CN117843377A - Sacrificial layer cladding powder based on Leidenfrost effect and application thereof in powder core wire arc additive - Google Patents
Sacrificial layer cladding powder based on Leidenfrost effect and application thereof in powder core wire arc additive Download PDFInfo
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Abstract
Sacrificial layer cladding powder based on Leidenfrost effect and application thereof in powder core wire arc additive, wherein the cladding powder comprises ceramic matrix powder and sacrificial layer cladding powder; the application comprises the following steps: 1) Taking the sacrificial layer cladding powder as ceramic particles for additive manufacturing; 2) Based on the ceramic particles, ceramic particle reinforced metal matrix composites are produced. According to the invention, the surface of the ceramic particle is coated with the sacrificial layer, and in the arc additive manufacturing process, the sacrificial layer is instantaneously gasified in an arc high-temperature area to form the steam layer, so that the dissolution of the inner-layer ceramic particle can be effectively avoided, and the forming quality of the powder core wire arc additive manufacturing can be improved.
Description
Technical Field
The invention relates to the field of powder core wire arc additive manufacturing, in particular to a sacrificial layer cladding powder based on the Leidenfrost effect and application thereof in powder core wire arc additive manufacturing.
Background
The arc additive manufacturing technology is used as a branch of metal additive manufacturing technology, has the unique advantages of high deposition efficiency, low manufacturing cost, high material utilization rate, unlimited forming size and the like, is suitable for high-efficiency low-cost near-net forming of large-size complex components, and has wide application prospects in the fields of aviation, aerospace, automobiles, electronics, military industry and the like. The powder core wire is used as one of the forms of arc additive manufacturing raw materials, wire-powder coupling is realized at a material source, the powder transmission and the molten drop transition process are unified, the powder utilization rate is high, and the method has unique advantages in the aspect of arc additive manufacturing of particle reinforced metal matrix composite. However, due to the large heat input of the arc additive manufacturing process, the ceramic particles may completely or partially melt and react with the matrix to form brittle intermetallic compounds, deteriorating the mechanical properties of the shaped composite. In addition, the preparation process of the powder core wire material relates to the filling of ceramic powder, small-size ceramic particles are easy to agglomerate, and the fluidity is poor, so that great challenges are provided for the preparation of the powder core wire material. The factors severely restrict the development of the powder core wire arc additive manufacturing technology.
Disclosure of Invention
The invention aims to provide a sacrificial layer cladding powder based on the Leidenfrost effect and application thereof in powder core wire arc additive.
The technical scheme adopted for realizing the technical purpose of the invention is that the sacrificial layer cladding powder based on the Leidenfrost effect comprises ceramic matrix powder and sacrificial layer cladding powder.
The sacrificial layer coating powder is coated outside the ceramic matrix powder.
The preparation method of the sacrificial layer cladding powder comprises the following steps:
s1, placing the reactor in a heated electrode, and enabling the electrode to heat the reactor.
S2, placing ceramic matrix powder into a reaction area of a reactor, and introducing active gas and a silicon source to enable sacrificial layer coating powder generated by the reaction of the active gas and the silicon source to coat the ceramic matrix powder, thereby obtaining sacrificial layer coating powder.
Further, the ceramic matrix powder is a reinforcing particle with a melting point higher than that of the metal matrix material.
Further, the reactor is cleaned prior to use of the reactor to prepare the sacrificial layer cladding powder.
Further, the boiling point of the sacrificial layer coating powder is lower than the melting point of the ceramic matrix powder.
Further, the reactive gas includes an oxidant and a reactant gas.
Further, the oxidizing agent includes oxygen.
The reaction gas includes chlorine gas.
The flow rates of the oxygen and the chlorine are adjustable.
The silicon source comprises silane.
The mass flow ratio of the silane to the oxygen is 1:10.
Further, the electrode heating temperature ranges from 600 ℃ to 800 ℃.
Further, a condenser is arranged at the outlet of the reactor.
