utilized to adjust the transmission flow of the solution medium, and the function of adjusting the liquid level height of the solution medium in the high-pressure cavity is realized.
In some embodiments, the device further comprises a micro vacuum unit, wherein the micro vacuum unit comprises a vacuum pump and a vacuum degree detector, the vacuum pump is arranged outside the high-pressure cabin unit, the air suction end of the vacuum pump is communicated with the high-pressure cavity through an exhaust valve, a three-way pipe joint and a pipeline, and the empty end of the three-way pipe joint is connected with an electric control exhaust valve; the vacuum degree detector is arranged on the inner top surface of the high-pressure cavity so as to monitor the vacuum degree of the gas in the high-pressure cavity. Therefore, by arranging the micro vacuum unit, the vacuum pump is used for pumping the gas in the high-pressure cavity, so that the air content in the high-pressure cavity is reduced, and the oxygen content in unit air is also reduced, and the situation that the substrate material is oxidized is mainly reduced.
In some embodiments, the high pressure compartment unit includes a high pressure compartment having a compartment with an opening facing upward, and a hatch cover installed on a top surface of the high pressure compartment and covering the opening of the compartment, and a sealing process is used at a connection position between the high pressure compartment and the hatch cover, and the compartment between the high pressure compartment and the hatch cover forms a high pressure chamber. Therefore, the dry area unit is mainly convenient to install in the dry area unit by arranging the high-pressure cabin and the cabin cover, and the dry area unit is simple and convenient to install.
A method of operating an environmentally tunable plasma arc-laser composite additive manufacturing system, comprising:
1) An environment construction step including construction of a solution medium environment and construction of a high-pressure environment;
construction of a solution medium environment: starting a liquid supply assembly to discharge a solution medium into the high-pressure cavity, wherein the solution medium is not passed through the dry area unit, so that the dry area unit is in a corresponding solution medium environment;
building a high-pressure environment: opening the air compressor to be in a high-pressure environment state in the high-pressure cavity and the cavity;
2) A feed preparation step including gas mixing preparation and powder mixing preparation;
and (3) gas mixing preparation: opening the corresponding flow rates of the protective gas cylinder, the low ionization energy gas cylinder and the ion gas cylinder, enabling quantitative protective gas, low ionization energy gas and ion gas to enter a gas mixing device, mixing the low ionization energy gas and the ion gas in the mixing device to form mixed ion gas, and controlling the flow valve to enable the proportion of the low ionization gas in the mixed ion gas to be 5% -49%;
preparing mixed powder: the shielding gas is partially discharged into the powder mixing equipment from the gas mixing equipment so as to protect the stability of the metal powder in the powder mixing equipment;
3) A process adjustment step including adjustment of the overall position, adjustment of the plasma arc torch position, and adjustment of the laser position;
And (3) adjusting the overall position: placing a substrate material on the inner bottom surface of the high-pressure cavity, and controlling the mechanical arm to move the movable frame so that the laser and the plasma arc spray gun are both positioned on the substrate material;
adjustment of plasma arc spray gun position: adjusting the plasma arc spray gun to keep a proper distance with the substrate material;
adjustment of laser position: adjusting the laser to keep a proper distance with the substrate material, and enabling the laser emitting end of the laser to be opposite to the position of the substrate material corresponding to the arc spraying end of the plasma arc spray gun;
4) The manufacturing and processing steps are as follows: starting a laser to irradiate the substrate material corresponding to the bottom of the plasma arc spray gun with laser, and then introducing mixed ion gas in the gas mixing equipment into an ion transmission port of the plasma arc spray gun so as to combine the laser and the mixed ion gas and improve the arc striking of an arc spraying end of the plasma arc spray gun; then, metal powder in the powder mixing equipment enters a powder outlet of a plasma arc spray gun under the action of protective gas, the plasma arc spray gun is electrified and sprayed with plasma arc so as to fuse and deposit the metal powder, after the deposition is finished, the plasma arc spray gun is closed, and a laser is started to repeatedly irradiate a deposition position by laser to carry out surface remelting.
The working method of the environment-adjustable plasma arc-laser composite additive manufacturing system has the following beneficial effects: the method mainly comprises an environment construction step, a feeding preparation step, a processing adjustment step and a manufacturing and processing step, wherein the environment construction step can provide a high-pressure environment and a nonflammable and explosive solution medium environment for the high-pressure cavity, and can change working environment parameters in the high-pressure cavity according to the characteristics of substrate materials; the feeding preparation step is used for preparing shielding gas, preparing mixed ion gas (low ionization energy gas and ion gas mixture) and preparing metal powder so as to facilitate the timely transmission of corresponding gas or powder; the processing adjustment step mainly comprises the adjustment of the position of the integral dry area unit so that the plasma arc of the plasma arc spray gun acts on the substrate material, the adjustment of the position of the plasma arc spray gun so that the arc spraying end of the plasma arc spray gun and the substrate material are kept at proper heights, and the adjustment of the position of the laser can swing the position of the laser so that the laser emitting end of the laser is opposite to the arc spraying end of the plasma arc spray gun, so that the laser emitted by the laser is combined with mixed ion gas at the arc spraying end of the plasma arc spray gun, and the arc striking capability of the plasma arc is improved; the manufacturing and processing steps are that shielding gas and mixed ion gas are respectively transmitted to a laser and a plasma arc spray gun through a gas mixing device, so that laser and plasma gas are combined, the striking of the arc spraying end of the plasma arc spray gun is improved, metal powder is further transmitted to the plasma arc spray gun through a powder mixing device, deposition on a substrate material is achieved, and then the laser is remelted on the surface of the substrate material.
