WO2016070778A1 - 金属构件电熔成形方法 - Google Patents
金属构件电熔成形方法 Download PDFInfo
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- WO2016070778A1 WO2016070778A1 PCT/CN2015/093636 CN2015093636W WO2016070778A1 WO 2016070778 A1 WO2016070778 A1 WO 2016070778A1 CN 2015093636 W CN2015093636 W CN 2015093636W WO 2016070778 A1 WO2016070778 A1 WO 2016070778A1
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- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B23K28/00—Welding or cutting not covered by any of the preceding groups, e.g. electrolytic welding
- B23K28/02—Combined welding or cutting procedures or apparatus
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
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- B05C19/00—Apparatus specially adapted for applying particulate materials to surfaces
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- B22F10/20—Direct sintering or melting
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- B22F12/50—Means for feeding of material, e.g. heads
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- B23K25/00—Slag welding, i.e. using a heated layer or mass of powder, slag, or the like in contact with the material to be joined
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- B23K9/00—Arc welding or cutting
- B23K9/18—Submerged-arc welding
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- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/141—Processes of additive manufacturing using only solid materials
- B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/264—Arrangements for irradiation
- B29C64/277—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
- B29C64/282—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] of the same type, e.g. using different energy levels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/295—Heating elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/82—Forcing wires, nets or the like partially or completely into the surface of an article, e.g. by cutting and pressing
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- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
- H05K3/103—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern by bonding or embedding conductive wires or strips
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/66—Treatment of workpieces or articles after build-up by mechanical means
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/70—Recycling
- B22F10/73—Recycling of powder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/10—Auxiliary heating means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/20—Cooling means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2202/00—Treatment under specific physical conditions
- B22F2202/06—Use of electric fields
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the diameter of the raw material wire may be 2 mm to 20 mm, and is specifically set according to the size and shape of the formed workpiece; the length of the electrofusion head (electrical length) is 20 mm depending on the diameter of the raw material wire. 150mm.
- the raw material filament forms a molten pool on the surface of the lower metal layer, and the molten droplet enters the molten pool in the form of a jet and solidifies to form the two layers of metal into one body, thereby realizing layer forming and integral fusion, thereby ensuring The overall properties of the formed metal component.
- the utilization rate of the raw material yarn is close to 100%; compared with the conventional processing technology (forging, casting, etc.), the number of manufacturing processes is small (no complicated heat treatment is required), the cycle is short, and the efficiency is high.
- the machining allowance of the components is very small, while reducing the finishing time and saving a lot of material.
- all of the electrofusion heads 401 automatically lift a layer of deposition thickness (ie, layer thickness) to start the first layer of fused deposition of the second layer, the first layer of fused deposition
- the end point of the head 401 is the starting point of the first track of the second layer, and is continuously deposited;
- step (7) is repeated to complete the remaining fused deposition track, so as to reach the required thickness of the workpiece, so as to complete the fused deposition of the second layer;
- the production of shaped workpieces The H08A ordinary low-carbon steel wire material is selected, and a head metal member is vertically grown by a metal member electrofusion forming method, and the equipment used in the embodiment includes
- the profiled (head) workpiece is formed by the electrofusion method, and the forming efficiency is greatly improved due to the addition of 30% iron powder in the production process.
- the overall formation of the steam generator cylinder This example describes the overall forming method of the nuclear electric evaporator cylinder electrofusion.
- the whole cylinder is divided into 6 sections (2 sections of the upper cylinder, 3 sections of the lower cylinder, and 1 section of the conical section), and respectively forged.
- the cylinder material is SA508Gr3CL2 low alloy steel.
- the inner wall needs to be welded with 308 stainless steel with a thickness of about 8mm.
- the method of the invention can be integrally formed at one time.
- the equipment used in the method includes:
- step (4) After the second pass is completed, repeat step (4) to complete the formation of the other fused deposition tracks.