The condenser is used for condensing water vapor generated in the reaction process into liquid and discharging the liquid.
Further, the size of the ceramic matrix powder is 20-40 μm.
The size of the sacrificial layer coating powder is 200nm-500nm.
The thickness of the sacrificial layer coating powder on the surface of the ceramic matrix powder is 10-15 mu m.
Use of a sacrificial layer cladding powder based on the leidenfrost effect in powder core wire arc additive, comprising the steps of:
the sacrificial layer cladding powder described above was used as ceramic particles.
Ceramic particles are doped into the metal matrix material to manufacture the ceramic particle reinforced metal matrix composite.
The ceramic particle reinforced metal matrix composite is used as a cored wire for additive manufacturing.
The invention has the technical effects that the invention is inspired by the Leidenfrost effect, the surface of the ceramic particle is coated with a sacrificial layer, the sacrificial layer is gasified under the high-temperature condition of the electric arc in the electric arc additive manufacturing process, and the heat transmission is effectively isolated by forming a steam layer on the surface of the ceramic particle, so that the melting of the ceramic particle in the cladding is avoided.
The invention provides a sacrificial layer cladding powder based on the Leidenfrost effect and application thereof in powder core wire arc additive manufacturing, wherein a layer of sacrificial layer is coated on the surface of ceramic particles, and in the arc additive manufacturing process, the sacrificial layer is instantaneously gasified in an arc high-temperature area to form a steam layer, so that the dissolution of inner-layer ceramic particles can be effectively avoided, and the forming quality of powder core wire arc additive manufacturing is improved.
The invention provides a Leidenfrost effect-based sacrificial layer cladding powder and application thereof in powder core wire arc material increase, wherein a sacrificial layer is deposited on the surface of a small-size micron-sized ceramic matrix powder by adopting an ALD chemical vapor deposition method, and the small-size ceramic particles are coated with the sacrificial layer on the surface so that the overall particle size is increased, the fluidity of the powder is improved, and the preparation difficulty of the powder core wire is greatly reduced. Meanwhile, the surface coating layer is instantaneously gasified in a high-temperature area of arc additive manufacturing to serve as a sacrificial layer, so that the dissolution of ceramic particles in the deposition process is effectively avoided. The invention solves the problems of difficult preparation of the cored wire caused by poor fluidity of the small-size reinforced particles, complete dissolution of the small-size particles induced by high heat input in the arc additive manufacturing, poor forming quality of the large-size particle reinforced composite material and the like, can effectively solve the dual problems of difficult wire manufacturing caused by poor fluidity of the small-size ceramic particles and particle melting in the arc additive manufacturing, improves the forming quality of the metal matrix composite material in the arc additive manufacturing of the cored wire, and widens the application field of the arc additive manufacturing technology.
The beneficial effects of the invention include:
1. the invention effectively solves the double problems of difficult wire making caused by poor fluidity of small and medium-sized ceramic particles in the arc additive manufacturing and particle melting in the arc additive manufacturing, can improve the forming quality of metal matrix composite materials in the powder core wire arc additive manufacturing, and widens the application field of arc additive manufacturing technology.
2. The invention can indirectly control the thickness of the powder coating by controlling the flow rate and the deposition time of the reaction gas in the reactor, and has flexible powder coating scheme and strong applicability.
3. According to the invention, the nano-scale ceramic particles are coated on the surfaces of the micron-sized ceramic particles, so that a uniform and compact coating layer can be obtained, meanwhile, the wettability of the ceramic particles and a matrix material is improved, and the forming quality of the metal matrix composite material manufactured by powder core wire arc additive is improved.
4. The carrier gas environment can be formed in the reaction area by adding the Cl2 reaction gas, so that the silane and the oxygen are uniformly mixed and diffused, the effective area and the effective rate of the reaction are increased, the decomposition and the reaction of the silane are promoted, and meanwhile, the deposition rate and the quality of a reaction product (SiO 2) can be promoted.