In some embodiments, in the construction process of the solution medium environment, the liquid inlet valve is started, so that the solution medium enters the high-pressure cavity from the liquid storage container, the solution medium in the high-pressure cavity is enabled to bypass the dry area unit, the liquid discharge valve is opened when the liquid level of the solution medium is regulated, the solution medium in the high-pressure cavity is discharged into the liquid discharge container, and the liquid inlet valve are closed when the liquid level of the solution medium in the high-pressure cavity reaches the corresponding height. Therefore, the liquid level of the solution medium is adjusted by starting or closing the liquid inlet valve and the liquid outlet valve.
In some embodiments, during adjustment of the laser position, the rotating member is activated to swing the first pushrod and the laser to form an angle with the vertical, and the rotating member is further activated to rotate the laser such that an intersection is created between the laser firing end extension of the laser and the arc end extension of the plasma arc torch, and the lifting member is further activated to lift the laser such that the intersection is centered on the substrate material.
In some embodiments, the environmental construction step further comprises construction of a micro vacuum environment, construction of a micro vacuum environment: starting a vacuum pump to discharge the gas in the high-pressure cavity outwards through the vacuum pump, wherein the outwards-discharged flow rate of the vacuum pump is larger than the total gas transmission flow rate of the gas mixing equipment into the sealing cavity in unit time when the gas mixing equipment is started; in the manufacturing and processing steps, before the powder mixing equipment is used for introducing metal powder and shielding gas into the plasma arc spray gun, the powder mixing equipment needs to be started when the vacuum degree in the high-pressure cavity reaches a proper threshold value and no reduction occurs. Therefore, when the micro-vacuum environment is required to be built in the high-pressure cavity, the micro-vacuum environment can be built through the vacuum pump, and meanwhile, when the micro-vacuum environment is built, the flow of the exhaust gas of the vacuum pump is required to be kept to be larger than the total flow of the gas transmission of the gas mixing equipment to the sealed cavity, so that the high-pressure cavity is always kept in a micro-vacuum state, and meanwhile, the metal powder can be transmitted to the plasma arc spray gun under the condition that the vacuum degree in the high-pressure cavity reaches a proper range.
Drawings
FIG. 1 is a schematic diagram of an environmentally tunable plasma arc-laser composite additive manufacturing system of the present invention;
fig. 2 is a schematic diagram of a dry cell unit of the present invention.
In the figure:
101. a hyperbaric chamber; 102. a solution medium; 103. a movable frame; 104. a first air inlet; 105. a mechanical arm; 106. an air compressor; 107. a first air inlet pipe; 108. a first air valve; 109. a second air valve; 110. a hatch cover; 111. a second air inlet; 112. a second air inlet pipe; 113. an exhaust port; 114. a first exhaust pipe; 115. a first exhaust valve; 116. a second exhaust valve; 117. a second exhaust pipe; 118. a vacuum pump; 119. a vacuum degree detector;
201. a low ionization energy gas cylinder; 202. a first air supply valve; 203. an ion gas cylinder; 204. a second air supply valve; 205. protecting the gas cylinder; 206. a third air supply valve; 207. a first gas supply pipe; 208. a second gas supply pipe; 209. a third gas supply pipe; 210. a gas mixing device; 211. a first air inlet pipe; 212. a second air inlet pipe; 213. a first intake valve; 214. a third air inlet pipe; 215. a second intake valve; 216. a fourth air inlet pipe; 217. a third intake valve; 218. a fifth air inlet pipe; 219. powder mixing equipment; 220. a sixth air intake pipe; 221. a fourth intake valve;
301. A liquid storage container; 302. a liquid inlet valve; 303. a liquid inlet; 304. a solution state sensor; 305. a liquid outlet; 306. a liquid discharge valve; 307. a liquid discharge pipe; 308. a liquid discharge container;
401. a rotation module; 402. a first motor; 403. a ball screw; 404. a high-speed camera; 405. a second motor; 406. a rotation shaft main body; 407. a laser; 408. a first push rod; 409. a third motor; 410. a thermal insulator; 411. plasma arc spray gun; 412. a tungsten electrode; 413. an anode; 414. a powder outlet; 415. ion-transporting gas ports; 416. a substrate material; 417. a second push rod; 418. and a fourth motor.
Detailed Description
The technical solutions in 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.
Example 1:
the embodiment of the plasma arc-laser composite additive manufacturing system and the working method with adjustable environments are characterized in that the working method is implemented based on the system, and the system and the working method can provide experimental simulation conditions for additive manufacturing under extreme or special environments, so that a high-performance metal deposition layer is prepared.
As shown in fig. 1 and 2, an environment-adjustable plasma arc-laser composite additive manufacturing system comprises a high-pressure chamber, a gas supply unit, a solution environment construction unit, a dry area unit and a micro vacuum unit, wherein the high-pressure chamber is provided with a high-pressure chamber, the inner bottom surface of the high-pressure chamber is used for placing a substrate material 416, the high-pressure chamber can be provided with a high-pressure environment, the gas supply unit is used for providing a protective gas, mixed ion gas of low ionization energy gas and ion gas and metal powder, the solution environment construction unit can be used for providing a non-flammable and explosive liquid environment in the high-pressure chamber, the dry area unit is arranged in the high-pressure chamber and is used for irradiating laser and plasma arcs on the substrate material 416, laser and mixed ion gas are needed to be combined in operation, so that the arc striking effect of the plasma arcs is improved, the metal powder is further transmitted to the dry area unit through the gas supply unit, so that the metal powder is deposited in a hot melting mode, and the micro vacuum unit can reduce the oxygen content in the high-pressure chamber, so that oxidation occurs when a metal deposition layer is manufactured on the substrate material 416.
The high pressure cabin unit may provide a high pressure environment and a solution medium 102 environment, which includes a high pressure cabin 101 body, an air compressor 106, a cabin cover 110, and a second air inlet 111. The hyperbaric chamber 101 is provided with a cabin with an upward opening, the cabin cover 110 is arranged on the top surface of the hyperbaric chamber 101 main body and covers the opening of the cabin, a sealing process (such as a sealing ring and the like) is adopted between the hyperbaric chamber 101 main body and the cabin cover 110, the first air valve 108 is opened, the air compressor 106 operates, compressed air enters the dry area unit cavity through the first air inlet pipe 107 to realize a local dry area, and meanwhile, compressed air also enters the hyperbaric chamber through the second air inlet pipe 112 to realize pressurization of the hyperbaric chamber.
