WO2020155540A1 - Additive manufacturing device using combined resistance-induction heating of metal wire material - Google Patents

Additive manufacturing device using combined resistance-induction heating of metal wire material Download PDF

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WO2020155540A1
WO2020155540A1 PCT/CN2019/093332 CN2019093332W WO2020155540A1 WO 2020155540 A1 WO2020155540 A1 WO 2020155540A1 CN 2019093332 W CN2019093332 W CN 2019093332W WO 2020155540 A1 WO2020155540 A1 WO 2020155540A1
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substrate
metal wire
power supply
additive manufacturing
resistance
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PCT/CN2019/093332
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French (fr)
Chinese (zh)
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李波波
卢秉恒
张丽娟
任晓飞
王强
李晓强
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西安增材制造国家研究院有限公司
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • B22F3/105Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • B22F3/105Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B22F2003/1053Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding by induction
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

Definitions

  • the invention relates to the field of metal additive manufacturing, in particular to a resistance induction composite heating metal wire additive manufacturing device.
  • additive manufacturing (AM) technology is based on CAD/CAM design and uses a layer-by-layer accumulation method to manufacture solid parts. Compared with traditional subtractive manufacturing (cutting) technology, it is a material accumulation manufacturing method.
  • Additive manufacturing technology commonly known as 3D printing technology, is an advanced manufacturing technology that has developed rapidly in the past 30 years. Its advantage lies in the rapid and free manufacturing of three-dimensional structures. It is widely used in new product development and single-piece small-batch manufacturing. Among them, direct metal forming is Difficulties and hot spots in additive manufacturing technology.
  • the additive manufacturing technology of metal powder as a raw material is not only expensive, but also has the risk of explosion. In the processing process, it is necessary to pay attention to the harm of metal powder to the human body, resulting in higher processing costs.
  • the disadvantages of high-energy beam additive manufacturing technology mainly include high equipment cost, complex equipment structure, relatively large equipment volume, radiation pollution, and low molding efficiency under the same power.
  • the electron beam will be accompanied by the emission of gamma rays during the deposition process. If the device is not designed properly, it will cause radiation leakage and cause environmental pollution; another example is that laser sintering or laser melting technology cannot be applied to all metals, especially for laser reflection.
  • Metals with higher rates have poor forming efficiency.
  • the shortcomings of the electric gusset additive manufacturing technology is that it will produce a lot of noise and arc pollution, and the molding accuracy is also poor.
  • Other metal additive manufacturing methods include direct metal inkjet 3D printing (the Israeli 3D printing start-up XJet has completed the prototype development). This method is limited by the ratio of special metal inks and has a narrow application range.
  • the metal wire additive manufacturing method based on resistance thermal fusion accumulation molding refers to the use of Joule heat generated by the current flowing in the wire to directly melt the metal wire to realize the metal additive manufacturing process.
  • This technology realizes the direct conversion of electrical energy into heat energy required for metal melting, and the direct use of electrical energy without multiple intermediate conversions can achieve high utilization, high quality, low cost, green and environmentally friendly additive manufacturing of metal parts. It is a kind of material , Machinery, measurement and control technology and information processing integrated metal additive manufacturing method. However, this method is currently less widely used.
  • One of the reasons is its poor stability, serious arcing and splashing during printing, and poor bonding between layers and with substrates.
  • the metal wire additive manufacturing device has been disclosed, for example, the patent application number 201580075879.9 American Digital Alloy Company.
  • Chinese invention application CN201611186726.4 a resistance electromagnetic induction composite heating metal wire forming method, its basic structure is shown in Figure 1, including metal wire 1, pulsating wire feeding mechanism 2, protective gas 3, gas protective cover 4 , Electromagnetic induction power supply 5, electromagnetic induction coil 6, conductive nozzle 7, three-dimensional motion control system 8, power supply 9, fusion forming parts 10, substrate 11; when the metal wire is formed, it is conveyed to the front end of the metal wire through the nozzle Shielding gas to avoid the oxidation of metal filaments during the melting and accumulation process.
  • the above metal wire additive manufacturing device only illustrates the method of resistance thermal additive manufacturing, but there are the following problems:
  • the wire is softened during the heating process, and the contact tip must be in contact to conduct electricity, resulting in serious problems such as failure to deliver smoothly and blockage during the wire feeding process;
  • the first layer of high-temperature molten metal droplets will form a spherical shape when contacting the low-temperature substrate, and the spherical metal particles cannot be effectively compatible. The same can be pushed to the second to the Nth layer. , Resulting in poor layer-by-layer bonding, and even unable to form.
  • the substrate needs a higher temperature (close to the melting point of the metal) to form a metallurgical structure with the molten metal droplets. It is unrealistic to heat the entire substrate to such a high temperature. , The biggest problem of this solution is that the resistance thermal melting can only melt the metal wire itself, but cannot effectively combine with the matrix, resulting in forming defects or even failure;
  • the present invention provides a resistance induction composite heating metal wire additive manufacturing device.
  • a resistance induction composite heating metal wire material additive manufacturing device comprising a wire feeder, a contact nozzle, a substrate, an atmosphere protection device, and a power supply.
  • the wire feeder, the contact nozzle and the substrate are sequentially arranged from top to bottom.
  • the power supply The positive pole is connected to the contact tip, and the negative pole is connected to the substrate.
  • the special feature is that it also includes an ultra-high frequency induction heating device and a substrate heating device;
  • the ultra-high frequency induction heating device is a high-frequency induction heating coil, The induction heating coil is wound on the outside of the wire at the lower end of the contact nozzle through a ceramic sleeve, and is connected to the power supply;
  • the ultra-high frequency induction heating device is provided with a contact temperature measuring element, and the contact temperature measuring element is arranged on the ceramic sleeve On the tube;
  • the substrate heating device is arranged under the substrate for heating the substrate;
  • the substrate is provided with a substrate temperature measuring element for measuring the temperature of the substrate.
  • the UHF induction heating coil is fixed on the wire feeder, UHF induction heating can not only realize non-contact heating, but also ensure smooth movement of the moving platform, and has high heating efficiency, which is applicable to all metals.
  • the high-frequency induction heating coil is a hollow copper tube, and a cooling medium is passed through the hollow copper tube.
  • the parallel resistor R1 also includes a parallel resistor R1, one end of the parallel resistor R1 is connected to the conductive tip, and the other end is connected to the substrate.
  • the resistance value of the parallel resistor R1 is greater than the contact resistance when the metal wire is connected to the substrate, and smaller than the breakdown resistance of the gas between the contact tip and the substrate, so that the current shunted during normal printing can be negligibly small. Basically no additional system heat loss,
  • one end of the parallel resistor R1 is connected to the conductive mouth through a wire nose.
  • the power supply is a programmable power supply, and the programmable power supply has a constant current output mode and a constant voltage output mode.
  • the constant current output mode is used for melting of metal, and the constant voltage output mode is used for powering the parallel resistor R1.
  • the atmosphere protection structure includes an airtight box body, an inert gas tank connected with the airtight box body, and the airtight box body and
  • the pipeline connecting the inert gas tank is provided with an air intake pump, and the airtight box is provided with a water and oxygen content detection sensor, and the closed loop of the sensor controls the intake and exhaust of the inert gas;
  • the molten molding area forms an atmosphere protection.
  • the ceramic sleeve is made of boron nitride or silicon nitride.
  • the substrate is moved by a three-dimensional motion platform, and a heat sink is provided on the three-dimensional motion platform.
  • the present invention has the following beneficial effects:
  • an ultra-high frequency induction heating device is arranged under the contact nozzle and above the area to be printed, so as to realize non-contact and high-efficiency heating of the forming area, improve the bond between the metal droplet and the substrate, and benefit the layers and layers.
  • the combination with the substrate realizes high-quality metal 3D forming.
  • the present invention adopts an ultra-high frequency induction heating device.
  • the high-frequency induction heating device realizes rapid non-contact heating of the metal.
  • a strong magnetic field with instantaneous polarity changes is generated in the ultra-high frequency induction coil, and the area to be printed is close to the high-frequency coil ,
  • the wire passes through the high-frequency coil, the magnetic beam will penetrate the entire area to be printed, and the corresponding strong eddy current is generated in the direction opposite to the induction heating current inside the induction heating object, because there is resistance in the induction heating metal.
  • the strong eddy current heat energy makes the temperature of induction heating objects rise rapidly, and the heating layer is extremely thin, generally 0.1-0.5mm. Therefore, the UHF induction heating device has the advantages of non-contact high-efficiency heating and high heating efficiency.
  • the contact between the metal wire and the high-frequency induction heating coil causes a short circuit.