5. The invention provides a sacrificial layer cladding powder based on the Leidenfrost effect and application thereof in powder core wire arc additive manufacturing, wherein the cladding powder can be applied to the fields of additive manufacturing, surface modification and the like, and the application scope of the powder core wire arc additive manufacturing technology is greatly widened.
Drawings
Fig. 1 is a schematic diagram of a preparation method of a sacrificial layer cladding powder based on the leidenfrost effect according to an embodiment of the present invention;
FIG. 2 is a schematic diagram illustrating a deposition process of a sacrificial layer cladding powder based on the Leidenfrost effect according to an embodiment of the present invention;
fig. 3 is a schematic diagram of a cladding result structure of a sacrificial layer cladding powder based on the leidenfrost effect according to an embodiment of the present invention; FIG. 3 (a) is a perspective view of the coating result; FIG. 3 (b) is a schematic view of the cut surface of the coating result;
fig. 4 is a schematic structural diagram of a sacrificial layer cladding powder based on the leidenfrost effect and its application in cored wire arc additive provided in an embodiment of the present invention;
in the figure, ceramic base powder 1, sacrificial layer coated powder 2, silane 3, oxygen 4, chlorine 5, valve 6, flow meter 7, gas guide tube 8, reactor 9, heat insulating plate 10, heating electrode 11, condenser 12, sacrificial layer 13, ceramic reinforcing particles 14, base 15, molten pool 16, arc 17, welding gun 18, cladding powder 19, metal belt 20, cored wire 21, and gasification layer 22.
Detailed Description
The present invention is further described below with reference to examples, but it should not be construed that the scope of the above subject matter of the present invention is limited to the following examples. Various substitutions and alterations are made according to the ordinary skill and familiar means of the art without departing from the technical spirit of the invention, and all such substitutions and alterations are intended to be included in the scope of the invention.
Example 1:
referring to fig. 1 to 4, a sacrificial layer cladding powder based on the leidenfrost effect comprises a ceramic matrix powder 1 and a sacrificial layer cladding powder 2.
The sacrificial layer coating powder 2 is coated outside the ceramic matrix powder 1.
The preparation method of the sacrificial layer cladding powder comprises the following steps:
s1, placing the reactor in a heated electrode, and enabling the electrode to heat the reactor.
S2, placing ceramic matrix powder into a reaction area of a reactor, and introducing active gas and a silicon source to enable sacrificial layer coating powder generated by the reaction of the active gas and the silicon source to coat the ceramic matrix powder, thereby obtaining sacrificial layer coating powder.
Example 2:
the main technical content of the sacrificial layer cladding powder based on the leidenfrost effect is shown in the embodiment 1, and further, the ceramic matrix powder 1 is reinforced particles with a melting point higher than that of a metal matrix material.
Example 3:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is shown in any one of examples 1 to 2, further, the reactor is cleaned before the sacrificial layer cladding powder is prepared by using the reactor.
Example 4:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is as in any one of embodiments 1 to 3, further, the boiling point of the sacrificial layer cladding powder 2 is lower than the melting point of the ceramic matrix powder 1.
Example 5:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is as described in any one of embodiments 1 to 4, further, the active gas comprises an oxidant and a reaction gas.
Example 6:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is as described in any one of embodiments 1 to 5, further, the oxidant comprises oxygen.
The reaction gas includes chlorine gas.
The flow rates of the oxygen and the chlorine are adjustable.
The silicon source comprises silane.
The mass flow ratio of the silane to the oxygen is 1:10.
Example 7:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is as in any one of examples 1 to 6, further, the heating temperature of the electrode ranges from 600 ℃ to 800 ℃.
Example 8:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is as described in any one of embodiments 1 to 7, further, a condenser is arranged at the outlet of the reactor.
The condenser is used for condensing water vapor generated in the reaction process into liquid and discharging the liquid.
Example 9:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is as in any one of embodiments 1 to 8, further, the size of the ceramic matrix powder 1 is 20 μm-40 μm.