The solution environment construction unit comprises a solution medium 102 and a solution supply assembly, wherein the solution supply assembly is provided with a solution supply end, the solution supply end is communicated with the high-pressure cavity, the solution medium 102 is a non-flammable and explosive liquid, and the types of the solution medium include, but are not limited to, pure water, sodium chloride solution, sodium phosphate solution, ferrous oxalate solution, acetic acid solution and the like. The solution medium 102 is fed into the high pressure chamber through the liquid supply assembly.
The liquid supply assembly of this embodiment includes a liquid storage container 301, a liquid inlet valve 302, a liquid inlet 303, a solution state sensor 304, a liquid outlet 305, a liquid discharge valve 306, a liquid discharge pipe 307, and a liquid discharge container 308. The liquid storage container 301 and the liquid discharge container 308 are both positioned outside the high-pressure cabin unit, the liquid storage container 301 is connected to the liquid inlet 303 through the liquid inlet valve 302 and communicated with the high-pressure cavity, and the liquid discharge container 308 is connected to the liquid outlet 305 through the liquid discharge valve 306 and the liquid discharge pipe 307 and communicated with the high-pressure cavity. The solution medium 102 is discharged into the high-pressure cavity through the liquid inlet valve 302 and is discharged into the liquid discharge container 308 through the liquid discharge valve 306, so that the input and output flow of the solution medium 102 is controlled through the liquid inlet valve 302 and the liquid discharge valve 306, and the liquid level of the solution medium 102 in the high-pressure cavity is regulated. A solution state sensor 304 is installed in the high pressure chamber to monitor solution state parameters of the liquid level pressure of the solution medium 102, the solution temperature, the solution pH, the solution oxygen content, etc. in the high pressure chamber.
The gas supply unit is located outside the high-pressure cabin unit, and comprises a gas mixing device 210, a powder mixing device 219, a protective gas cylinder 205, a low ionization energy gas cylinder 201 and an ion gas cylinder 203, wherein the gas mixing device 210 is provided with a plurality of gas inlet ends, a protective gas output end and a mixed gas output end, can realize uniform mixing of different gases, and belongs to conventional equipment. The powder mixing device 219 has an air inlet and a powder outlet 414, which can realize uniform mixing of different powders and control of powder feeding rate, and belongs to conventional devices. Shielding gases include, but are not limited to, argon, nitrogen, helium, and the like. The low ionization energy gas includes hernia, etc., and ion gas such as argon, etc. The low ionization energy gas cylinder 201, the ion gas cylinder 203 and the protection gas cylinder 205 are respectively communicated with corresponding gas inlet ends of the gas mixing device 210 through corresponding flow valves (a first gas supply valve 202, a second gas supply valve 204 and a third gas supply valve 206) and corresponding pipelines (a first gas supply pipe 207, a second gas supply pipe 208 and a third gas supply pipe 209), wherein the protection gas of the protection gas cylinder 205 is unidirectionally output through the gas mixing device 210, the low ionization energy gas of the low ionization energy gas cylinder 201 and the ion gas of the ion gas cylinder 203 are mixed through the gas mixing device 210 to form mixed ion gas output, the proportion of the low ionization gas in the mixed ion gas is 5% -49%, and the arc striking effect of the plasma arc spray gun 411 in a high pressure environment is improved through the mixing of the low ionization energy gas and the ion gas. The shielding gas output end of the mixing device 210 is connected to the air inlet position of the powder mixing device 219 through an air inlet valve (a third air inlet valve 217) and a pipeline (a fifth air inlet pipe 218), and the shielding gas is input to protect the metal powder in the powder mixing device 219.
As shown in fig. 1 and 2, the dry zone unit is disposed in a high pressure chamber, the solution medium 102 in the high pressure chamber is passed through the dry zone unit, the dry zone unit includes a movable frame 103, a laser 407, and a plasma arc torch 411, and the bottom surface of the high pressure chamber is used for placing a substrate material 416.
The movable frame 103 is installed in the high-pressure cavity and is located above the substrate material 416, the bottom surface of the movable frame 103 is provided with a cavity, the air compressor 106 simultaneously provides a high-pressure environment for the high-pressure cavity and the cavity through pipelines, the plasma arc spray gun 411 and the laser 407 are both installed on the inner top surface of the cavity, the plasma arc spray gun 411 is provided with an arc spraying end, an ion conveying air port 415 and a powder outlet 414 which is obliquely arranged downwards, the laser 407 is provided with a laser emitting end and an air inlet end which are communicated, and the laser 407 is also provided with a rotating shaft main body 406, an insulator 410, a tungsten electrode 412 and an anode 413 which are in a structure in the prior art and used for providing current for the arc spraying end.
The laser emission end is opposite to the arc spraying end after adjustment, the shielding gas output end of the gas mixing device 210 is respectively communicated with the gas inlet end of the laser 407 and the gas inlet position of the powder mixing device 219 through corresponding gas inlet valves (a first gas inlet valve 213, a third gas inlet valve 217) and pipelines (a third gas inlet valve 214 and a fifth gas inlet pipe 218), the gas mixing output end of the gas mixing device 210 is communicated with the ion transmission gas port 415 of the plasma arc spray gun 411 through corresponding gas inlet valves (a second gas inlet valve 215) and pipelines (a second gas inlet valve 212 and a fourth gas inlet pipe 216;) and the powder outlet 414 of the powder mixing device 219 is communicated with the powder inlet of the plasma arc spray gun 411 through corresponding gas inlet valves (a fourth gas inlet valve 221) and pipelines (a sixth gas inlet pipe 220).