- the last pass is reached, the last end point of the adjacent fused 404 and the first start point are Good lap joint, complete the first layer of fused deposition;
- step (7) When the completion of the second layer of the second fused deposition is completed, the step (7) is repeated, and the other fused deposition tracks are completed. When the last pass is reached, the last end point of the adjacent fused 404 is reached. It is well connected with the first starting point, so that the second layer of fused deposition is completed;
- the stainless steel substrate 204 becomes a part of the container cylinder after electrofusion forming, and the direct connection forming of the dissimilar materials is realized, and the conventional process is used to weld the 308 stainless steel on the inner wall after forging the SA508-3 cylinder.
- the manufacturing method in addition, because there are multiple (21)
- the electric fuse heads are integrally formed side by side, which changes the method of grouping and forging after the traditional forging process, simplifies the process, and improves work efficiency and quality.
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Abstract
一种金属构件电熔成形方法,其将电熔头(6)与基材(2)接至电源(12)两极,成形时金属原料丝材(1)经由送丝机构(5)和电熔头(6)送至基材(2)表面,在颗粒状辅料(3)的堆积保护下,原料丝材(1)与基材(2)间产生电弧(9),熔化部分堆敷辅料(3)形成熔融渣池(8),电流流过原料丝材(1)和熔融渣池(8)形成电阻热和电渣热,在电弧热、电阻热、电渣热三种热复合高能热源作用下使原料丝材(1)熔化,在基材(2)表面形成局部熔池(11),持续输送原料丝材(1)与辅料(3),根据成形构件的分层切片数据,采用计算机控制电熔头(6)与基材(2)的相对移动,实现熔池(11)在基材(2)上快速冷却逐层凝固堆积,最终逐层堆积成形出所需形状和尺寸的金属构件。
Description
本发明涉及一种金属构件电熔成形方法。