The size of the sacrificial layer coating powder 2 is 200nm-500nm.
The thickness of the sacrificial layer coating powder 2 coated on the surface of the ceramic matrix powder 1 is 10-15 mu m.
Example 10:
use of a sacrificial layer cladding powder based on the leidenfrost effect in powder core wire arc additive, comprising the steps of:
the sacrificial layer clad powder of any of examples 1-9 was used as ceramic particles.
Ceramic particles are doped into the metal matrix material to manufacture the ceramic particle reinforced metal matrix composite.
The ceramic particle reinforced metal matrix composite is used as a cored wire for additive manufacturing.
Example 11:
referring to fig. 1 to 4, a sacrificial layer cladding powder based on the leidenfrost effect comprises a ceramic matrix powder 1 and a sacrificial layer cladding powder 2.
The sacrificial layer coating powder 2 is coated outside the ceramic matrix powder 1.
The preparation method of the sacrificial layer cladding powder comprises the following steps:
s1, placing the reactor in a heated electrode, and enabling the electrode to heat the reactor.
S2, placing ceramic matrix powder into a reaction area of a reactor, and introducing active gas and a silicon source to enable sacrificial layer coating powder generated by the reaction of the active gas and the silicon source to coat the ceramic matrix powder, thereby obtaining sacrificial layer coating powder.
After the preparation is completed, after the temperature of the reactor is reduced to room temperature, the reactor is closed, and the deposited coating powder is taken out.
As shown in fig. 1, silane 3, oxygen 4 and chlorine 5 all enter a reactor 9 through a valve 6, a flow device 7 and an air duct 8 in sequence.
The front end of the reactor 9 is provided with a heat insulation plate 10.
The reactor 9 is placed in a heating electrode 11.
The sacrificial layer coating powder 2 is deposited in the reaction zone of the reactor 9.
The reactor is an atomic layer deposition (Atomic Layer Deposition, ALD) chemical vapor deposition reactor.
As shown in fig. 3, the sacrificial layer 13 composed of the sacrificial layer coating powder 2 coats the ceramic reinforcing particles 14.
Example 12:
the main technical content of the sacrificial layer cladding powder based on the leidenfrost effect is as shown in embodiment 11, and further, the ceramic matrix powder is reinforced particles with a melting point higher than that of the metal matrix material.
The metal matrix material comprises Fe metal matrix material and Ti metal matrix material.
The melting point of the ceramic matrix powder (core) material is higher than that of the metal matrix material.
Example 13:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is seen in any one of examples 11 to 12, further the reactor is cleaned before the reactor is used for preparing the sacrificial layer cladding powder.
The reactor is cleaned by a cleaner to remove impurities.
The cleaner is a high vacuum mass spectrometer that cleans the ALD reactor to remove any impurities that may cause oxidation.
Example 14:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is as described in any one of embodiments 11 to 13, further, the boiling point of the sacrificial layer cladding powder is lower than the melting point of the ceramic matrix powder.
Example 15:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is as described in any one of examples 11 to 14, further, the reactive gas comprises an oxidant and a reactive gas.
Example 16:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is as described in any one of examples 11 to 15, further wherein the oxidizing agent comprises oxygen.
The reaction gas includes chlorine gas.
The flow rates of the oxygen and the chlorine are adjustable.
The silicon source comprises silane.
The mass flow ratio of the silane to the oxygen is 1:10. The chlorine flow was 50ml/min.
Silane (SiH) selection 4 ) As a silicon source, oxygen (O 2 ) As an oxidizing agent, chlorine (Cl) 2 ) As a reaction gas.
The reactor was cleaned using a high vacuum mass spectrometer to remove any impurities that may cause oxidation, then placed in a heated electrode, oxygen and chlorine gas were introduced to form reactive gases and the oxygen and chlorine gas flow rates were regulated.