Therefore, the laser 407 can improve the arc striking of the plasma arc spray gun 411 in a high-pressure environment by preheating the substrate material 416 at the bottom of the plasma arc spray gun 411, the ion transmission port 415 can realize the transmission of uniformly mixed ion gas, and the laser preheating is combined with low ionization energy gas to improve the arc striking stability of the plasma arc in the high-pressure environment; the plasma arc torch 411 may achieve molten deposition of metal during additive manufacturing, with material delivery means including, but not limited to, powder delivery, wire delivery, and the like. The surface morphology of the component deposited by the plasma arc spray gun 411 can be subjected to surface remelting by the laser 407, so that the waviness of the surface of the component is reduced, and the deposition quality of the surface of the component is improved.
Further, the dry zone unit also includes a robotic arm 105, a laser 407 moving member, and a plasma arc torch 411 moving member. The mechanical arm 105 can realize multi-degree-of-freedom motion, and the multi-degree-of-freedom motion is installed in the high-pressure cavity, the movable frame 103 is installed at the moving end of the mechanical arm 105, so that the movable frame 103 is convenient to move, and the plasma arc spray gun 411 and the laser 407 are moved integrally, so that the deposition position on the substrate material 416 can be adjusted. The laser moving part comprises a rotating part, a lifting part and a rotating part, wherein the rotating part is a rotating module 401 driven by a motor and is arranged on the inner top surface of the cavity, the lifting part can adopt a linear screw rod structure or an electric driving lifting structure formed by a second motor 405 and a first push rod 408, the lifting part is provided with a lifting end, the rotating part adopts a third motor 409 which is arranged at the lifting end of the lifting part, and the laser 407 is arranged at the rotating end of the rotating part. The laser 407 is moved to a proper angle in the direction perpendicular to the gun of the plasma arc spray gun 411 by the rotating member and the rotating member, and the bottom of the plasma arc spray gun 411 is irradiated with the laser to preheat the substrate material 416, wherein the lifting member drives the laser 407 to move up and down mainly to match the working height of the plasma arc spray gun 411. The plasma arc spray gun moving part comprises an up-and-down moving part, wherein the up-and-down moving part can adopt a linear screw rod structure or an electric drive type lifting structure formed by a fourth motor 418 and a second push rod 417, the up-and-down moving part is arranged on the inner top surface of the cavity, the up-and-down moving part is provided with a moving end which moves up and down, and the plasma arc spray gun 411 is arranged at the moving end so as to adjust the plasma arc spray gun 411 and the substrate material 416 to be kept within a reasonable interval range.
Further, the dry zone unit further comprises a linear lifting member and a high-speed camera 404, the linear lifting member is mounted on the side wall of the cavity, the linear lifting member is a screw lifting module structure formed by the first motor 402 and the ball screw 403, the linear lifting member is provided with a lifting end which moves up and down, the high-speed camera 404 is mounted on the lifting end, and a photographic window of the high-speed camera 404 faces the laser 407 and the ion arc spray gun.
The micro vacuum unit comprises a vacuum pump 118 and a vacuum degree detector 119, the vacuum pump 118 is arranged outside the high-pressure cabin unit, the air suction end of the vacuum pump 118 is communicated with the high-pressure cavity through an exhaust valve (a second exhaust valve 116), a three-way pipe joint and a pipeline (a second exhaust pipe 117), and the empty end of the three-way pipe joint is connected with an electric control exhaust valve (a first exhaust valve 115 and a first exhaust pipe 114); a vacuum degree detector 119 is installed at the inner top surface of the high pressure chamber to monitor the vacuum degree of the gas in the high pressure chamber. By providing the micro vacuum unit, the air in the high-pressure chamber is pumped by the vacuum pump 118, and the air content in the high-pressure chamber is reduced, and the amount of oxygen in the unit air is also reduced, mainly because oxidation of the substrate material 416 is reduced.
Based on the structure of the system, the plasma arc-laser composite additive manufacturing system with adjustable environment provides a high-pressure environment and a nonflammable and explosive solution medium 102 environment for the high-pressure cavity and a better working environment for the working of the plasma arc spray gun 411 by arranging the high-pressure cabin unit and the solution environment construction unit; meanwhile, by arranging the gas supply unit and the dry zone unit, the mixed gas of the shielding gas, the low ionization energy gas and the ion gas is provided by using the gas mixing equipment 210, the proportion of the low ionization energy gas in the mixed ion gas is 5% -49%, the gas mixing equipment 210 can transmit the shielding gas into the laser 407 to protect the laser 407, the substrate material 416 which is opposite to the plasma arc spray gun 411 is heated and preheated by utilizing the laser emitted by the laser emitting end of the laser 407, and the mixed ion gas can be transmitted to the ion transmission port 415 of the plasma arc spray gun 411 by using the gas mixing equipment 210; because the laser emission end is opposite to the arc spraying end, the low ionization energy gas of the laser and the mixed ion gas is combined, so that the arc starting stability of the plasma arc spray gun 411 during working is improved, a better solution is provided for stable arc starting of the plasma arc under a higher pressure environment, and meanwhile, the cost is reduced; after plasma arc operation, laser remelting the surface of the component reduces the waviness of the surface of the component and improves the quality of the surface of the component.
A method of operating an environmentally tunable plasma arc-laser composite additive manufacturing system, comprising:
1) An environment construction step including construction of the environment of the solution medium 102 and construction of the high-pressure environment;
construction of the environment of the solution medium 102: starting a liquid supply assembly to discharge the solution medium 102 into the high-pressure cavity, wherein the solution medium 102 is over the dry area unit, so that the dry area unit is in the corresponding environment of the solution medium 102;
when the liquid level of the solution medium 102 needs to be regulated, the liquid inlet valve 302 is started, the solution medium 102 enters the high-pressure cavity from the liquid storage container 301, so that the solution medium 102 in the high-pressure cavity does not pass through the dry area unit, when the liquid level of the solution medium 102 is regulated, the liquid outlet valve 306 is opened, the solution medium 102 in the high-pressure cavity is discharged into the liquid outlet container 308, and when the liquid level of the solution medium 102 in the high-pressure cavity reaches the corresponding height, the liquid inlet valve 302 and the liquid inlet valve 302 are closed.