  • the ceramic sleeve can pass high-frequency magnetic fields well, and because of its incompatibility with metal droplets, it has the advantages of being difficult to plug.
  • a temperature measuring device is added to the wall of the casing to solve the difficulty of non-contact temperature measurement in the metal 3D printing process.
  • the contact temperature measurement is simple and convenient, and the temperature measurement is more accurate.
  • the molten metal is estimated based on the heat conduction equation.
  • Surface temperature through the control of resistance welding power supply, high-frequency induction power supply and substrate temperature control power supply to achieve precise control of closed-loop temperature in metal 3D, which helps to achieve high-quality metal 3D forming.
  • Ceramic bushings preferably use boron nitride and silicon nitride .
  • the present invention connects a resistor in parallel between the conductive tip and the substrate.
  • the parallel resistance creates a path for the current, thereby eliminating the arc and electric spark at the end of the conductive wire. This phenomenon avoids printing failures or major defects caused by violent melting and splashing of materials.
  • the present invention realizes a constant temperature environment in the printing area by heating the substrate by the heater at the bottom of the substrate, which can reduce the warpage and deformation of the printed article and improve the forming quality.
  • an airtight box is provided on the periphery of the printing area and contains an air intake and suction pump and a water and oxygen content detection sensor.
  • the box is equipped with an inert gas tank, which has a simple and reliable structure, accurate monitoring of the atmosphere and stable air pressure , The advantages of good protection effect.
  • Figure 1 is a diagram of an existing metal wire forming device with resistance electromagnetic induction composite heating
  • Figure 2 is a diagram of an additive manufacturing device for resistance induction composite heating metal wires of the present invention
  • FIG. 3 is a structural diagram of the ultra-high frequency induction heating device of the present invention.
  • FIG. 5 is a schematic diagram of the atmosphere protection box of the present invention.
  • Figure 6 is a schematic diagram of the additive manufacturing process of the metal wire of the present invention.
  • a resistance induction composite heating metal wire additive manufacturing device as shown in FIG. 2 includes a wire feeder 21, a conductive nozzle 22, a substrate 23, an atmosphere protection device 24 and a power supply, the wire feeder 21, a conductive nozzle 22 and a substrate 23 are arranged in order from top to bottom.
  • the positive pole of the power supply is connected to the contact tip 22, and the negative pole is connected to the substrate 23.
  • It also includes a parallel resistor R1, an ultra-high frequency induction heating device 25 and a substrate heating device 29.
  • One end of the parallel resistor R1 is connected to the conductive tip 22, and the other end is connected to the substrate 23.
  • One end of the parallel resistor R1 is specifically connected to the conductive tip 22 through the wire nose 27.
  • wire nose 27 is generally used for connection.
  • a parallel resistor of appropriate specifications is connected in parallel between the contact tip 22 and the substrate 23. When the metal wire 26 is separated from the substrate 23 due to some external reason, the parallel resistance creates a path for the current without arcing.
  • the principle of parallel resistance selection is much larger than the contact resistance when the metal wire 26 is turned on (the contact resistance when the metal wire 26 and the substrate 23 are turned on), so that during normal printing, the current shunted can be negligible. There is basically no additional system heat loss.
  • the resistance of the parallel resistance is smaller than the breakdown resistance of the macro protective gas (the gas breakdown resistance between the contact tip 22 and the substrate 23).
  • the parallel resistance is when the metal wire 26 and the substrate 23 are separated Play the role of diversion, and at the same time cooperate with the power control, from constant current to voltage source control, to ensure the minimum output power of the power supply, and further reduce the loss of the circuit.
  • the size and power of the appropriate parallel resistor need to be printed according to different Metal wire 26 to choose.
  • the ultra-high frequency induction heating device 25 includes a high frequency induction heating coil.
  • the high frequency induction heating coil is set on the metal wire 26 at the lower end of the contact tip 22 through a ceramic sleeve 28. It is connected to the power supply; the high-frequency induction heating coil can be a hollow copper tube, and the cooling medium is passed into the hollow copper tube.
  • the contact tip 22 connects the resistance welding current to the contact tip 22 through the wire nose 27.
  • the wire feeder 21 feeds the metal wire 26 into the contact tip 22, and continues to feed the high-frequency induction heating coil.
  • the high-frequency induction heating coil passes high-frequency current. , According to the size of the current, different structures can be designed.
  • the cooling water protection is introduced, because the large current can generate a strong magnetic field.
  • the resistance heat needs to be removed by circulating cold water, and a chiller is required; if If the current is small, it is not necessary.
  • High temperature wires can be used, or air cooling can be used.
  • a ceramic sleeve 28 is used to guide and insulate the metal wire 26.
  • the ceramic sleeve 28 allows the high-frequency magnetic field to pass through. There is a severe temperature gradient between the molten metal and it is in direct contact with the molten metal.
  • the sleeve has the characteristics of not blocking magnetic fields, good thermal shock resistance, and incompatible with metal droplets, so it has the advantages of not being easy to plug.
  • a temperature sensor is added to the casing wall, which solves the difficulty of non-contact temperature measurement in the metal 3D printing process, and realizes the contact temperature measurement simply and conveniently.
  • the surface temperature of the molten metal is estimated according to the heat conduction equation.
  • High-frequency induction power supply and substrate 23 temperature control power supply realize closed-loop temperature control of metal 3D printing, which helps to achieve high-quality metal 3D forming.
  • the substrate heating device 29 is provided on the substrate 23 for heating the substrate 23.
  • a temperature measuring element is provided on the substrate 23 for measuring the temperature of the substrate 23.
  • the temperature control power supply part of the substrate 23 realizes a constant temperature environment in the printing area, which can reduce the warpage and deformation of the printed article due to stress and improve the forming quality.
  • the substrate temperature control system can adopt various heating and temperature control methods, such as resistance heating or induction heating, etc., and need to add a temperature sensor to realize PID temperature control, and according to different heat treatment processes of different metal materials, different temperatures can be set If the substrate temperature is not high, no heat sink is required, or the substrate cooling is required to directly add cooling and heat dissipation to achieve a constant temperature environment for the substrate.
  • the power supply is a programmable power supply.
  • the programmable power supply has a constant current output mode and a constant voltage output mode.
  • the constant current output mode is used for metal melting, and the constant voltage output mode is used for parallel connection.
  • the programmable power supply is selected to supply power to the parallel resistor R1 in the constant voltage output mode.
  • the current limit is automatically adjusted to the constant voltage output mode through software. The maximum current and maximum voltage are set in the software, and they are automatically switched according to the load.
  • the resistance induction composite heating metal wire 26 additive manufacturing control system consists of six parts, namely the UHF power supply control part, the resistance welding control power supply part, the substrate temperature control power supply part, the three-dimensional motion control part, the wire feeding control part and the protective atmosphere Box control part.
  • the three parts of UHF power supply control part, resistance welding control power supply part and substrate temperature control power supply part can also be combined into an integrated power control.
  • the protective atmosphere box control part contains water and oxygen detection sensors, pressure detection sensors and air pump control.
  • the resistance welding control power supply part provides the electric energy for the melting of the metal wire. It can be produced by the method of DC, AC or pulse, or voltage source or current source, which is generated by the short circuit of the metal wire, mainly according to the characteristics of the melting and forming process of different metal materials. Joule hot-melting metal wire 26, according to different metal wires 26 and different forming efficiency, the general short-circuit resistance flow is selected from 1A-1000A. When the metal wire melts, the resistance changes drastically and nonlinearly. The power is realized through the power closed loop of the power supply. Tracking and matching of load.
  • the ultra-high frequency power supply part realizes the rapid non-contact heating of the metal.
  • a strong magnetic field with instantaneous polarity change is generated in the ultra-high frequency induction coil, and the area to be printed is close to the high-frequency coil.
  • the metal wire passes through the high-frequency coil, and the magnetic beam Will run through the entire area to be printed.
  • a corresponding strong eddy current is generated in the direction opposite to the induction heating current inside the induction heating object. Because there is electrical resistance in the metal that is heated by induction, strong eddy current heat energy is generated, which makes the temperature of the induction heated object rise rapidly, and the heating layer is extremely thin, generally 0.1-0.5mm.
  • the three-dimensional motion control part can be realized by constructing a motion control platform or a robot arm with a motor module.
  • the cabinet control part can be designed for atmosphere protection according to different metal materials, including gas purification system, circulation system and gas temperature control system. It needs water and oxygen sensor, pressure sensor, temperature sensor, gas tank, and gas pump.
  • the inlet and outlet control of the air valve can also be designed according to the vacuum-tight chamber, and a vacuum pump is required.