目前,核电、火电、石化、冶金、船舶等现代重型工业装备正日益向大型化、复杂化、高性能参数和极端条件下高可靠性、长寿命服役方向快速发展,所需低合金高强度钢、耐热合金等关键金属构件尺寸也越来越大、质量要求越来越高。其制造方式主要采用数百吨级大型钢锭冶炼、铸造和万吨水压机等重型锻造工业装备锻压成形,并辅以最终机加工。该方法基本能够满足技术质量要求,但制造工序繁多、生产周期长、材料利用率低,导致构件成本高昂;另一方面,工艺复杂、化学与力学性能控制难度大,也造成质量稳定性差,废品率高;且囿于我国当前自身制造能力,特殊高性能大型金属构件还需从日本制钢、斗山重工等公司进口。价格居高不下、出口限制严格,严重影响着项目建设进度,也制约我国重型装备制造业的发展。
为解决上述问题,国家与企业均寄望重型装备制造业取得重大突破。困难与机遇并存!近年来方兴未艾的熔融沉积快速成型也即3D打印技术正成为一个重要的发展方向。
3D打印,由于其制造柔性化程度高、成形周期短、加工速度快等优点,已被广泛应用于产品模块模型的成形,如利用石蜡、树脂等低熔点材料成形工件模型,也在特定行业如航空航天钛合金金属构件制造中取得重大突破与应用,但对于想要全面进入制造业尤其是重型装备制造业,还有许多困难需要攻克。包括熔化高熔点金属元素所需的高能量密度热源的选取以及完全创新的3D系统设备的设计制造;对应成形工件的原材料丝材或粉末的研发和制备;另外如何攻克重型金属构件大尺寸和复杂形状成形过程中裂纹、气孔、化学偏析、全截面性能要求等难题;最重要的,如何确保工艺稳定成熟,媲美甚至超越
传统锻造工艺,满足要求越来越高的各行业重型金属构件的力学和化学性能。
发明内容
有鉴于此,本发明的主要目的在于,提供一种高效、低成本、具有良好力学性能的金属构件电熔成形方法。
为了达到上述目的,本发明中,电熔成形方法是采用电弧热、电阻热、电渣热复合而成的高能热源,熔化连续输送的金属原料丝材,在基材上逐层凝固堆积成形制造金属构件;
将电熔头与基材接至电源两极,成形时金属原料丝材经由输送机构和电熔头送至基材表面,在颗粒状辅料的堆积保护下,原料丝材与基材间产生电弧,熔化部分堆敷辅料形成熔融渣池,电流流过原料丝材和熔融辅料渣池形成电阻热和电渣热,在电弧热、电阻热、电渣热三种热复合高能热源作用下使原料丝材熔化,在基材表面形成局部熔池,持续输送原料丝材与辅料,根据成形构件的分层切片数据,采用计算机控制电熔头与基材的相对移动,实现熔池在基材上快速冷却逐层凝固堆积,最终逐层堆积成形出所需形状和尺寸的金属构件。
在本发明中,电源参数中的电流可以为200A~6000A,电压可以为20V~60V,电源可以是直流或交流电源,在使用直流电源时,电熔头可接正极或负极。
在本发明中,原料丝材的直径可以为2mm~20mm,具体根据成形工件的尺寸形状等要求设定;根据原料丝材直径不等,伸出电熔头的长度(通电长度)为20mm~150mm。
在本发明中,成形过程中辅料覆盖厚度为15mm~120mm;辅料包含氧化物或者氧化物与卤化物或者氧化物与卤化物及金属粉末组成。根据成形效率和构件金属成分要求,可在辅料中添加总量不超过30%的合金粉末以及/或者单质金属粉末。
颗粒辅料在成形过程中参与熔池元素反应,调整熔池中合金元素,改善成形工件的力学性能,降低生产成本。
在本发明中,控制基材或堆积金属层的表面温度为100~600℃,电熔头与基材的相对移动速度为150~3000mm/min,实现熔池的快速凝固,从而获得晶粒细密、无宏观偏析、组织均匀的材料,极大的改善成形工件的塑性、韧性和高温蠕变等力学性能,另外高温熔池对下一层热影响区沉积金属层进行热处理,工件逐层进行自回火热处理,晶粒更为细密,组织更为稳定。
在本发明中,在逐层成形的过程中,原料丝在下层金属表面形成熔池,熔滴以射流形态进入熔池后凝固使两层金属形成一体,实现分层成形、整体融合,保证了成形金属构件的整体性能。
在本发明中,单个电熔头对原料丝材熔化效率为10~80Kg/h,电熔头与基材相对移动而堆积的金属层的层高为1~8mm。另外,为提高堆积效率实现快速成形,电熔头的数量可以按需要调整为1~100个,当多电熔头排布时,相邻电熔头间距为50~500mm。