Building a high-pressure environment: opening the air compressor 106 to be in a high-pressure environment state into the high-pressure cavity and the cavity;
2) A feed preparation step including gas mixing preparation and powder mixing preparation;
and (3) gas mixing preparation: opening the corresponding flow rates of the protective gas cylinder 205, the low ionization energy gas cylinder 201 and the ion gas cylinder 203, enabling quantitative protective gas, low ionization energy gas and ion gas to enter the gas mixing equipment 210, mixing the low ionization energy gas and the ion gas in the mixing equipment to form mixed ion gas, and controlling the low ionization energy gas and the ion gas to account for 5% -49% of the mixed ion gas through a flow valve;
Preparing mixed powder: the shielding gas is partially discharged from the gas mixing device 210 into the powder mixing device to protect the stability of the metal powder in the powder mixing device 219;
3) A process adjustment step including adjustment of the overall position, adjustment of the position of the plasma arc torch 411, and adjustment of the position of the laser 407;
and (3) adjusting the overall position: placing a substrate material 416 on the inner bottom surface of the high pressure chamber, and controlling the mechanical arm 105 to move the movable frame 103 so that the laser 407 and the plasma arc torch 411 are both positioned above the substrate material 416;
adjustment of plasma arc torch 411 position: adjusting the plasma arc torch 411 to maintain a proper spacing from the substrate material 416;
adjustment of the laser 407 position: adjusting the laser 407 to maintain a suitable spacing from the substrate material 416 and positioning the laser emitting end of the laser 407 relative to the substrate material 416 at a position corresponding to the arc end of the plasma arc torch 411;
specifically, in the adjustment process of the position of the laser 407, the rotating member is started to swing the first push rod 408 and the laser 407 to form an angle with the vertical direction, and the rotating member is further started to rotate the laser 407, so that an intersection point is generated between the extending direction of the laser emitting end of the laser 407 and the extending direction of the arc spraying end of the plasma arc spraying gun 411, and the lifting member is further started to lift the laser 407, so that the intersection point is concentrated on the substrate material 416.
4) The manufacturing and processing steps are as follows: starting a laser 407 to enable laser to irradiate a substrate material 416 corresponding to the bottom of the plasma arc spray gun 411, and then introducing mixed ion gas in the gas mixing equipment 210 into an ion transmission port 415 of the plasma arc spray gun 411 so as to enable the laser to be combined with the mixed ion gas and improve arc striking of an arc spraying end of the plasma arc spray gun 411; then, the metal powder in the powder mixing device 219 enters a powder outlet 414 of the plasma arc spray gun 411 under the action of the shielding gas, the plasma arc sprayed out of the plasma arc spray gun 411 is electrified to enable the metal powder to be fused and deposited, after the deposition is finished, the plasma arc spray gun 411 is closed, and the laser 407 is started to enable laser to repeatedly irradiate the deposition position to carry out surface remelting.
Based on the working method of the system structure, the working method of the plasma arc-laser composite additive manufacturing system with adjustable environment mainly comprises an environment construction step, a feeding preparation step, a processing adjustment step and a manufacturing and processing step, wherein the environment construction step can provide a high-pressure environment and a nonflammable and explosive solution medium 102 environment for a high-pressure cavity, and can change working environment parameters in the high-pressure cavity according to the characteristics of a substrate material 416; the feeding preparation step is used for preparing shielding gas, preparing mixed ion gas (low ionization energy gas and ion gas mixture) and preparing metal powder so as to facilitate the timely transmission of corresponding gas or powder; the processing adjustment step mainly comprises the adjustment of the position of the integral dry zone unit, so that the plasma arc of the plasma arc spray gun 411 acts on the substrate material 416, the adjustment of the position of the plasma arc spray gun 411, so that the arc spraying end of the plasma arc spray gun 411 and the substrate material 416 are kept at proper heights, and the adjustment of the position of the laser 407, which can swing the position of the laser 407, so that the laser emitting end of the laser 407 is opposite to the arc spraying end of the plasma arc spray gun 411, so that the laser emitted by the laser 407 is combined with the mixed ion gas of the arc spraying end of the plasma arc spray gun 411, and the arc striking capability of the plasma arc is improved; in the manufacturing and processing step, shielding gas and mixed ion gas are respectively transmitted to the laser 407 and the plasma arc spray gun 411 through the gas mixing equipment 210, so that laser and plasma gas are combined, the striking of the arc spraying end of the plasma arc spray gun 411 is improved, metal powder is further transmitted to the plasma arc spray gun 411 through the powder mixing equipment 219, deposition on the substrate material 416 is realized, and then remelting is further carried out on the surface of the substrate material 416 through laser.
Incorporated into this example 1, the specific working procedure is as follows:
in a high pressure medium solution: as shown in fig. 1 and 2, the main body of the hyperbaric chamber 101 is connected with the hatch cover 110 of the hyperbaric chamber 101 in a sealing manner, and the mechanical arm 105 is arranged in the hyperbaric chamber 101, so that the movement with multiple degrees of freedom can be realized. Delivering a proper medium solution into the main body of the hyperbaric chamber 101 through a liquid inlet valve 302, wherein the dry zone unit keeps vertical downward before the medium solution delivery process, and the laser 407 and the plasma arc spray gun 411 move to the highest position in the dry zone unit; the air compressor 106 is opened, the second air valve 109 is opened, compressed air enters the dry area unit through the first air inlet pipe 107 and the first air inlet 104, the liquid inlet valve 302 is opened, medium solution enters the main body of the high-pressure cabin 101 from the liquid inlet 303, the medium solution environment is built, and the liquid inlet valve 302 is closed.