  • the atmosphere protection device 24 may specifically include an airtight box 241, an inert gas tank connected to the airtight box 241, an air pump 242 is provided on the pipeline connecting the airtight box 241 and the inert gas tank, and the airtight box 241 A water and oxygen content detection sensor is installed on it.
  • Different metal materials can be designed with different atmosphere protections.
  • Various gas purity sensors can include sensors such as water and oxygen content, gas pressure, etc., according to different needs, to achieve closed-loop control of gas quality and gas pressure, and can also be designed according to vacuum tight chambers , Need to be equipped with a vacuum pump. The wire feeding speed and movement speed need to match the process parameters.
  • the energy input part is the power control part, the space motion control part, the print head and wire feed control part and the box air pump control part need to be connected to the printer and the overall control system, and coordinate and control according to the process characteristics of different metal materials.
  • the movement mechanism of the present invention is arranged at the bottom of the base plate. Considering that the movement platform cannot withstand high temperature for a long time, resulting in deformation and movement inaccuracy, a radiator 31 is provided on the movement platform, and the radiator 31 can be selected according to the failure conditions. Cold, water cooling, semiconductor refrigeration and so on.
  • the principle of the present invention is based on the resistance heat generated after the metal wire is energized, and the metal wire is melted and formed by the resistance heat.
  • the metal wire is fed into the contact tip 22 through the automatic wire feeder 21, and the contact tip 22 is connected to the positive electrode of the resistance welding power source.
  • the metal substrate 23 is connected to the negative electrode of the resistance welding power source, and the top of the metal wire forms a loop with the substrate 23.
  • a certain form of current is passed to melt the end of the metal wire instantaneously. After melting, metal droplets are deposited on the substrate 23 due to gravity and surface tension. Above, there is a high-frequency induction coil between the contact tip 22 and the substrate 23.
  • the ultra-high-frequency induction power supply generates a strong magnetic field with instantaneous changes in polarity between the molten metal droplet and the substrate 23. This area generates eddy current heat to make the molten metal
  • the drop and the substrate 23 realize a metallurgical combination.
  • stacked metal parts can be formed on the substrate 23 to realize metal additive manufacturing.
  • the present invention connects the contact tip 22 and the substrate 23 in parallel with parallel resistors of appropriate specifications.
  • the parallel resistors create a path for the current to avoid arcing.
  • the printing process of the metal wire additive manufacturing device of the present invention is as follows:

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Abstract

The invention relates to an additive manufacturing device using combined resistance-induction heating of a metal wire material, and solves the problem of poor bonding between plugs, layers, and base plates encountered in the manufacturing processes of existing additive manufacturing devices using metal wire materials. The device comprises a wire feeder, a conductive nozzle, a base plate, an atmosphere protection device, and a power supply. The wire feeder, the conductive nozzle, and the base plate are sequentially provided from top to bottom. A positive electrode of the power supply is connected to the conductive nozzle, and a negative electrode is connected to the base plate. The device further comprises an ultrahigh-frequency induction heating device and a base plate heating device. The ultrahigh-frequency induction heating device is a high-frequency induction heating coil. The high-frequency induction heating coil is wound around the wire material at a lower end of the conductive nozzle by means of a ceramic bushing, and is connected to the power supply. A contact temperature measurement element is provided on the ceramic bushing. The base plate heating device is provided below the base plate, and is used to heat the base plate. A base plate temperature measurement element is provided on the base plate, and is used to measure the temperature of the base plate.

Description

一种电阻感应复合加热金属丝材增材制造装置Resistance induction composite heating metal wire material additive manufacturing device 技术领域Technical field
本发明涉及金属增材制造领域,具体涉及一种电阻感应复合加热金属丝材增材制造装置。The invention relates to the field of metal additive manufacturing, in particular to a resistance induction composite heating metal wire additive manufacturing device.
背景技术Background technique
增材制造(additive manufacturing,AM)技术是根据CAD/CAM设计,采用逐层累积的方法制造实体零件的技术,相对于传统的减材制造(切削加工)技术,它是一种材料累积的制造方法。增材制造技术俗称3D打印技术,是近30年快速发展的先进制造技术,其优势在于三维结构的快速和自由制造,被广泛应用于新产品开发、单件小批量制造,其中金属直接成型是增材制造技术中的难点和热点技术。Additive manufacturing (AM) technology is based on CAD/CAM design and uses a layer-by-layer accumulation method to manufacture solid parts. Compared with traditional subtractive manufacturing (cutting) technology, it is a material accumulation manufacturing method. Additive manufacturing technology, commonly known as 3D printing technology, is an advanced manufacturing technology that has developed rapidly in the past 30 years. Its advantage lies in the rapid and free manufacturing of three-dimensional structures. It is widely used in new product development and single-piece small-batch manufacturing. Among them, direct metal forming is Difficulties and hot spots in additive manufacturing technology.
金属直接成型目前有多种传统方法,但各有利弊。金属粉末作为原材料的增材制造技术,不仅原材料昂贵,而且有爆炸的风险,并在加工过程中需注意金属粉末对人体的危害,导致加工成本较高。高能束流增材制造技术缺点主要有设备造价高、设备结构复杂、设备体积比较庞大、具有辐射污染、同等功率下成型效率较低等。例如,电子束在沉积过程中会伴随伽玛射线的发射,如果装置设计不合理会造成射线的泄露,导致环境污染;又如激光烧结或激光熔融技术不能适用于所有金属,特别是对激光反射率较高的金属,成形效率差。电孤增材制造技术的缺点是会产生大量的噪声和弧光污染,成型精度也较差。其他的金属增材制造方法还有直接金属喷墨3D打印(以色列3D打印初创企业XJet已经完成样机的研发),该方法受限于特种金属墨水的配比,适用面狭窄。There are many traditional methods for direct metal forming, but each has its advantages and disadvantages. The additive manufacturing technology of metal powder as a raw material is not only expensive, but also has the risk of explosion. In the processing process, it is necessary to pay attention to the harm of metal powder to the human body, resulting in higher processing costs. The disadvantages of high-energy beam additive manufacturing technology mainly include high equipment cost, complex equipment structure, relatively large equipment volume, radiation pollution, and low molding efficiency under the same power. For example, the electron beam will be accompanied by the emission of gamma rays during the deposition process. If the device is not designed properly, it will cause radiation leakage and cause environmental pollution; another example is that laser sintering or laser melting technology cannot be applied to all metals, especially for laser reflection. Metals with higher rates have poor forming efficiency. The shortcomings of the electric gusset additive manufacturing technology is that it will produce a lot of noise and arc pollution, and the molding accuracy is also poor. Other metal additive manufacturing methods include direct metal inkjet 3D printing (the Israeli 3D printing start-up XJet has completed the prototype development). This method is limited by the ratio of special metal inks and has a narrow application range.
基于电阻热熔融堆积成型的金属细丝增材制造方法,是指利用丝材中流过的电流产出的焦耳热,直接将金属丝熔化,实现金属增材制造过程。该技术实现了电能直接转化为金属熔化需要的热能,电能直接利用而无需中间多次转化,能实现高利用率、高质量、低成本、绿色环保的金属零件增材制造,是一种将材料、机械、测控技术和信息 处理集为一体的金属增材制造方法。但是,目前该方法应用较少,其中一个原因是其稳定性差,在打印过程中起弧飞溅严重,而且层层之间以及和基板之间结合差。The metal wire additive manufacturing method based on resistance thermal fusion accumulation molding refers to the use of Joule heat generated by the current flowing in the wire to directly melt the metal wire to realize the metal additive manufacturing process. This technology realizes the direct conversion of electrical energy into heat energy required for metal melting, and the direct use of electrical energy without multiple intermediate conversions can achieve high utilization, high quality, low cost, green and environmentally friendly additive manufacturing of metal parts. It is a kind of material , Machinery, measurement and control technology and information processing integrated metal additive manufacturing method. However, this method is currently less widely used. One of the reasons is its poor stability, serious arcing and splashing during printing, and poor bonding between layers and with substrates.