在本发明中,金属构件成形边缘可以由辅料或金属基板支撑保护。如此,能够防止产生熔融金属溢流;基材尺寸、形状与在其表面堆积的最初一层堆积金属形状匹配,厚度最好不小于5mm;基材与堆积金属可以是相同或不同材料,不同材料时,基材可以通过后续机加工去除或者作为金属构件一部分予以保留。
本发明摆脱了复杂的工装、模具和专用工具的约束;成形即为近净形坯件,生产后只需少量精加工,大大简化加工工序,缩短产品周期;所成形工件具有媲美传统锻造工艺的力学和化学性能,强度、韧性、耐蚀等性能均十分突出;本发明的方法可用于各行业重型金属构件如低合金钢、耐热钢、不锈钢、镍基合金材料的成形与生产。
图1A为用于说明具体实施方式中的金属构件电熔成形方法的示意图;
图1B为图1A中A位置附近的局部放大图;
图2为用于说明实施例1中的成形方法的示意图;
图3为用于说明实施例2中的成形方法的示意图;
图4为用于说明实施例3中的成形方法的示意图;
图5为用于说明实施例4中的成形方法的示意图。
下面参照附图对本发明的具体实施方式进行说明。图1A本实施方式中涉及的金属构件电熔成形方法的说明图;图1B为图1A中A所示位置附近的局部放大图。由于是原理图,因而,图中部件是示意性的,其实际形状与尺寸关系等不受图中所示限制。
该成形方法是将原料丝材1熔化而逐层(图1中所示为堆积至第N层时的状态)堆积在基础材2上,从而最终形成所需的金属构件。
具体实施工序为:
A.送丝机构5将原料丝材1送至放置于工作台21上的基材2的表面,其上覆盖由送粉机构4输送的颗粒状辅料。
B.启动电源12,电源电压使原料丝材1与基材2间形成电弧9产生电弧热,电弧热使部分辅料3熔融,形成辅料渣池8,电流经由电熔头(熔化头)6流过原料丝材1形成电阻热,并流过熔融渣池8形成电渣热,三种热源复合而成高能热源,熔化原料丝材,在基材2表面形成熔池11。
C.控制电熔头6与基材2的相对移动和基材2的温度,实现熔池11与基材换热凝固沉积。
D.送丝机构5与送粉机构4持续输送原料丝材1和辅料3,在辅料3覆盖熔池11和基材2的状态下,原料丝材1逐层堆积在基材2上,最终成形工件。
控制装置(计算机)根据成形构件的(数值模拟、数学模型)分层切片数据控制电熔头6与基材2的相对移动方式。
在本发明图示中电熔头电极接正,工件接负只作示意作用,也可以电熔头接负,工件接正,或采取交流电源。
在本发明中,为了保证形成良好的高能热源,尤其是为了产生充
分的电渣热,可以适当地调节辅料的成分、原料丝材的直径、电流、基材与原料丝材的相对移动速度等参数。
在本发明中,原料丝1的形态可以是圆棒状、带状,实芯或者药芯的;原料丝1的直径可以根据成形工件的尺寸设定为2~20mm;根据丝材1直径不同,伸出电熔头的长度(通电长度)为20mm~150mm。
在本发明中,辅料3覆盖厚度为15mm~120mm,使用辅料3的作用包括:覆盖电弧9,防止电弧飞溅;覆盖熔池11,隔绝空气,使熔池金属免受空气中氧、氮、氢等的侵害;对熔池金属形成保温;冶金反应过程中去除杂质、掺入合金;形成的渣池8(渣壳7)以机械方式保护沉积金属10良好成形等。
辅料3的成分包含氧化物或者氧化物与卤化物。由于辅料3参与熔池反应,调整工件(金属构件、产品)成分,因而根据所要形成的金属构件的成分和效率要求,还可以在辅料中添加合金粉末以及/或者单质金属粉末,降低生产成本。
另外,在C工序中,可以附带回收残余辅料以及去除渣池8凝固而形成的渣壳7的操作。去除时,可以在原料丝1的相对移动后方400mm~500mm处开始机器去除或人工去除作业。
采用本实施方式的电熔成形方法,原料丝利用率接近100%;相比现有的加工技术(锻造、铸造等),制造工序少(不需要复杂的热处理),周期短,效率高,金属构件的机械加工余量非常小,同时减少了精加工时间及节约了大量的材料。
【实施例1】
回转筒体的卧式制作。本实例描述通过卧式电熔成形方法制作筒体的过程,材料为普通低碳钢,所使用的设备包括:
(1)回转支撑台;(2)电熔电源;(3)电熔头;(4)自动送丝装置;(5)辅料自动输送与辅料自动回收装置;(6)加热装置;(7)冷却装置;(8)基材;(9)控制装置(计算机)。