The first air valve 108 is opened and compressed air is introduced into the main body of the hyperbaric chamber 101 through the second air inlet pipe 112, and at this time, the flow rate of the second air valve 109 is ensured to be greater than that of the first air valve 108, so that the medium solution is prevented from entering the inside of the dry zone unit. The valves are kept closed except for the second air valve 109 and the first air valve 108 during the construction of the high-pressure environment; after the pressure reaches the rated value, the opening of the first air valve 108 and the opening of the first exhaust valve 115 are regulated in real time to keep the pressure inside the high-pressure cabin 101 stable, and the construction of the high-pressure environment is completed.
The third air supply valve 206 and the first air inlet valve 213 are opened, and the protection air enters the laser 407 through the first air inlet pipe 211, so as to protect the laser 407; the laser 407 is rotated by the rotating module 401, the high-speed camera 404 is driven to move up and down by the cooperation of the first motor 402 and the ball screw 403, and the internal movement condition of the dry area unit is observed; the plasma arc spray gun 411 is moved up and down by the third motor 409 and the second push rod 417, and the plasma arc spray gun 411 is moved to a proper height from the substrate material 416; the up-and-down movement of the laser 407 is realized by the cooperation movement of the third motor 409 and the push rod, and the torsion of the laser 407 is realized by the second motor 405 and the rotating shaft; moving the laser 407 to a proper angle with the vertical direction of the plasma arc spray gun 411, and irradiating the bottom of the plasma arc spray gun 411 with laser to preheat the substrate material 416; the first air supply valve 202 and the second air supply valve 204 are opened, low ionization energy gas and ion gas enter the gas mixing equipment 210 through the first air supply pipe 207 and the second air supply pipe 208, wherein the proportion of the low ionization energy gas is 5% -49%, the ion gas enters the ion conveying air port 415 through the second air inlet pipe 212 and the second air inlet valve 215 after being uniformly mixed, and the laser and the ionization energy gas are combined to improve the arc striking effect.
And the third air inlet valve 217 and the fourth air inlet valve 221 are opened, metal powder enters a powder outlet 414 of the plasma arc spray gun 411 through the sixth air inlet pipe 220 under the action of protective gas, plasma arc is electrified, deposition of metal materials is realized under proper technological parameters, the feedback value of the solution state sensor 304 is observed in real time, and change data are recorded.
After the deposition, the first air supply valve 202, the second air supply valve 204, the second air inlet valve 215, the third air inlet valve 217 and the fourth air inlet valve 221 are closed, the plasma arc spray gun 411 moves to the highest point of the dry area unit, the laser 407 is vertical to the substrate material 416 and moves to a proper height under the action of the first push rod 408 and the rotating shaft, the laser 407 is opened, the surface remelting is carried out under proper technological parameters, the reduction of the surface waviness of the component after the plasma arc deposition is realized, and the surface quality is improved.
After the remelting is finished, the laser 407 is moved to the highest point of the dry zone unit, the first air inlet valve 213 and the third air supply valve 206 are closed, the liquid discharge valve 306 is opened, liquid is discharged under pressure, after the pressure in the belt is consistent with the pressure in the belt and the pressure outside the belt are discharged completely, the air compressor 106, the first air valve 108 and the second air valve 109 are closed, and the hatch cover 110 of the hyperbaric chamber 101 is opened to obtain a deposition member.
Example 2
The main difference between example 2 and example 1 is that the working method takes into account the fact that the substrate material 416 is subject to highly sensitive oxidation.
The environment construction step further comprises construction of a micro-vacuum environment, wherein the construction of the micro-vacuum environment is as follows: starting the vacuum pump 118 to discharge the gas in the high-pressure cavity outwards through the vacuum pump 118, wherein the outwards discharged flow rate of the vacuum pump 118 is larger than the total gas flow rate of the gas mixing equipment 210 in the sealed cavity in unit time when the gas mixing equipment 210 is started; in the manufacturing process step, the powder mixing device 219 is started when the vacuum level in the high-pressure chamber reaches a proper threshold value and no reduction occurs before introducing the metal powder and the shielding gas into the plasma arc spray gun 411. Therefore, when the micro vacuum environment is required to be built in the high-pressure cavity, the micro vacuum environment can be realized by the vacuum pump 118, and when the micro vacuum environment is built, the flow of the exhaust gas of the vacuum pump 118 is required to be kept to be larger than the total flow of the gas transmission of the gas mixing equipment 210 into the sealed cavity, so that the high-pressure cavity is always kept in a micro vacuum state, and meanwhile, the metal powder in the plasma arc spray gun 411 can be transmitted under the condition that the vacuum degree in the high-pressure cavity reaches a proper range.
The working method of the invention, incorporated in examples 1 and 2, is as follows:
in a micro vacuum environment, as shown in fig. 1 and 2, all gas and liquid valves of the entire system are closed, moving the dry zone unit to a suitable height from the substrate material 416; the cabin cover 110 of the high-pressure cabin 101 is moved to the upper part of the main body of the high-pressure cabin 101, the second exhaust valve 116 is opened through sealing connection, and the vacuum pump 118 operates; the first gas supply valve 202 and the second gas supply valve 204 are opened, the low ionization energy gas and the ion gas enter the gas mixing device 210 through the first gas supply pipe 207 and the second gas supply pipe 208, and the ion gas enters the ion delivery port 415 through the second gas inlet pipe 212 and the second gas inlet valve 215 after being uniformly mixed.