目前已经公开的金属丝材增材制造装置,例如申请号201580075879.9美国数字合金公司的专利。例如中国发明申请CN201611186726.4,一种电阻电磁感应复合加热金属丝材成形方法,其基本结构如图1所示,包括金属丝材1、脉动送丝机构2、保护气体3、气体保护罩4、电磁感应电源5、电磁感应线圈6、导电嘴7、三维运动控制系统8、电源9、熔积成形零件10、基板11;在金属丝材熔积成型时,通过喷嘴向金属丝材前端输送保护气体,以避免金属细丝在熔融堆积过程中氧化,上述金属丝材增材制造装置只说明了电阻热增材制造的方法,但存在以下问题:At present, the metal wire additive manufacturing device has been disclosed, for example, the patent application number 201580075879.9 American Digital Alloy Company. For example, Chinese invention application CN201611186726.4, a resistance electromagnetic induction composite heating metal wire forming method, its basic structure is shown in Figure 1, including metal wire 1, pulsating wire feeding mechanism 2, protective gas 3, gas protective cover 4 , Electromagnetic induction power supply 5, electromagnetic induction coil 6, conductive nozzle 7, three-dimensional motion control system 8, power supply 9, fusion forming parts 10, substrate 11; when the metal wire is formed, it is conveyed to the front end of the metal wire through the nozzle Shielding gas to avoid the oxidation of metal filaments during the melting and accumulation process. The above metal wire additive manufacturing device only illustrates the method of resistance thermal additive manufacturing, but there are the following problems:
1、电阻热熔融堆积成型的金属微细丝增材制造过程中,当导电嘴带动丝材运动时,丝材和导电基板接触过程中容易发生起弧飞溅,导致成形效果差、打印不稳定、系统难以控制等问题;1. In the additive manufacturing process of metal microwires formed by resistance thermal fusion accumulation, when the conductive nozzle drives the wire movement, the wire and the conductive substrate are prone to arcing and splashing during the contact process, resulting in poor forming effects, unstable printing, and system Difficult to control and other problems;
2、丝材在加热过程中有软化现象,而导电嘴必须接触才能导电,导致在送丝过程中发生无法顺利递送以及产生堵头等严重问题;2. The wire is softened during the heating process, and the contact tip must be in contact to conduct electricity, resulting in serious problems such as failure to deliver smoothly and blockage during the wire feeding process;
3、因为很难做到重熔,第一层高温融化的金属液滴接触低温基板会形成球状,各球形金属颗粒之间无法有效亲和,同理也可以推到第二层至第N层,导致层层结合差,甚至无法成形,从金属材料学理论得知基板需要较高温度(接近金属熔点)才能和熔融金属液滴互相成形冶金结构,而基板整体加热到如此高温是不现实的,该方案最大的问题是电阻热熔融只能融化金属丝材本身,而无法和基体有效结合,导致成形缺陷甚至失败;3. Because it is difficult to remelt, the first layer of high-temperature molten metal droplets will form a spherical shape when contacting the low-temperature substrate, and the spherical metal particles cannot be effectively compatible. The same can be pushed to the second to the Nth layer. , Resulting in poor layer-by-layer bonding, and even unable to form. From the theory of metal materials, it is known that the substrate needs a higher temperature (close to the melting point of the metal) to form a metallurgical structure with the molten metal droplets. It is unrealistic to heat the entire substrate to such a high temperature. , The biggest problem of this solution is that the resistance thermal melting can only melt the metal wire itself, but cannot effectively combine with the matrix, resulting in forming defects or even failure;
4、材料学里材料润湿理论得知,基板或者下一层母体加热需要到接近金属熔点才能实现有效浸润,而将基板加热到如此高温,第一需要很大的能量,第二基板在这么高的温度,会发生变形失稳流动坍塌现象,仅靠基板加热也不现实;4. The theory of material wetting in materials science knows that the substrate or the next layer of matrix needs to be heated close to the melting point of the metal to achieve effective infiltration, and heating the substrate to such a high temperature requires a lot of energy first, and the second substrate is so High temperature will cause deformation, instability, flow and collapse, and it is not realistic to rely on substrate heating alone;
5、现有打印物品的温度场不均匀会导致翘曲、变形、开裂,导 致打印缺陷;5. The uneven temperature field of existing printed items will cause warping, deformation, cracking, and printing defects;
6、局部气氛保护无法实现良好的气氛保护,在气流小时仍然有金属氧化的现象;气流大时,影响工艺过程,气流会把金属液滴吹散,导致成形缺陷,而且对其他已经未冷却的打印区域无法形成有效保护。6. Local atmosphere protection cannot achieve good atmosphere protection, and metal oxidation will still occur when the airflow is small; when the airflow is large, the process will be affected, and the airflow will blow the metal droplets away, resulting in forming defects, and for other uncooled The printing area cannot be effectively protected.
发明内容Summary of the invention
为了解决现有金属丝材增材制造装置在加工过程中存在堵头、层层之间以及和基板之间结合差的问题,本发明提供一种电阻感应复合加热金属丝材增材制造装置。In order to solve the problems of plugging, poor bonding between layers and substrates in existing metal wire additive manufacturing devices during processing, the present invention provides a resistance induction composite heating metal wire additive manufacturing device.
本发明的技术解决方案如下:The technical solution of the present invention is as follows:
一种电阻感应复合加热金属丝材增材制造装置,包括送丝机、导电嘴、基板、气氛保护装置及电源,所述送丝机、导电嘴及基板由上至下依次设置,所述电源的正极与导电嘴连接,负极与基板连接,其特殊之处在于:还包括超高频感应加热装置和基板加热装置;所述超高频感应加热装置为高频感应加热线圈,所述高频感应加热线圈通过陶瓷套管缠绕在导电嘴下端的丝材外侧,且与电源连接;所述超高频感应加热装置上设置有接触式测温元件,所述接触式测温元件设置在陶瓷套管上;所述基板加热装置设置在基板下方,用于对基板进行加热;所述基板上设置有基板测温元件,用于测量基板的温度。仅基板加热无法达到材料润湿所需的温度,因此在导电嘴下方还设置有局部加热器----超高频感应加热,用于对基板成型区域进行加热,实现金属液滴和母体的重熔连接,所述超高频感应加热线圈固定在送丝机上,超高频感应加热不仅能实现非接触加热,可以保证运动平台的流畅运动,而且加热效率高,对所有金属都适用。A resistance induction composite heating metal wire material additive manufacturing device, comprising a wire feeder, a contact nozzle, a substrate, an atmosphere protection device, and a power supply. The wire feeder, the contact nozzle and the substrate are sequentially arranged from top to bottom. The power supply The positive pole is connected to the contact tip, and the negative pole is connected to the substrate. The special feature is that it also includes an ultra-high frequency induction heating device and a substrate heating device; the ultra-high frequency induction heating device is a high-frequency induction heating coil, The induction heating coil is wound on the outside of the wire at the lower end of the contact nozzle through a ceramic sleeve, and is connected to the power supply; the ultra-high frequency induction heating device is provided with a contact temperature measuring element, and the contact temperature measuring element is arranged on the ceramic sleeve On the tube; the substrate heating device is arranged under the substrate for heating the substrate; the substrate is provided with a substrate temperature measuring element for measuring the temperature of the substrate. Only the substrate heating can not reach the temperature required for material wetting, so a local heater—ultra-high frequency induction heating is also provided under the contact tip to heat the substrate forming area to achieve the metal droplet and matrix Remelting connection, the UHF induction heating coil is fixed on the wire feeder, UHF induction heating can not only realize non-contact heating, but also ensure smooth movement of the moving platform, and has high heating efficiency, which is applicable to all metals.
进一步地,所述高频感应加热线圈为空心铜管,空心铜管中通入冷却介质。Further, the high-frequency induction heating coil is a hollow copper tube, and a cooling medium is passed through the hollow copper tube.
进一步地,还包括并联电阻R1,所述并联电阻R1的一端与导电嘴连接,另一端与基板连接。所述并联电阻R1的阻值大于金属丝材与基板导通时的接触电阻,小于导电嘴与基板之间气体的击穿电阻, 这样在正常打印时,分流到的电流可以小到忽略不计,基本不会外加系统热损耗,Further, it also includes a parallel resistor R1, one end of the parallel resistor R1 is connected to the conductive tip, and the other end is connected to the substrate. The resistance value of the parallel resistor R1 is greater than the contact resistance when the metal wire is connected to the substrate, and smaller than the breakdown resistance of the gas between the contact tip and the substrate, so that the current shunted during normal printing can be negligibly small. Basically no additional system heat loss,
进一步地,所述并联电阻R1的一端通过线鼻与导电嘴连接。Further, one end of the parallel resistor R1 is connected to the conductive mouth through a wire nose.
进一步地,所述电源为可编程电源,所述可编程电源具有恒流输出模式和恒压输出模式,恒流输出模式用于金属的熔融,恒压输出模式用于并联电阻R1的供电。Further, the power supply is a programmable power supply, and the programmable power supply has a constant current output mode and a constant voltage output mode. The constant current output mode is used for melting of metal, and the constant voltage output mode is used for powering the parallel resistor R1.