图2为用于表示本实施例的电熔成形方法的示意性说明图,图中省略了电源、自动送丝装置等装置。如图2所示,选用普通低碳钢原料丝
材101、直径4mm,19个电熔头401,电熔电源为直流电源,采用电熔头401接电源负极,基材201接电源正极(直流时,电熔头接电源负极,基材接电源正极,能够大大提高加工效率),电熔工艺参数为:电熔电流700A,电熔电压35V,电熔头401与基材201相对移动速度500~600mm/min,采用金属构件电熔成形方法制作环形金属构件,其实施步骤如下:
(1)将圆筒形的基材201的轴线水平配置,并支撑在回转支撑台上,将20个电熔头401以200mm的间距(即,相邻原料丝材中心距)平均横向布置在基材201的上方,且调整好每个电熔头401与基材201表面(外周面)的距离,并选取电熔的起点;
(2)将原料丝材101与辅料301送至基材201表面,启动电源,导入高能热源,熔化原料丝材101及辅料301,同时转动基材201,开始每个电熔头第一层第一道(每一层由轴向排列的多道构成)的电熔沉积;
(3)当电熔头401与电熔起点之间形成一段距离后,开始启动辅料301回收装置将其未熔化的辅料301收回,露出渣壳并将其清除,以便于下一道的电熔沉积(堆积);随后启动冷却装置或加热装置对电熔沉积金属进行冷却或加热,将其基体(第一层时是指基材201,其他层时是指前一层堆积金属)的温度控制在200~300℃;
(4)当基材201转动一圈完成第一道电熔沉积时,在控制装置的控制下,所有电熔头401同时往左直线移动3/4熔道宽度距离,同时调整各电熔头401与基材201的表面之间的距离,以保证电熔的稳定性,之后开始第一层第二道的电熔沉积成形,此过程中要保证其左右圈道间搭接良好;
(5)当第二道完成后,重复步骤(4)再完成其它的电熔沉积道的成形,当达到最后一道时,其相邻电熔头401的最后一道结束点与第一道起点要搭接良好,以至完成第一层的电熔沉积;
(6)当完成第一层的电熔沉积后,所有电熔头401自动提升一层沉积厚度(即层厚)之高度,开始第二层的第一道电熔沉积,第一层电熔头401的结束点即为第二层第一道的开始点,连续沉积;
(7)当第二层第一道电熔沉积完成后,所有电熔头401同时往右直线移动3/4熔道距离,同时各电熔头401自动调整其与基材之间的距离,以保证电熔的稳定性,开始第二层第二道的电熔沉积,使其左右圈道间搭接良好;
(8)当完成第二层第二道电熔沉积完成时,重复步骤(7),再完成其它的电熔沉积道,当达到最后一道时,其相邻电熔头401的最后一道结束点与第一道起点要搭接良好,以至完成第二层的电熔沉积;
(9)重复步骤(6)至步骤(8),再完成其它电熔沉积层,此过程中,相邻电熔沉积层电熔头401的移动方向相反,最终连续电熔沉积形成整个金属构件。
本方法采用多个(19个)电熔头401并排排布,同时进行成形,因而能够提高成形效率。
【实施例2】
回转体的立式制作。采用一种金属构件电熔成形方法立式生长制作一筒体金属构件,本实施例中使用的设备包括,
(1)回转支撑台;(2)电熔电源;(3)电熔头;(4)自动送丝装置;(5)辅料自动输送与辅料自动回收装置;(6)挡辅料装置;(7)加热装置;(8)冷却装置;(9)基材;(10)控制装置。
图3为表示本实施例的电熔成形方法的示意性说明图,图中省略了回转支承台、电源等装置。如图3所示,选用普通低碳钢原料丝材、直径5mm,专用辅料,一个电熔头602,电熔电源为直流电源,采用电熔头接电源正极,基材202接电源负极,电熔工艺参数为:电熔电流900A,电熔电压36V,电熔头602与基板相对移动速度600~700mm/min,基材202为平板、材质与原料丝材相同,采用金属构件电熔成形方法制作环形金属构件,其实施步骤如下:
(1)将基材202固定在水平回转支撑台上,其板面方向与水平方向一致,在基材202上选取电熔起点,安装好挡辅料302装置,让其能够间接地通过辅料302挡住位于所要成形的构件边缘处的辅料,同时启动电源、送丝装置、辅料输送装置,并启动回转支撑台使基材以X轴线为