The flow of the second exhaust valve 116 is ensured to be far greater than the flow of the second air inlet valve 215 and the fourth air inlet valve 221 in the whole vacuumizing process; the vacuum degree detector 119 displays the vacuum degree in the high-pressure chamber 101 in real time, after the proper vacuum degree is achieved, the third air inlet valve 217 and the fourth air inlet valve 221 are opened, and the protective air enters the powder outlet 414 of the plasma arc spray gun 411 through the sixth air inlet pipe 220, and the process realizes only air supply and no powder supply through the powder mixing equipment 219; and continuing vacuumizing, when the vacuum degree in the high-pressure chamber 101 reaches a proper value and no reduction occurs, turning on a powder feeding switch of the powder mixing equipment 219, and after waiting for 10 seconds, powering on the plasma arc spray gun 411 to realize additive manufacturing of the easily-oxidized material.
After the deposition is completed, the second air inlet valve 215 and the fourth air inlet valve 221 are closed, the vacuumizing state is kept continuously, after the deposition surface of the component is cooled, the operation of the vacuum pump 118 is stopped, and the second air outlet valve 116 is closed; the air compressor 106 operates, compressed air enters the main body of the high-pressure cabin 101 through the second air inlet pipe 112, after the internal pressure and the external pressure are consistent, the air compressor 106 and the first air valve 108 are closed, the first exhaust valve 115 is slowly opened, and the cabin cover 110 of the high-pressure cabin 101 is opened to obtain a deposition component.
What has been described above is merely some embodiments of the present invention. It will be apparent to those skilled in the art that various modifications and improvements can be made without departing from the spirit of the invention.
Claims (10)
1. An environmentally adjustable plasma arc-laser composite additive manufacturing system, comprising:
a high pressure cabin unit having a high pressure chamber, and an air compressor for supplying high pressure gas into the high pressure chamber;
the gas supply unit is positioned outside the high-pressure cabin unit and comprises a gas mixing device, a powder mixing device, a protection gas cylinder, a low ionization energy gas cylinder and an ion gas cylinder, wherein the gas mixing device is provided with a plurality of gas inlet ends, a protection gas output end and a mixed gas output end, the powder mixing device is provided with a gas inlet position and a powder outlet, the low ionization energy gas cylinder, the ion gas cylinder and the protection gas cylinder are respectively communicated with the corresponding gas inlet ends of the gas mixing device through corresponding flow valves, the protection gas of the protection gas cylinder is unidirectionally output through the gas mixing device, the low ionization energy gas of the low ionization energy gas cylinder and the ion gas of the ion gas cylinder are mixed through the gas mixing device to form mixed ion gas output, the proportion of the low ionization gas in the mixed ion gas is 5% -49%, and the protection gas output end of the gas mixing device is connected with the gas inlet position of the powder mixing device through a pipeline;
The solution environment construction unit comprises a solution medium and a liquid supply assembly, wherein the liquid supply assembly is provided with a liquid supply end, the liquid supply end is communicated with the high-pressure cavity, the solution medium is nonflammable and explosive liquid, and the solution medium is input into the high-pressure cavity through the liquid supply assembly;
the dry zone unit is arranged in a high-pressure cavity, a solution medium in the high-pressure cavity is not over the dry zone unit, the dry zone unit comprises a movable frame, a laser and a plasma arc spray gun, the bottom surface of the high-pressure cavity is used for placing substrate materials, the movable frame is arranged above the substrate materials in the high-pressure cavity, the bottom surface of the movable frame is provided with a cavity, the air compressor is used for providing a high-pressure environment for the high-pressure cavity and the cavity, the plasma arc spray gun and the laser are arranged on the inner top surface of the cavity, the plasma arc spray gun is provided with an arc spraying end, an ion transmission air port and a powder outlet which are communicated uniformly, the laser is provided with a laser emitting end and an air inlet end which are communicated, the laser emitting end is opposite to the arc spraying end, the protecting air output end of the air mixing device is respectively communicated with the air inlet end of the laser and the air inlet position of the powder mixing device, the air mixing output end of the air mixing device is communicated with the ion transmission air port of the plasma arc spray gun through corresponding air inlet valves, and the powder outlet of the powder mixing device is communicated with the powder inlet of the plasma arc spray gun through corresponding air inlet valves.
2. The plasma arc-laser composite additive manufacturing system of claim 1 wherein the dry zone unit further comprises a robotic arm, a laser mover, a plasma arc torch mover;
the mechanical arm is arranged in the high-pressure cavity, and the movable frame is arranged at the moving end of the mechanical arm;
the laser moving part comprises a rotating part, a lifting part and a rotating part, the rotating part is arranged on the inner top surface of the cavity, the lifting part is arranged at the rotating end of the rotating part, the lifting part is provided with a lifting end, the rotating part is arranged at the lifting end of the lifting part, and the laser is arranged at the rotating end of the rotating part;
the plasma arc spray gun moving part comprises an up-down moving part, the up-down moving part is arranged on the inner top surface of the cavity, the up-down moving part is provided with a moving end which moves up and down, and the plasma arc spray gun is arranged at the moving end.
3. The plasma arc-laser composite additive manufacturing system of claim 1 wherein the dry zone unit further comprises a linear lifter mounted to a side wall of the cavity, the linear lifter having a lifting end that moves up and down, and a high speed camera mounted to the lifting end, a camera window of the high speed camera facing the laser and the ion arc torch.
4. The plasma arc-laser composite additive manufacturing system of claim 1 wherein the liquid supply assembly comprises a liquid reservoir, a liquid drain reservoir, and a solution state sensor;
the liquid storage container and the liquid discharge container are both positioned outside the high-pressure cabin unit, the liquid storage container is communicated with the high-pressure cavity through the liquid inlet valve, the liquid discharge container is communicated with the high-pressure cavity through the liquid discharge valve, and the solution medium is discharged into the high-pressure cavity through the liquid inlet valve and is discharged into the liquid discharge container through the liquid discharge valve at the same time so as to adjust the liquid level of the solution medium in the high-pressure cavity;
the solution state sensor is arranged in the high-pressure cavity to monitor the liquid level pressure, the solution temperature, the solution pH value and the solution state parameters of the oxygen content of the solution in the high-pressure cavity.