进一步地,为防止金属丝氧化,并保证保护气体对金属成型不产生影响,所述气氛保护结构包括气密箱体、与气密箱体连通的惰性气体气罐,所述气密箱体与惰性气体气罐连通的管路上设置有进抽气泵,气密箱体上设置有水氧含量检测传感器,由传感器闭环来控制惰性气体的进气及排气;所述气密箱体对金属丝熔融成型区域形成气氛保护。Further, in order to prevent the oxidation of the metal wire and ensure that the protective gas does not affect the metal forming, the atmosphere protection structure includes an airtight box body, an inert gas tank connected with the airtight box body, and the airtight box body and The pipeline connecting the inert gas tank is provided with an air intake pump, and the airtight box is provided with a water and oxygen content detection sensor, and the closed loop of the sensor controls the intake and exhaust of the inert gas; The molten molding area forms an atmosphere protection.
进一步地,所述陶瓷套管由氮化硼或氮化硅制作。Further, the ceramic sleeve is made of boron nitride or silicon nitride.
进一步地,所述基板通过三维运动平台移动,所述三维运动平台上设置有散热器。Further, the substrate is moved by a three-dimensional motion platform, and a heat sink is provided on the three-dimensional motion platform.
本发明与现有技术相比,有益效果是:Compared with the prior art, the present invention has the following beneficial effects:
1.本发明通过在导电嘴下部,待打印区域上方设置超高频感应加热装置,实现成型区域的非接触高效加热,提高金属液滴和基板的结合性,有利于层与层之间、层与基板之间的结合,实现高质量的金属3D成形。1. In the present invention, an ultra-high frequency induction heating device is arranged under the contact nozzle and above the area to be printed, so as to realize non-contact and high-efficiency heating of the forming area, improve the bond between the metal droplet and the substrate, and benefit the layers and layers. The combination with the substrate realizes high-quality metal 3D forming.
2.本发明采用超高频感应加热装置,高频感应加热装置实现了金属局部快速非接触加热,由超高频感应线圈内产生极性瞬间变化的强大磁场,将待打印区域靠近高频线圈,丝材通过高频线圈内,磁束就会贯通整个待打印区域,在感应加热物体的内部与感应加热电流相反的方向,产生相对应的强大涡电流,因为感应加热的金属内存在电阻,产生强的涡流热能,使感应加热物体温度迅速上升,加热层极薄,一般为0.1-0.5mm。因此,超高频感应加热装置具有非接触高效加热,加热效率高等优点。2. The present invention adopts an ultra-high frequency induction heating device. The high-frequency induction heating device realizes rapid non-contact heating of the metal. A strong magnetic field with instantaneous polarity changes is generated in the ultra-high frequency induction coil, and the area to be printed is close to the high-frequency coil , The wire passes through the high-frequency coil, the magnetic beam will penetrate the entire area to be printed, and the corresponding strong eddy current is generated in the direction opposite to the induction heating current inside the induction heating object, because there is resistance in the induction heating metal. The strong eddy current heat energy makes the temperature of induction heating objects rise rapidly, and the heating layer is extremely thin, generally 0.1-0.5mm. Therefore, the UHF induction heating device has the advantages of non-contact high-efficiency heating and high heating efficiency.
3.本发明装置中,金属丝材和高频感应加热线圈接触导致短路现象,同时在感应线圈和熔融金属之间有剧烈的温度梯度,并直接和熔融金属接触,所以采用陶瓷套管来进行丝材引导和绝缘,该陶瓷套管具备不阻隔磁场、抗热冲击好,同时和金属液滴不亲和等特性。陶瓷套管可让高频磁场很好通过,并且因具有与金属液滴不亲和等特性,实现了不易堵头等优点。同时在套管壁上加测温装置,解决了金属3D打印过程中非接触测温的困难,简易方便的实现了接触测温,也使温度测量更为准确,同时根据热传导方程来估算熔融金属表面温度,通过控制电阻焊电源、高频感应电源及基板温控电源实现金属3D中的闭环温度精准控制,有助实现高质量的金属3D成形,陶瓷套管优选采用氮化硼和氮化硅。3. In the device of the present invention, the contact between the metal wire and the high-frequency induction heating coil causes a short circuit. At the same time, there is a severe temperature gradient between the induction coil and the molten metal, and directly contacts the molten metal, so ceramic sleeves are used for Wire guide and insulation, the ceramic sleeve has the characteristics of not blocking magnetic fields, good thermal shock resistance, and incompatibility with metal droplets. The ceramic sleeve can pass high-frequency magnetic fields well, and because of its incompatibility with metal droplets, it has the advantages of being difficult to plug. At the same time, a temperature measuring device is added to the wall of the casing to solve the difficulty of non-contact temperature measurement in the metal 3D printing process. The contact temperature measurement is simple and convenient, and the temperature measurement is more accurate. At the same time, the molten metal is estimated based on the heat conduction equation. Surface temperature, through the control of resistance welding power supply, high-frequency induction power supply and substrate temperature control power supply to achieve precise control of closed-loop temperature in metal 3D, which helps to achieve high-quality metal 3D forming. Ceramic bushings preferably use boron nitride and silicon nitride .
4.本发明通过在导电嘴与基板之间并联电阻,当某种外部原因导致丝材和基板分离时,由于并联电阻给电流制造了通路,从而消除了导电丝才端部的电弧和电火花现象,避免了材料剧烈融化及飞溅所导致的打印失败或大的缺陷。4. The present invention connects a resistor in parallel between the conductive tip and the substrate. When the wire is separated from the substrate due to some external reason, the parallel resistance creates a path for the current, thereby eliminating the arc and electric spark at the end of the conductive wire. This phenomenon avoids printing failures or major defects caused by violent melting and splashing of materials.
5.本发明通过在基板的底部加热器对基板加热,使打印区域实现恒温环境,能减少打印物品的翘曲和变形,提高成形质量。5. The present invention realizes a constant temperature environment in the printing area by heating the substrate by the heater at the bottom of the substrate, which can reduce the warpage and deformation of the printed article and improve the forming quality.
6.本发明通过在打印区域的外围设置气密箱体并包含有进、抽气泵和水氧含量检测传感器,箱外配有惰性气体气罐,具有结构简单可靠,气氛环境监测精准,气压稳定、保护效果好的优点。6. In the present invention, an airtight box is provided on the periphery of the printing area and contains an air intake and suction pump and a water and oxygen content detection sensor. The box is equipped with an inert gas tank, which has a simple and reliable structure, accurate monitoring of the atmosphere and stable air pressure , The advantages of good protection effect.
附图说明Description of the drawings
图1为现有电阻电磁感应复合加热金属丝材成形装置图;Figure 1 is a diagram of an existing metal wire forming device with resistance electromagnetic induction composite heating;
附图标记:1-金属丝材、2-脉动送丝系统、3-保护气体、4-气体保护罩、5-电磁感应电源、6-电磁感应线圈、7-导电嘴、8-三维运动控制系统、9-可编程电源、10-熔积成形零件,11-基材;Reference signs: 1-metal wire, 2-pulsating wire feeding system, 3-protective gas, 4-gas protective cover, 5-electromagnetic induction power supply, 6-electromagnetic induction coil, 7-conductive nozzle, 8-three-dimensional motion control System, 9-programmable power supply, 10-fusion forming parts, 11-substrate;
图2为本发明电阻感应复合加热金属丝材增材制造装置图;Figure 2 is a diagram of an additive manufacturing device for resistance induction composite heating metal wires of the present invention;
图3为本发明超高频感应加热装置结构图;Figure 3 is a structural diagram of the ultra-high frequency induction heating device of the present invention;
图4为本发明超高频感应加热装置剖面图;4 is a cross-sectional view of the ultra-high frequency induction heating device of the present invention;
图5为本发明气氛保护箱体原理图;Figure 5 is a schematic diagram of the atmosphere protection box of the present invention;
图6为本发明金属丝材增材制造过程示意图。Figure 6 is a schematic diagram of the additive manufacturing process of the metal wire of the present invention.
附图标记:21-送丝机,22-导电嘴,23-基板,24-气氛保护装置,25-超高频感应加热装置,26-丝材,27-线鼻,28-陶瓷套管,29-基板加热装置,30-接触式测温元件,31-散热器,32-三维运动平台,241-气密箱体,242-抽气泵。Reference signs: 21-wire feeder, 22-conduction nozzle, 23-substrate, 24-atmosphere protection device, 25-ultra-high frequency induction heating device, 26-wire, 27-wire nose, 28-ceramic sleeve, 29-Substrate heating device, 30-contact temperature measuring element, 31-radiator, 32-three-dimensional motion platform, 241-airtight box, 242-pump.