Example 17:
the sacrificial layer cladding powder based on the Leidenfrost effect has the main technical content as shown in any one of examples 11 to 16, and further comprises an electrode heating temperature of 600 ℃ and a reaction zone air pressure of 1.33X10-3 MPa. The deposition time was 30 minutes.
Example 18:
the sacrificial layer cladding powder based on the Leidenfrost effect has the main technical content as shown in any one of the embodiments 11 to 17, and further comprises an electrode heating temperature of 800 ℃ and a reaction zone air pressure of 1.33 multiplied by 10 < -3 > MPa. The deposition time was 30 minutes.
Example 19:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is as described in any one of examples 11 to 18, further wherein a condenser is provided at the outlet of the reactor.
The condenser is used for condensing water vapor generated in the reaction process into liquid and discharging the liquid.
As shown in fig. 1, a condenser 12 is provided at the outlet of the reactor 9.
Example 20:
a sacrificial layer cladding powder based on the leidenfrost effect, the main technical content of which is as in any one of examples 11 to 19, further, the size of the ceramic matrix powder 1 is 20 μm-40 μm.
The size of the sacrificial layer coating powder 2 is 200nm-500nm.
The thickness of the sacrificial layer coating powder 2 coated on the surface of the ceramic matrix powder 1 is 10-15 mu m.
The ceramic matrix powder (core) is a reinforcement in ceramic particle reinforced metal matrix composite materials in the field of additive manufacturing, and the size is 20-40 mu m.
The nano-scale ceramic particle coating powder (shell) is ceramic particles with the size of 200nm-500nm for the field of additive manufacturing.
The coating thickness of the nano-scale ceramic particle coating powder (shell) on the surface of the ceramic matrix powder (core) is 10-15 mu m.
Example 21:
use of a sacrificial layer cladding powder based on the leidenfrost effect in powder core wire arc additive, comprising the steps of:
the sacrificial layer clad powder of any of examples 11-20 was used as ceramic particles.
Ceramic particles are doped into the metal matrix material to manufacture the ceramic particle reinforced metal matrix composite.
The ceramic particle reinforced metal matrix composite is used as a cored wire for additive manufacturing.
Example 22:
the application of the Leidenfrost effect-based sacrificial layer cladding powder in the electric arc additive of the powder core wire is disclosed in the embodiment 21, and the application of the Leidenfrost effect-based sacrificial layer cladding powder in the field of preparing metal matrix composite materials in the electric arc additive manufacturing is disclosed.
As shown in fig. 4, the powder core wire 21 is melted by an arc 17 generated by a welding gun 18, and a molten pool 16 is formed on the base 15.
The cored wire 21 includes an overclad powder 19 and a metal ribbon 20.
The cladding powder 19 includes a ceramic base powder 1 and a sacrificial layer cladding powder 2.
During the droplet process, the gas formed by the gasification of the sacrificial layer coating powder 2 does not escape, and enters the molten pool 16 to form the gasification layer 22.
Example 23:
an application method of a sacrificial layer cladding powder based on the Leidenfrost effect comprises the following steps:
1) The sacrificial layer clad powder is used as ceramic particles.
2) Ceramic particles are doped into the metal matrix material to manufacture the ceramic particle reinforced metal matrix composite.
3) The ceramic particle reinforced metal matrix composite is used as a cored wire for additive manufacturing.
Example 24:
a preparation method of sacrificial layer cladding powder based on the Leidenfrost effect comprises the following steps:
1) The reactor is placed in a heated electrode, which is caused to heat the reactor.
2) And placing the ceramic matrix powder into a reaction area of the reactor, and introducing active gas and a silicon source to enable the sacrificial layer coating powder generated by the reaction of the active gas and the silicon source to coat the ceramic matrix powder, thereby obtaining the sacrificial layer coating powder.
Example 25:
referring to fig. 1 to 4, a sacrificial layer cladding powder based on the leidenfrost effect and its application in cored wire arc additive, mainly comprises the following:
a sacrificial layer cladding powder based on the leidenfrost effect comprising: micron-sized ceramic particle matrix powder (core), nano-sized ceramic particle coating powder (shell), sacrificial layer powder source material, a reactor and a cleaner.