中心在水平面内转动,开始第一层的第一道电熔沉积;
(2)当电熔头602与电熔起点之间形成一段距离后,开始启动辅料302回收装置将其未熔化的辅料302收回,露出渣壳并将其清除,以便于下一道的电熔沉积,随后启动冷却装置或加热装置对电熔沉积金属进行冷却或加热,将其基体(第一层时是指基材,其他层时是指前一层堆积金属)的温度控制在200~300℃;
(3)当第一圈电熔沉积回到起点时,完成第一层第一道的电熔沉积,同时启动电熔头602的移动,使其沿径向直线移动,向圆环内侧移动一段距离,连续地开始第一层第二道的电熔沉积,其里外圈道间搭接良好;
(4)电熔头602的径向直线移动与回转支撑台的转动复合,使得单层电熔沉积轨迹为螺旋状,当完成第二道电熔沉积完成时,重复步骤(4),连续地完成剩下的电熔沉积道,以至达到工件需求的厚度(径向尺寸),最终完成第一层的电熔沉积;
(5)当完成第一层电熔沉积后,电熔头602自动提升到设定高度,开始第二层的第一道电熔沉积,第一层的结束点即为第二层的开始点,连续沉积;
(6)当第二层第一道电熔沉积完成后,电熔头602沿径向直线往外侧移动一段距离,开始第二层第二道电熔沉积,其里外圈道间搭接良好;
(7)当完成第二层第二道电熔沉积完成时,重复步骤(7),完成剩下的电熔沉积道,以至达到工件需求的厚度,以至完成第二层的电熔沉积;
(8)重复步骤(5)至步骤(7),再完成其它电熔沉积层,最终形成整个金属构件,在整个金属构件制作过程中相邻电熔沉积层,电熔头602的移动方向相反,挡辅料装置随着电熔沉积的增高而提升,最终成形工件。
在成形过程中,除立式成形工艺外,另外采用挡辅料装置130随着所形成的堆积金属的增长而提升。由其支承(承接)辅料302,使辅料302填充(挡)在金属构件的外侧,防止成形过程中熔融金属溢流。
【实施例3】
异形工件的制作。选用H08A普通低碳钢丝材,采用一种金属构件电熔成形方法立式生长制作一封头金属构件,本实施例中使用的设备包括,
(1)回转支撑台;(2)电熔电源;(3)电熔头;(4)自动送丝装置;(5)辅料自动输送与辅料自动回收装置;(6)挡辅料装置;(7)加热装置;(8)冷却装置;(9)基材;(10)控制装置。
图4为表示本实施例的电熔成形方法的示意性说明图,为简化计,图中将设备予以省略。选用参数为:丝棒直径5mm,辅料在标准熔炼焊剂SJ101中加入了30%Fe粉,设置电熔电流900A,电熔电压40V,电熔头403接正极,基材203接负极,送丝速度2200mm/min,旋转线速度750mm。
具体实施如下:
(1)将基材203固定在回转支撑台上,选取电熔沉积熔堆起点,同时开启辅料输送装置送辅料303,开始第一层第一道圆环的熔道堆敷;
(2)待将原料丝103堆敷一段熔道以后,一般距电熔头400~500mm距离开始启动辅料303回收装置将其未熔化的辅料303收回再利用,同时去除渣壳开始开启冷却装置进行冷却,将道间温度控制在150~300℃之间,待下一圈电熔堆敷;
(3)待第一圈电熔堆敷闭合时,立即启动电熔头403的移动,其从外往里缓慢移动,配合着回转支撑台使电熔头403在基础垫层板上成水平螺旋轨迹如图4进行电熔堆敷,直至达到构件的壁厚;
(4)当电熔头403移动到螺旋轨迹最后点时,停止螺旋移动,开始圆形移动(保证工件的圆度)电熔堆积,如此完成第一层的熔堆;
(5)当第一层完成熔堆时,电熔头403的自动调高系统检测到电熔头403与熔堆金属间的距离跟设定值进行比较进行自动调整电熔头403的高度,并调节电熔头403从里往外缓慢移动,以至形成往外螺旋移动轨迹,同时开始进行下一层的电熔堆积;
(6)重复上述步骤(1)-(5),完成第二层电熔堆积;
(7)反复上述过程,奇数层电熔头403从外往里移动,偶数层电
熔头403从里往外移动进行逐层熔堆,最终获得一个完整的重型金属构件503。