具体实施方式detailed description
如图2所示的一种电阻感应复合加热金属丝材增材制造装置,包括送丝机21、导电嘴22、基板23、气氛保护装置24及电源,送丝机21、导电嘴22及基板23由上至下依次设置,电源的正极与导电嘴22连接,负极与基板23连接,还包括并联电阻R1、超高频感应加热装置25和基板加热装置29。A resistance induction composite heating metal wire additive manufacturing device as shown in FIG. 2 includes a wire feeder 21, a conductive nozzle 22, a substrate 23, an atmosphere protection device 24 and a power supply, the wire feeder 21, a conductive nozzle 22 and a substrate 23 are arranged in order from top to bottom. The positive pole of the power supply is connected to the contact tip 22, and the negative pole is connected to the substrate 23. It also includes a parallel resistor R1, an ultra-high frequency induction heating device 25 and a substrate heating device 29.
并联电阻R1的一端与导电嘴22连接,另一端与基板23连接,并联电阻R1的一端具体通过线鼻27与导电嘴22连接。对于大电流粗口径的电线连接而言,为了更好的接触,减少接触电阻,一般采用线鼻27连接。在导电嘴22和基板23处并联合适规格的并联电阻,当某种外部原因导致金属丝材26和基板23分离时,由于并联电阻给电流制造了通路,而不会发生起弧现象。并联电阻选型原则要远大于金属丝材26导通时的接触电阻(金属丝材26与基板23导通时的接触电阻),这样在正常打印时,分流到的电流可以小到忽略不计,基本不会外加系统热损耗,并联电阻的阻值小于微距保护气体的击穿电阻(导电嘴22与基板23之间的气体击穿电阻),并联电阻在金属丝材26和基板23分离时起到导流的作用,同时配合电源控制,从恒流自动变为电压源控制,保证电源输出功率最小,也进一步减少了电路的损耗,具体合适的并联电阻的大小及功率需要根据不同的打印金属丝材26来选择。One end of the parallel resistor R1 is connected to the conductive tip 22, and the other end is connected to the substrate 23. One end of the parallel resistor R1 is specifically connected to the conductive tip 22 through the wire nose 27. For the connection of large-current and large-caliber wires, in order to better contact and reduce contact resistance, wire nose 27 is generally used for connection. A parallel resistor of appropriate specifications is connected in parallel between the contact tip 22 and the substrate 23. When the metal wire 26 is separated from the substrate 23 due to some external reason, the parallel resistance creates a path for the current without arcing. The principle of parallel resistance selection is much larger than the contact resistance when the metal wire 26 is turned on (the contact resistance when the metal wire 26 and the substrate 23 are turned on), so that during normal printing, the current shunted can be negligible. There is basically no additional system heat loss. The resistance of the parallel resistance is smaller than the breakdown resistance of the macro protective gas (the gas breakdown resistance between the contact tip 22 and the substrate 23). The parallel resistance is when the metal wire 26 and the substrate 23 are separated Play the role of diversion, and at the same time cooperate with the power control, from constant current to voltage source control, to ensure the minimum output power of the power supply, and further reduce the loss of the circuit. The size and power of the appropriate parallel resistor need to be printed according to different Metal wire 26 to choose.
本发明打印头具体结构如图3、图4所示,超高频感应加热装置25包括高频感应加热线圈,高频感应加热线圈通过陶瓷套管28设置在导电嘴22下端的金属丝材26上,且与电源连接;高频感应加热线圈具体可采用空心铜管,空心铜管中通入冷却介质。导电嘴22通过 线鼻27将电阻焊电流接入导电嘴22,送丝机21将金属丝材26送入导电嘴22,继续送入高频感应加热线圈,高频感应加热线圈通高频电流,根据电流的大小可以设计不同结构,若电流过大,则通入冷却水保护,因为大电流可以产生强磁场,同时由于电阻存在,电阻热量需要循环冷水带走,并需要配备冷水机;如果电流小则不需要,可以采用高温导线,或者用风冷既可。The specific structure of the print head of the present invention is shown in Figures 3 and 4. The ultra-high frequency induction heating device 25 includes a high frequency induction heating coil. The high frequency induction heating coil is set on the metal wire 26 at the lower end of the contact tip 22 through a ceramic sleeve 28. It is connected to the power supply; the high-frequency induction heating coil can be a hollow copper tube, and the cooling medium is passed into the hollow copper tube. The contact tip 22 connects the resistance welding current to the contact tip 22 through the wire nose 27. The wire feeder 21 feeds the metal wire 26 into the contact tip 22, and continues to feed the high-frequency induction heating coil. The high-frequency induction heating coil passes high-frequency current. , According to the size of the current, different structures can be designed. If the current is too large, the cooling water protection is introduced, because the large current can generate a strong magnetic field. At the same time, due to the existence of resistance, the resistance heat needs to be removed by circulating cold water, and a chiller is required; if If the current is small, it is not necessary. High temperature wires can be used, or air cooling can be used.
金属丝材26和高频感应加热线圈接触导致短路现象,所以需采用陶瓷套管28来进行金属丝材26引导和绝缘,陶瓷套管28可让高频磁场很好通过,同时在感应线圈和熔融金属之间有剧烈的温度梯度,并直接和熔融金属接触。该套管具备不阻隔磁场、抗热冲击好,同时和金属液滴不亲和等特性,因此具有不易堵头等优点。同时在套管壁上加温度传感器,解决了金属3D打印过程中非接触测温的困难,简易方便的实现了接触测温,同时根据热传导方程来估算熔融金属表面温度,通过控制电阻焊电源、高频感应电源及基板23温控电源实现金属3D打印闭环温度控制,有助实现高质量的金属3D成形。The contact between the metal wire 26 and the high-frequency induction heating coil leads to a short circuit. Therefore, a ceramic sleeve 28 is used to guide and insulate the metal wire 26. The ceramic sleeve 28 allows the high-frequency magnetic field to pass through. There is a severe temperature gradient between the molten metal and it is in direct contact with the molten metal. The sleeve has the characteristics of not blocking magnetic fields, good thermal shock resistance, and incompatible with metal droplets, so it has the advantages of not being easy to plug. At the same time, a temperature sensor is added to the casing wall, which solves the difficulty of non-contact temperature measurement in the metal 3D printing process, and realizes the contact temperature measurement simply and conveniently. At the same time, the surface temperature of the molten metal is estimated according to the heat conduction equation. By controlling the resistance welding power supply, High-frequency induction power supply and substrate 23 temperature control power supply realize closed-loop temperature control of metal 3D printing, which helps to achieve high-quality metal 3D forming.
基板加热装置29设置在基板23上,用于对基板23进行加热。基板23上设置有测温元件,用于测量基板23的温度。基板23温控电源部分使打印区域实现恒温环境,能减少打印物品因应力引起的翘曲和变形,提高成形质量。基板温控控制系统可以采用各种加热和温控方式,比如电阻加热或者感应加热等,并需要加上温度传感器实现PID控温,而且根据不同金属材料热处理工艺的不同,可以设定不同的温度,如果基板要求温度不高也可以不加散热器,或者要求基板冷却直接加冷却散热实现基板恒温环境。The substrate heating device 29 is provided on the substrate 23 for heating the substrate 23. A temperature measuring element is provided on the substrate 23 for measuring the temperature of the substrate 23. The temperature control power supply part of the substrate 23 realizes a constant temperature environment in the printing area, which can reduce the warpage and deformation of the printed article due to stress and improve the forming quality. The substrate temperature control system can adopt various heating and temperature control methods, such as resistance heating or induction heating, etc., and need to add a temperature sensor to realize PID temperature control, and according to different heat treatment processes of different metal materials, different temperatures can be set If the substrate temperature is not high, no heat sink is required, or the substrate cooling is required to directly add cooling and heat dissipation to achieve a constant temperature environment for the substrate.