The ceramic matrix powder (core) is a reinforcement in ceramic particle reinforced metal matrix composite materials in the field of additive manufacturing, and the size is 20-40 mu m.
The nano-scale ceramic particle coating powder (shell) is ceramic particles with the size of 200-500nm for the field of additive manufacturing.
The source material of the coating layer is a mixed gas of a plurality of nano-scale ceramic particle coating powders generated by high-temperature gas reaction.
The reactor is an Atomic Layer Deposition (ALD) chemical vapor deposition reactor.
The cleaner is a high vacuum mass spectrometer that cleans the ALD reactor to remove any impurities that may cause oxidation.
The ceramic matrix powder (core) is a reinforced particle of a high-melting-point metal matrix material, such as Fe and Ti metal matrix.
The melting point of the ceramic matrix powder (core) material is higher than that of the metal matrix material.
The particle size of the ceramic matrix powder (core) is 20-40 mu m.
The nano-scale ceramic particle coating powder (shell) is ceramic particles coated on the surface of the ceramic matrix powder (core).
The boiling point of the nano-scale ceramic particle coating powder (shell) material is higher than the melting point of the metal matrix material and lower than the melting point of the ceramic matrix powder (core) material.
The particle size of the nano-scale ceramic particle coated powder (shell) is 200-500nm.
The coating thickness of the nano-scale ceramic particle coating powder (shell) on the surface of the ceramic matrix powder (core) is 10-15 mu m.
A preparation method of sacrificial layer cladding powder based on the Leidenfrost effect comprises the following steps:
(1) silane (SiH) selection 4 ) As a silicon source, oxygen (O 2 ) As an oxidizing agent, chlorine (Cl) 2 ) As a reaction gas.
(2) The reactor was cleaned using a high vacuum mass spectrometer to remove any impurities that could lead to oxidation, then placed in a heated electrode, and O was vented 2 And Cl 2 To form reactive gas and regulate O 2 And Cl 2 Flow rate.
(3) And (3) placing the ceramic matrix powder (core) into a reaction area for deposition.
(4) After the deposition, the reactor temperature was lowered to room temperature, the reactor was closed and the deposited coating powder was removed.
SiH in step (1) 4 And Cl 2 The mass flow ratio of (C) is 1:10, cl 2 The flow rate was 50ml/min.
In the step (2), the electrode heating temperature is 1000 ℃, and the reaction zone air pressure is 1.33X10-3 MPa.
The deposition time in step (3) was 30 minutes.
And a condenser is arranged at the outlet of the reaction chamber to condense water vapor generated in the reaction process into liquid and discharge the liquid.
The application of the Leidenfrost effect-based sacrificial layer cladding powder in the field of preparing metal matrix composite materials by arc additive manufacturing is characterized in that the Leidenfrost effect-based sacrificial layer cladding powder is used, and coated ceramic particles are filled in the powder core wire.
Example 26:
referring to fig. 1 to 4, a sacrificial layer cladding powder based on the leidenfrost effect and its application in cored wire arc additive, mainly comprises the following:
the sacrifice layer cladding powder based on the Leidenfrost effect has the advantages that the overall particle size is increased by cladding a sacrifice layer on the surface of small-size reinforced particles, the fluidity of the powder is improved, the preparation difficulty of powder core wires is greatly reduced, the contradiction problem between the reinforced particle size and the preparation of the powder core wires is solved, and the research and application fields of arc additive manufacturing are favorably expanded.
The method specifically comprises the following steps:
(1) silane (SiH) selection 4 ) As a silicon source, oxygen (O 2 ) As an oxidizing agent, chlorine (Cl) 2 ) As a reaction gas.
(2) The reactor was cleaned using a high vacuum mass spectrometer to remove any impurities that could lead to oxidation, then placed in a heated electrode, and O was vented 2 And Cl 2 To form reactive gas and regulate O 2 And Cl 2 Flow rate.