本实施例,采用电熔方法成形了异形(封头)工件,并且由于在生产过程中加入了30%铁粉,极大地提高了成形效率。
【实施例4】
蒸汽发生器筒体的整体成形。本实例描述核电蒸发器筒体电熔整体成形方法,采用传统锻造工艺时,整个筒体分为6段(上筒体2段,下筒体3段,锥形段1段),采取分别锻造后组焊而成,筒体材质为SA508Gr3CL2低合金钢,成形后内壁需堆焊厚度约8mm的308不锈钢,采用本发明方法可一次性整体成形,本方法所使用的设备包括:
(1)回转支撑台;(2)电熔电源;(3)电熔头;(4)自动送丝装置;(5)辅料自动输送与辅料自动回收装置;(6)加热装置;(7)冷却装置;(8)基材;(9)控制装置。
图5为用于表示本实施例的电熔成形方法的示意性说明图,图中省略了电源、自动送丝装置等装置。如图2所示,选用特殊研制的低合金钢原料丝材104(C:0.11-0.12%,其它元素与SA508-3一致)、直径5mm,特殊研制的辅料304,成分为29.5%CaO+MgO;30%AL2O3+MnO;20.5%SiO2+TiO;20%CaF2;21个电熔头404,电熔电源为直流电源,采用电熔头404接电源负极,基材201接电源正极,电熔工艺参数为:电熔电流900A,电熔电压42V,电熔头404与基材204相对移动速度600~700mm/min,基材204为已成形好的308不锈钢圆筒,采用金属构件电熔成形方法制作环形金属构件,其实施步骤如下:
(1)将圆筒形的基材204的轴线水平配置,并支撑在回转支撑台上,将20个电熔头以200mm的间距(即,相邻原料丝材中心距)平均横向布置在基材204的上方,且调整好每个电熔头与基材204表面(外周面)的距离,并选取电熔的起点;
(2)将原料丝材104与辅料送至基材204表面,启动电源,导入高能热源,熔化原料丝材及辅料,同时转动基材204,开始每个电熔头第一层第一道(每一层由轴向排列的多道构成)的电熔沉积;
(3)当电熔头404与电熔起点之间形成一段距离后,开始启动辅料回收装置将其未熔化的辅料304收回,露出渣壳并将其清除,以便于下一道的电熔沉积(堆积);随后启动冷却装置或加热装置对电熔沉积金属进行冷却或加热,将其基体(第一层时是指基材201,其他层时是指前一层堆积金属)的温度控制在200~300℃;
(4)当基材204转动一圈完成第一道电熔沉积时,在控制装置的控制下,所有电熔头404同时往左直线移动3/4熔道宽度距离,同时调整各电熔头404与基材204的表面之间的距离,以保证电熔的稳定性,之后开始第一层第二道的电熔沉积成形,此过程中要保证其左右圈道间搭接良好;
(5)当第二道完成后,重复步骤(4)再完成其它的电熔沉积道的成形,当达到最后一道时,其相邻电熔头404的最后一道结束点与第一道起点要搭接良好,完成第一层的电熔沉积;
(6)当完成第一层的电熔沉积后,所有电熔头404自动提升一层沉积厚度(即层后)之高度,开始第二层的第一道电熔沉积,第一层电熔头的结束点即为第二层第一道的开始点,连续沉积;
(7)当第二层第一道电熔沉积完成后,所有电熔头404同时往右直线移动3/4熔道距离,同时各电熔头404自动调整其与基材之间的距离,以保证电熔的稳定性,开始第二层第二道的电熔沉积,使其左右圈道间搭接良好;
(8)当完成第二层第二道电熔沉积完成时,重复步骤(7),再完成其它的电熔沉积道,当达到最后一道时,其相邻电熔头404的最后一道结束点与第一道起点要搭接良好,以至完成第二层的电熔沉积;
(9)重复步骤(6)至步骤(8),再完成其它电熔沉积层,此过程中,相邻电熔沉积层电熔头404的移动方向相反,最终连续电熔沉积形成整个金属构件。
在本实施例中,不锈钢基材204在电熔成形后成为容器筒体的一部分,实现了异种材料直接连接成形,改变了传统工艺在锻造SA508-3筒体后再在其内壁堆焊308不锈钢的制造方式,另外,由于是多个(21个)
电熔头并排排布整体成形,改变了传统锻造工艺分段锻制后再组焊的方法,简化了工艺工序,提高了工作效率和质量。