5. The plasma arc-laser composite additive manufacturing system according to claim 1, further comprising a micro vacuum unit, wherein the micro vacuum unit comprises a vacuum pump and a vacuum degree detector, the vacuum pump is arranged outside the high-pressure cabin unit, the air suction end of the vacuum pump is communicated with the inside of the high-pressure cavity through an exhaust valve, a three-way pipe joint and a pipeline, and the empty end of the three-way pipe joint is connected with an electric control exhaust valve; the vacuum degree detector is arranged on the inner top surface of the high-pressure cavity so as to monitor the vacuum degree of gas in the high-pressure cavity.
6. The plasma arc-laser composite additive manufacturing system according to claim 1, wherein the high pressure chamber unit comprises a high pressure chamber having a chamber with an opening facing upward, and a cover installed on a top surface of the high pressure chamber and covering the opening of the chamber, a sealing process is used at a connection position between the high pressure chamber and the cover, and the chamber between the high pressure chamber and the cover forms the high pressure chamber.
7. A method of operating a plasma arc-laser composite additive manufacturing system according to any one of claims 1 to 6, comprising:
1) An environment construction step including construction of a solution medium environment and construction of a high-pressure environment;
construction of a solution medium environment: starting a liquid supply assembly to discharge a solution medium into the high-pressure cavity, wherein the solution medium is not passed through the dry area unit, so that the dry area unit is in a corresponding solution medium environment;
building a high-pressure environment: opening the air compressor to be in a high-pressure environment state in the high-pressure cavity and the cavity;
2) A feed preparation step including gas mixing preparation and powder mixing preparation;
and (3) gas mixing preparation: opening the corresponding flow rates of the protective gas cylinder, the low ionization energy gas cylinder and the ion gas cylinder, enabling quantitative protective gas, low ionization energy gas and ion gas to enter a gas mixing device, mixing the low ionization energy gas and the ion gas in the mixing device to form mixed ion gas, and controlling the flow valve to enable the proportion of the low ionization gas in the mixed ion gas to be 5% -49%;
Preparing mixed powder: the shielding gas is partially discharged into the powder mixing equipment from the gas mixing equipment so as to protect the stability of the metal powder in the powder mixing equipment;
3) A process adjustment step including adjustment of the overall position, adjustment of the plasma arc torch position, and adjustment of the laser position;
and (3) adjusting the overall position: placing a substrate material on the inner bottom surface of the high-pressure cavity, and controlling the mechanical arm to move the movable frame so that the laser and the plasma arc spray gun are both positioned on the substrate material;
adjustment of plasma arc spray gun position: adjusting the plasma arc spray gun to keep a proper distance with the substrate material;
adjustment of laser position: adjusting the laser to keep a proper distance with the substrate material, and enabling the laser emitting end of the laser to be opposite to the position of the substrate material corresponding to the arc spraying end of the plasma arc spray gun;
4) The manufacturing and processing steps are as follows: starting a laser to irradiate the substrate material corresponding to the bottom of the plasma arc spray gun with laser, and then introducing mixed ion gas in the gas mixing equipment into an ion transmission port of the plasma arc spray gun so as to combine the laser and the mixed ion gas and improve the arc striking of an arc spraying end of the plasma arc spray gun; then, metal powder in the powder mixing equipment enters a powder outlet of a plasma arc spray gun under the action of protective gas, plasma arcs sprayed out of the plasma arc spray gun are electrified to enable the metal powder to be fused and deposited, after the deposition is completed, the plasma arc spray gun is closed, and a laser is started to enable laser to repeatedly irradiate a deposition position to carry out surface remelting.
8. The method according to claim 7, wherein the liquid inlet valve is started during the construction of the environment of the solution medium, so that the solution medium in the high-pressure chamber enters the high-pressure chamber from the liquid storage container, the solution medium in the high-pressure chamber is made to pass through the dry area unit, the liquid discharge valve is opened when the liquid level of the solution medium is adjusted, the solution medium in the high-pressure chamber is discharged into the liquid discharge container, and the liquid inlet valve and the liquid discharge valve are closed when the liquid level of the solution medium in the high-pressure chamber reaches the corresponding height.
9. The method of claim 7, wherein during the adjustment of the laser position, the rotating member is activated to oscillate the first pushrod and the laser to form an angle with the vertical, the rotating member is further activated to rotate the laser such that the laser emitting end extension direction of the laser and the arc spraying end extension direction of the plasma arc torch create a junction, and the lifting member is further activated to lift the laser such that the junction is centered on the substrate material.
10. The method of operating a plasma arc-laser composite additive manufacturing system according to any one of claims 7 to 9, wherein the environmental construction step further comprises construction of a micro vacuum environment, the construction of the micro vacuum environment: starting a vacuum pump to discharge the gas in the high-pressure cavity outwards through the vacuum pump, wherein the outwards-discharged flow rate of the vacuum pump is larger than the total gas transmission flow rate of the gas mixing equipment into the sealing cavity in unit time when the gas mixing equipment is started; in the manufacturing and processing steps, before the powder mixing equipment is used for introducing metal powder and shielding gas into the plasma arc spray gun, the powder mixing equipment needs to be started when the vacuum degree in the high-pressure cavity reaches a proper threshold value and no reduction occurs.
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| CN105834428A (en) * | 2016-05-30 | 2016-08-10 | 重庆理工大学 | Laser three-dimensional fast forming and manufacturing method based on micro arc powder carrying |
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| CN105834428A (en) * | 2016-05-30 | 2016-08-10 | 重庆理工大学 | Laser three-dimensional fast forming and manufacturing method based on micro arc powder carrying |
| CN106825929A (en) * | 2017-02-17 | 2017-06-13 | 北京工业大学 | A kind of alternating current arc welding method of laser stabilising arc |
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