为了减少电路损耗,保证电源的输出功率不变,电源为可编程电源,可编程电源具有恒流输出模式和恒压输出模式,恒流输出模式用于金属的熔融,恒压输出模式用于并联电阻R1的供电。本发明中金属熔融时,所需的电流比较大,如果用金属熔融时的电流给并联电阻R1供电,势必花费很大的功率;并联电阻R1只起到导流的作用,因此,本发明中选用了可编程电源在恒压输出模式下给并联电 阻R1供电,目前是通过软件限流自动调整为恒压输出模式,在软件里设置了最大电流和最大电压,根据负载情况自动切换。In order to reduce circuit loss and ensure that the output power of the power supply remains unchanged, the power supply is a programmable power supply. The programmable power supply has a constant current output mode and a constant voltage output mode. The constant current output mode is used for metal melting, and the constant voltage output mode is used for parallel connection. Power supply for resistor R1. In the present invention, when the metal is melted, the required current is relatively large. If the current when the metal is melted is used to supply power to the parallel resistor R1, it will inevitably spend a lot of power; the parallel resistor R1 only plays a role of diversion, therefore, in the present invention The programmable power supply is selected to supply power to the parallel resistor R1 in the constant voltage output mode. At present, the current limit is automatically adjusted to the constant voltage output mode through software. The maximum current and maximum voltage are set in the software, and they are automatically switched according to the load.
电阻感应复合加热金属丝材26增材制造控制系统包含六部分,分别是超高频电源控制部分、电阻焊控制电源部分、基板温控电源部分、三维运动控制部分、送丝控制部分和保护气氛箱体控制部分。超高频电源控制部分、电阻焊控制电源部分和基板温控电源部分这三部分也可以合并为一个集成电源控制,保护气氛箱体控制部分包含水氧检测传感器、压力检测传感器和气泵控制。The resistance induction composite heating metal wire 26 additive manufacturing control system consists of six parts, namely the UHF power supply control part, the resistance welding control power supply part, the substrate temperature control power supply part, the three-dimensional motion control part, the wire feeding control part and the protective atmosphere Box control part. The three parts of UHF power supply control part, resistance welding control power supply part and substrate temperature control power supply part can also be combined into an integrated power control. The protective atmosphere box control part contains water and oxygen detection sensors, pressure detection sensors and air pump control.
电阻焊控制电源部分提供金属丝熔融的电能,主要根据不同金属材料的熔融成型工艺特点,可以采用直流交流或者脉冲的方式,也可以采用电压源或电流源的方式,通过金属丝短路瞬间产生的焦耳热熔融金属丝材26,根据不同的金属丝材26和不同的成形效率,一般短路电阻流在1A-1000A选择,金属丝融化时电阻为剧烈的非线性变化,通过电源的功率闭环实现功率对负载的跟踪和匹配。The resistance welding control power supply part provides the electric energy for the melting of the metal wire. It can be produced by the method of DC, AC or pulse, or voltage source or current source, which is generated by the short circuit of the metal wire, mainly according to the characteristics of the melting and forming process of different metal materials. Joule hot-melting metal wire 26, according to different metal wires 26 and different forming efficiency, the general short-circuit resistance flow is selected from 1A-1000A. When the metal wire melts, the resistance changes drastically and nonlinearly. The power is realized through the power closed loop of the power supply. Tracking and matching of load.
超高频电源部分实现了金属局部快速非接触加热,由超高频感应线圈内产生极性瞬间变化的强大磁场,将待打印区域靠近高频线圈,金属丝材通过高频线圈内,磁束就会贯通整个待打印区域。在感应加热物体的内部与感应加热电流相反的方向,产生相对应的强大涡电流。因为感应加热的金属内存在电阻,因此产生强的涡流热能,使感应加热物体温度迅速上升,加热层极薄,一般为0.1-0.5mm。并可以通过红外测温仪或者红外成像仪等非接触测温设备构成闭环控制超高频电源功率输出,实现打印区域局部温度控制。这部分温度控制可以实现成型区域的非接触高效加热,弥补了电阻焊加热很难实现金属液滴和基板的结合的问题,高效实现了层与层之间、层与基板之间的互溶结合,实现高质量的金属3D成形。The ultra-high frequency power supply part realizes the rapid non-contact heating of the metal. A strong magnetic field with instantaneous polarity change is generated in the ultra-high frequency induction coil, and the area to be printed is close to the high-frequency coil. The metal wire passes through the high-frequency coil, and the magnetic beam Will run through the entire area to be printed. In the direction opposite to the induction heating current inside the induction heating object, a corresponding strong eddy current is generated. Because there is electrical resistance in the metal that is heated by induction, strong eddy current heat energy is generated, which makes the temperature of the induction heated object rise rapidly, and the heating layer is extremely thin, generally 0.1-0.5mm. And can form a closed-loop control of UHF power output by non-contact temperature measuring devices such as infrared thermometers or infrared imagers to achieve local temperature control in the printing area. This part of the temperature control can realize the non-contact and high-efficiency heating of the forming area, which makes up for the problem that resistance welding heating is difficult to achieve the combination of metal droplets and the substrate, and efficiently realizes the mutual fusion combination between layers and between layers and substrates. Realize high-quality metal 3D forming.
三维运动控制部分可以用电机模组构建运动控制平台或者机械臂来实现。The three-dimensional motion control part can be realized by constructing a motion control platform or a robot arm with a motor module.
如图5所示,箱体控制部分,根据不同的金属材料可以设计气氛保护,包含气体净化系统、循环系统和气体温控系统,需要有水氧传 感器、压力传感器、温度传感器、气罐、气泵及气阀的进出控制,也可以按照真空密闭腔体设计,需要配备真空泵。气氛保护装置24具体可包括气密箱体241、与气密箱体241连通惰性气体气罐,气密箱体241与惰性气体气罐连通的管路上设置有抽气泵242,气密箱体241上设置有水氧含量检测传感器。不同的金属材料可以设计不同的气氛保护,各种气体纯度传感器用于根据不同需要可以包含水氧含量,气体压强等等传感器,实现气体质量气体压力等闭环控制,也可以按照真空密闭腔体设计,需要配备真空泵。送丝速度、运动速度需要和工艺参数相匹配。As shown in Figure 5, the cabinet control part can be designed for atmosphere protection according to different metal materials, including gas purification system, circulation system and gas temperature control system. It needs water and oxygen sensor, pressure sensor, temperature sensor, gas tank, and gas pump. The inlet and outlet control of the air valve can also be designed according to the vacuum-tight chamber, and a vacuum pump is required. The atmosphere protection device 24 may specifically include an airtight box 241, an inert gas tank connected to the airtight box 241, an air pump 242 is provided on the pipeline connecting the airtight box 241 and the inert gas tank, and the airtight box 241 A water and oxygen content detection sensor is installed on it. Different metal materials can be designed with different atmosphere protections. Various gas purity sensors can include sensors such as water and oxygen content, gas pressure, etc., according to different needs, to achieve closed-loop control of gas quality and gas pressure, and can also be designed according to vacuum tight chambers , Need to be equipped with a vacuum pump. The wire feeding speed and movement speed need to match the process parameters.
能量输入部分即电源控制部分,空间运动控制部分、打印头及送丝控制部分和箱体气泵控制部分都需要连接到打印机及总体控制系统,根据不同的金属材料的工艺特点统一协调控制。The energy input part is the power control part, the space motion control part, the print head and wire feed control part and the box air pump control part need to be connected to the printer and the overall control system, and coordinate and control according to the process characteristics of different metal materials.
本发明的运动机构是设置在基板底部的,考虑到运动平台无法长期承受高温,导致形变和运动的失准性,在运动平台上设置了散热器31,散热器31可以根据不通过条件选择风冷,水冷,半导体制冷等等。The movement mechanism of the present invention is arranged at the bottom of the base plate. Considering that the movement platform cannot withstand high temperature for a long time, resulting in deformation and movement inaccuracy, a radiator 31 is provided on the movement platform, and the radiator 31 can be selected according to the failure conditions. Cold, water cooling, semiconductor refrigeration and so on.