Claims (10)
- 一种金属构件电熔成形方法,其特征在于:该方法是采用电弧热、电阻热、电渣热复合而成的高能热源,熔化连续输送的金属原料丝材,在基材上逐层凝固堆积成形制造金属构件;将电熔头与基材接至电源两极,成形时金属原料丝材经由输送机构和电熔头送至基材表面,在颗粒状辅料的堆积保护下,原料丝材与基材间产生电弧,熔化部分堆敷辅料形成熔融渣池,电流流过原料丝材和熔融辅料渣池形成电阻热和电渣热,在电弧热、电阻热、电渣热三种热复合高能热源作用下使原料丝材熔化,在基材表面形成局部熔池,持续输送原料丝材与辅料,根据成形构件的分层切片数据,采用计算机控制电熔头与基材的相对移动,实现熔池在基材上快速冷却逐层凝固堆积,最终逐层堆积成形出所需形状和尺寸的金属构件。
- 根据权利要求1所述的金属构件电熔成形方法,其特征在于:所述原料丝材的材质为低合金钢、耐热钢、不锈钢或者镍基合金,直径为2mm~20mm。
- 根据权利要求1所述的金属构件电熔成形方法,其特征在于:所述辅料为颗粒状,由金属氧化物或者金属氧化物与卤化物或者金属氧化物与卤化物及金属粉末组成,覆盖在熔池上,厚度为15mm~120mm,为提高生产效率,可向辅料中添加总量不超过30%的合金粉末以及/或者金属单质粉末。
- 根据权利要求1所述的金属构件电熔成形方法,其特征在于:所使用的电源是直流电源或交流电源,在使用直流电源时,对所 述原料丝材供电的电熔头接正极或负极,根据原料丝材直径的不同,电流为200A~6000A,电压为20V~60V。
- 根据权利要求1所述的金属构件电熔成形方法,其特征在于:根据电流电压参数的不同,电熔头与基材的相对移动速度为150~3000mm/min,单电熔头熔化效率为5~80Kg/h,单层堆积层高为1~8mm。
- 根据权利要求1所述的金属构件电熔成形方法,其特征在于:根据成形工件材料和尺寸要求,对基材或堆积金属进行加热或冷却,控制基材或堆积金属层的表面温度为100~600℃。
- 根据权利要求1所述的金属构件电熔成形方法,其特征在于:根据成形金属构件的尺寸、形状和效率要求,电熔头的数量设定为1~100个,多电熔头排布时,相邻电熔头间距为50~500mm。
- 根据权利要求1所述的金属构件电熔成形方法,其特征在于:基材用于为构件成形提供工装支撑,其尺寸、形状按照堆积金属要求设计制作,厚度不小于5mm。
- 根据权利要求1所述的金属构件电熔成形方法,其特征在于:根据生产要求不同,基材选用与堆积金属相同或不同的材料,在金属堆积完成后,基材予以保留作为成形构件一部分或通过后续机加工去除。
- 根据权利要求1所述的金属构件电熔成形方法,其特征在于:根据原料丝材直径的不同,通电长度即原料丝材伸出电熔头的长度为20mm~150mm。
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US11806820B2 (en) * | 2017-09-15 | 2023-11-07 | Kobe Steel, Ltd. | Laminated molding and method of manufacturing laminated molding |
Also Published As
Publication number | Publication date |
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CN104526171B (zh) | 2016-10-12 |
US20170320277A1 (en) | 2017-11-09 |
EP3213863A4 (en) | 2017-12-13 |
CN104526171A (zh) | 2015-04-22 |
EP3213863A1 (en) | 2017-09-06 |
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