(3) And (3) placing the ceramic matrix powder (core) into a reaction area for deposition.
(4) After the deposition, the reactor temperature was lowered to room temperature, the reactor was closed and the deposited coating powder was removed.
SiH in step (1) 4 And O 2 The mass flow ratio of (C) is 1:10, cl 2 The flow rate was 50ml/min.
In the step (2), the electrode heating temperature is 1000 ℃, and the reaction zone air pressure is 1.33X10-3 MPa.
The deposition time in step (3) was 30 minutes.
In the embodiment, the sacrificial layer with specific thickness can be simply and effectively coated on the surface of the small-size reinforced particles by reasonably planning coating process parameters such as the source material of the powder of the sacrificial layer, the relative mass ratio, the flow, the reaction temperature, the reaction time and the like, so that the contradiction problem between the size of the reinforced particles and the preparation of the powder core wire is fundamentally solved.
Example 27:
referring to fig. 1 to 4, a sacrificial layer cladding powder based on the leidenfrost effect and its application in cored wire arc additive, mainly comprises the following:
the application of the sacrificial layer cladding powder based on the Leidenfrost effect in the field of powder core wire arc additive manufacturing uses the coated reinforced particle powder in the field of powder core wire arc additive manufacturing. The surface coating layer is instantly gasified in a high-temperature area of arc additive manufacturing to serve as a sacrificial layer, so that the dissolution of ceramic particles in the deposition process is effectively avoided, the contradiction problem between the dissolution of the particles in the arc additive manufacturing and the forming quality of a composite material is solved, the forming quality of an arc additive manufacturing component is greatly improved, and the technical application field is widened.
Taking the substrate 316L stainless steel as an example, a 7X 0.3mm 316L stainless steel belt and SiO are used 2 Preparation of TiC-coated ceramic composite powder cored wire for arc additive manufacturing and SiO 2 The ceramic grain size is 200-500nm, tiC ceramic grain size is 20-40 μm, and the mixed gas of argon and carbon dioxide with the flow rate of 20L/min is used as the protective gas in the arc additive manufacturing process for cold metal transition consumable electrode active gas shielded welding.
Determining arc additive manufacturing deposition process parameters based on cold metal transition according to the prepared composite material powder core wire and the adopted arc additive manufacturing technology type, wherein the arc additive manufacturing deposition process parameters comprise: the diameter of the welding wire is 1.2mm, the welding current is 149A, the welding voltage is 14.6V, the wire feeding speed is 4.4m/min, the welding speed is 0.3m/min, the protection gas flow is 20L/min, the size of the 316L stainless steel substrate is 200mm multiplied by 10mm, and the mass fraction of TiC ceramic particles is 10wt%.
In the embodiment, the coated composite powder is used in the field of powder core wire preparation and arc additive manufacturing metal matrix composite forming, tiC reinforced 316L stainless steel composite deposition process parameters in arc additive manufacturing are determined according to the prepared powder core wire and arc additive manufacturing technology types, dissolution of ceramic reinforced particles in the composite forming process is greatly inhibited, microstructure and mechanical properties of a deposition layer are improved, and arc additive manufacturing forming quality is improved.
Example 28:
referring to fig. 1 to 4, a sacrificial layer cladding powder based on the leidenfrost effect and its application in cored wire arc additive, mainly comprises the following:
a method for inhibiting air hole defects of sacrificial layer cladding powder in powder core wire arc additive based on the Leidenfrost effect. By taking ultrasonic vibration of the substrate as an example, the reduction or elimination of the porosity of a molten pool caused by gasification of the sacrificial layer can be realized and the forming quality can be improved by reasonably regulating and controlling the arc additive manufacturing and ultrasonic vibration coupling process parameters of the powder core wire.