本发明的原理是基于金属丝通电后会产生电阻热,通过电阻热实现金属丝熔融堆覆成型,金属丝通过自动送丝机21送入导电嘴22,导电嘴22连接电阻焊电源的正极,金属基板23连接电源电阻焊电源负极,在金属丝的顶端和基板23构成回路,通以一定形式的电流,瞬间熔融金属丝端,熔化后金属液滴由于重力和表面张力的作用沉积在基板23上,在导电嘴22和基板23之间有高频感应线圈,由超高频感应电源在熔化金属液滴和基板23之间产生极性瞬间变化的强大磁场,该区域生成涡流热使金属液滴和基板23实现冶金结合,随着基板23的移动和不断的递送金属丝材26,在基板23上即可形成堆积的金属零件,实现金属增材制造。但是在打印过程中,由于金属细丝的电阻率随温度变化,加上金属丝材26材质可能会有杂质或者变形导致送丝过程中的不稳定性等因素,导致导电金属丝材26和基板23不接触,这时会发生电弧和电火花现象使沉积的材料剧烈融化及 飞溅,导致打印失败或大的缺陷。为此,本发明在导电嘴22和基板23处并联合适规格的并联电阻,当某种外部原因导致金属丝材26和基板23分离时,并联电阻给电流制造通路,避免发生起弧现象。The principle of the present invention is based on the resistance heat generated after the metal wire is energized, and the metal wire is melted and formed by the resistance heat. The metal wire is fed into the contact tip 22 through the automatic wire feeder 21, and the contact tip 22 is connected to the positive electrode of the resistance welding power source. The metal substrate 23 is connected to the negative electrode of the resistance welding power source, and the top of the metal wire forms a loop with the substrate 23. A certain form of current is passed to melt the end of the metal wire instantaneously. After melting, metal droplets are deposited on the substrate 23 due to gravity and surface tension. Above, there is a high-frequency induction coil between the contact tip 22 and the substrate 23. The ultra-high-frequency induction power supply generates a strong magnetic field with instantaneous changes in polarity between the molten metal droplet and the substrate 23. This area generates eddy current heat to make the molten metal The drop and the substrate 23 realize a metallurgical combination. With the movement of the substrate 23 and the continuous delivery of the metal wire 26, stacked metal parts can be formed on the substrate 23 to realize metal additive manufacturing. However, during the printing process, since the resistivity of the metal filament changes with temperature, and the material of the metal wire 26 may contain impurities or deformation, resulting in instability during the wire feeding process, etc., the conductive metal wire 26 and the substrate 23 No contact, arc and electric spark will occur at this time, the deposited material will melt and splash violently, resulting in printing failure or large defects. For this reason, the present invention connects the contact tip 22 and the substrate 23 in parallel with parallel resistors of appropriate specifications. When the metal wire 26 and the substrate 23 are separated due to some external reason, the parallel resistors create a path for the current to avoid arcing.
如图6所示,本发明的金属丝材增材制造装置的打印过程如下:As shown in Figure 6, the printing process of the metal wire additive manufacturing device of the present invention is as follows:
1.根据成型零件的需要,确定成型材料的属性,及成型的各种工艺参数,并保证金属丝材26表面无氧化物及干燥处理。1. According to the needs of the molded parts, determine the properties of the molding material and various process parameters of the molding, and ensure that the surface of the metal wire 26 is free of oxides and dry treatment.
2.使用气氛保护结构实现保护气氛或者真空环境,将金属丝材26通过送丝机21构送入导电嘴22,并与基板23保持接触。2. Use an atmosphere protection structure to achieve a protective atmosphere or a vacuum environment, and feed the metal wire 26 into the conductive nozzle 22 through the wire feeder 21 structure, and keep in contact with the substrate 23.
3.根据预设的参数启动打印机,在运动机构,基板23温控电源、电阻焊电源及高频感应加热电源及送丝机21的协同工作下,实现金属材料逐层累加堆积成型,实现金属零件的增材制造。3. Start the printer according to the preset parameters. Under the coordinated work of the movement mechanism, the temperature control power supply of the substrate 23, the resistance welding power supply and the high-frequency induction heating power supply, and the wire feeder 21, the metal materials are accumulated and formed layer by layer to realize the metal Additive manufacturing of parts.

Claims (8)

  1. 一种电阻感应复合加热金属丝材增材制造装置,包括送丝机(21)、导电嘴(22)、基板(23)、气氛保护装置(24)及电源,所述送丝机(21)、导电嘴(22)及基板(23)由上至下依次设置,所述电源的正极与导电嘴(22)连接,负极与基板(23)连接,其特征在于:A resistance induction composite heating metal wire material additive manufacturing device, comprising a wire feeder (21), a contact tip (22), a substrate (23), an atmosphere protection device (24) and a power supply. The wire feeder (21) , The conductive tip (22) and the substrate (23) are arranged in order from top to bottom, the positive pole of the power supply is connected to the conductive tip (22), and the negative pole is connected to the substrate (23), characterized in that:
    还包括超高频感应加热装置(25)和基板加热装置(29);It also includes an ultra-high frequency induction heating device (25) and a substrate heating device (29);
    所述超高频感应加热装置(25)为高频感应加热线圈,所述高频感应加热线圈通过陶瓷套管(28)缠绕在导电嘴(22)下端的金属丝材(26)外侧,且与电源连接;所述陶瓷套管(28)上设置有接触式测温元件(30);The ultra-high frequency induction heating device (25) is a high frequency induction heating coil, and the high frequency induction heating coil is wound on the outside of the metal wire (26) at the lower end of the contact tip (22) through a ceramic sleeve (28), and Connected to the power supply; the ceramic bushing (28) is provided with a contact temperature measuring element (30);
    所述基板加热装置(29)设置在基板(23)下方,用于对基板(23)进行加热;所述基板(23)上设置有基板测温元件,用于测量基板(23)的温度。The substrate heating device (29) is arranged under the substrate (23) for heating the substrate (23); a substrate temperature measuring element is arranged on the substrate (23) for measuring the temperature of the substrate (23).
  2. 根据权利要求1所述的电阻感应复合加热金属丝材增材制造装置,其特征在于:所述高频感应加热线圈为空心铜管,空心铜管中通入冷却介质。The resistance induction composite heating metal wire additive manufacturing device according to claim 1, wherein the high frequency induction heating coil is a hollow copper tube, and a cooling medium is passed into the hollow copper tube.
  3. 根据权利要求1或2所述的电阻感应复合加热金属丝材增材制造装置,其特征在于:还包括并联电阻R1,所述并联电阻R1的一端与导电嘴(22)连接,另一端与基板(23)连接,所述并联电阻R1的阻值大于金属丝材(26)与基板(23)导通时的接触电阻,小于导电嘴(22)与基板(23)之间气体的击穿电阻。The resistance induction composite heating metal wire additive manufacturing device according to claim 1 or 2, characterized in that it further comprises a parallel resistor R1, one end of the parallel resistor R1 is connected to the contact tip (22), and the other end is connected to the substrate (23) Connection, the resistance value of the parallel resistor R1 is greater than the contact resistance when the metal wire (26) is connected to the substrate (23), and smaller than the breakdown resistance of the gas between the contact tip (22) and the substrate (23) .
  4. 根据权利要求3所述的电阻感应复合加热金属丝材增材制造装置,其特征在于:所述并联电阻R1的一端通过线鼻(27)与导电嘴(22)连接。The resistance induction composite heating metal wire additive manufacturing device according to claim 3, wherein one end of the parallel resistor R1 is connected to the conductive tip (22) through a wire nose (27).
  5. 根据权利要求4所述的电阻感应复合加热金属丝材增材制造装置,其特征在于:所述电源为可编程电源,所述可编程电源具有恒 流输出模式和恒压输出模式,恒流输出模式用于金属的熔融,恒压输出模式用于并联电阻R1的供电。The resistance induction composite heating metal wire additive manufacturing device according to claim 4, wherein the power supply is a programmable power supply, and the programmable power supply has a constant current output mode and a constant voltage output mode, and a constant current output The mode is used for the melting of metal, and the constant voltage output mode is used for the power supply of parallel resistor R1.
  6. 根据权利要求5所述的电阻感应复合加热金属丝材增材制造装置,其特征在于:所述气氛保护装置(24)包括气密箱体(241)、与气密箱体(241)连通的惰性气体气罐,所述气密箱体(241)与惰性气体气罐连通的管路上设置有抽气泵(242),气密箱体(241)上设置有水氧含量检测传感器。The resistance induction composite heating metal wire additive manufacturing device according to claim 5, characterized in that: the atmosphere protection device (24) comprises an airtight box (241), connected to the airtight box (241) An inert gas tank, a pipeline connecting the airtight box (241) and the inert gas tank is provided with an air pump (242), and the airtight box (241) is provided with a water and oxygen content detection sensor.
  7. 根据权利要求6所述的电阻感应复合加热金属丝材增材制造装置,其特征在于:所述陶瓷套管(28)由氮化硼或氮化硅制作。The resistance induction composite heating metal wire additive manufacturing device according to claim 6, wherein the ceramic sleeve (28) is made of boron nitride or silicon nitride.
  8. 根据权利要求7所述的电阻感应复合加热金属丝材增材制造装置,其特征在于:所述基板(23)通过三维运动平台(32)移动,所述三维运动平台(32)上设置有散热器(31)。The resistance induction composite heating metal wire additive manufacturing device according to claim 7, wherein the substrate (23) is moved by a three-dimensional motion platform (32), and the three-dimensional motion platform (32) is provided with heat dissipation器(31).
PCT/CN2019/093332 2019-01-28 2019-06-27 Additive manufacturing device using combined resistance-induction heating of metal wire material WO2020155540A1 (en)

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