Placing the pretreated substrate on an ultrasonic vibration platform, clamping, and carrying out arc additive manufacturing process parameters, wherein the vibration frequency of the ultrasonic vibration platform is 20KHz, and the average amplitude is 20 mu m, and the arc additive manufacturing process parameters are as follows: the diameter of the welding wire is 0.8-1.6mm, the welding current is 20-250A, the welding voltage is 5-15V, the wire feeding speed is 1.0-9.0m/min, and the welding speed is 0.1-1.5m/min.
And starting the ultrasonic vibration platform to work before the arc is started by the arc additive manufacturing equipment, performing powder core wire arc additive manufacturing after the ultrasonic vibration platform works stably, and stopping the ultrasonic vibration platform to work after the arc is extinguished by the arc additive manufacturing equipment after the deposition is completed.
In this embodiment, because the time of the transition stage of the molten drop is short, the gas formed by gasifying part of the sacrificial layer does not escape into the molten pool to form the air hole defect, and for this problem, the embodiment provides the deposition process to assist in realizing the reduction and the inhibition of the porosity by ultrasonic vibration, improves the manufacturing and forming quality of the powder core wire arc additive manufacturing, and expands the research and application fields thereof.
Claims (10)
1. The sacrificial layer cladding powder based on the Leidenfrost effect is characterized by comprising ceramic matrix powder (1) and sacrificial layer cladding powder (2);
the sacrificial layer coating powder (2) is coated outside the ceramic matrix powder (1).
The preparation method of the sacrificial layer cladding powder comprises the following steps:
s1, placing the reactor in a heated electrode, and enabling the electrode to heat the reactor.
S2, placing ceramic matrix powder into a reaction area of a reactor, and introducing active gas and a silicon source to enable sacrificial layer coating powder generated by the reaction of the active gas and the silicon source to coat the ceramic matrix powder, thereby obtaining sacrificial layer coating powder.
2. A sacrificial layer cladding powder based on the leidenfrost effect according to claim 1, wherein said ceramic matrix powder (1) is a reinforcing particle having a melting point higher than that of the metal matrix material.
3. A sacrificial layer cladding powder based on the leidenfrost effect according to claim 1, wherein the reactor is also cleaned before being used for preparing the sacrificial layer cladding powder.
4. A sacrificial layer cladding powder based on the leidenfrost effect according to claim 1, characterized in that the boiling point of the sacrificial layer cladding powder (2) is lower than the melting point of the ceramic matrix powder (1).
5. A sacrificial layer cladding powder based on the leidenfrost effect according to claim 1, wherein said reactive gas comprises an oxidizing agent and a reactive gas.
6. A sacrificial layer cladding powder based on the leidenfrost effect according to claim 5, wherein said oxidizing agent comprises oxygen;
the reaction gas includes chlorine gas;
the flow rates of the oxygen and the chlorine are adjustable;
the silicon source comprises silane;
the mass flow ratio of the silane to the oxygen is 1:10.
7. A sacrificial layer cladding powder based on the leidenfrost effect according to claim 1, wherein said electrode heating temperature is in the range of 600-800 ℃.
8. A sacrificial layer cladding powder based on the leidenfrost effect according to claim 1, wherein a condenser is provided at the outlet of the reactor;
the condenser is used for condensing water vapor generated in the reaction process into liquid and discharging the liquid.
9. A sacrificial layer cladding powder based on the leidenfrost effect according to claim 1, wherein the ceramic matrix powder (1) has a size of 20 μm-40 μm;
the size of the sacrificial layer coating powder (2) is 200nm-500nm;
the thickness of the sacrificial layer coating powder (2) coating the surface of the ceramic matrix powder (1) is 10-15 mu m.
10. Use of a sacrificial layer cladding powder based on the leidenfrost effect in powder core wire arc additive, comprising the steps of:
the sacrificial layer clad powder of any one of claims 1-9 as ceramic particles;
ceramic particles are doped into a metal matrix material to manufacture a ceramic particle reinforced metal matrix composite material;
the ceramic particle reinforced metal matrix composite is used as a cored wire for additive manufacturing.
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