WO2020215634A1 - 一种采用 mig/mag 作为热源的双金属电弧增材制造方法 - Google Patents

一种采用 mig/mag 作为热源的双金属电弧增材制造方法 Download PDF

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WO2020215634A1
WO2020215634A1 PCT/CN2019/112727 CN2019112727W WO2020215634A1 WO 2020215634 A1 WO2020215634 A1 WO 2020215634A1 CN 2019112727 W CN2019112727 W CN 2019112727W WO 2020215634 A1 WO2020215634 A1 WO 2020215634A1
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layer
additive manufacturing
welding wire
mig
mag
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PCT/CN2019/112727
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English (en)
French (fr)
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程远
吴晓
袁玉荣
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南京英尼格玛工业自动化技术有限公司
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Publication of WO2020215634A1 publication Critical patent/WO2020215634A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/04—Welding for other purposes than joining, e.g. built-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
    • B23K9/232—Arc welding or cutting taking account of the properties of the materials to be welded of different metals
    • 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

Definitions

  • the invention relates to a bimetallic arc additive manufacturing method using MIG/MAG as a heat source, and belongs to the technical field of directional energy deposition system equipment.
  • additive Manufacturing commonly known as 3D printing, combines computer-aided design, material processing and molding technology, based on digital model files, and integrates special metal materials, non-metal materials and medical biological materials through software and numerical control systems. , According to the methods of extrusion, sintering, melting, light curing, spraying, etc., it is stacked layer by layer to produce the manufacturing technology of physical objects.
  • Additive manufacturing technology is often used in mold manufacturing, industrial design and other fields to make models, and then gradually used in the direct manufacturing of some products. There are already parts printed using this technology.
  • the technology has applications in jewelry, footwear, industrial design, architecture, engineering and construction (AEC), automotive, aerospace, dental and medical industries, education, geographic information systems, civil engineering, guns, and other fields.
  • AEC engineering and construction
  • Arc Additive Manufacturing Technology (Wire Arc Additive Manufacture, WAAM) is a method that uses the principle of layer-by-layer cladding, and uses arcs generated by welding machines such as MIG, TIG and PA as the heat source , Through the addition of wires, under the control of the software program, according to the three-dimensional digital model, the advanced digital manufacturing technology of metal parts is gradually formed from the line-surface-body.
  • the technical problem to be solved by the present invention is to provide a bimetallic arc additive manufacturing method using MIG/MAG as a heat source.
  • This method can print out the strength and hardness of the outer layer of the part, but the strength of the inner layer of the product And parts with low hardness requirements, such as parts of mining machinery and equipment: crusher hammers, sprocket of middle groove scraper, etc., have special performance requirements on the surface of the parts, so it can effectively reduce the cost of product preparation.
  • a bimetallic arc additive manufacturing method that uses MIG/MAG as a heat source.
  • the method uses a dual-wire MIG/MAG welding machine as a heat source, and the welding wire A and the welding wire B in the bimetallic welding wire are used as depositing filler materials.
  • the manufacturing software models the workpiece to be printed. According to the material properties of the workpiece, the additive layer height of each layer is determined.
  • the arc additive manufacturing slicing software is used to slice the digital model of the part according to the determined layer height in the Z direction.
  • the cladding method of each slice of the top layer is: the outer wall uses welding wire A for back-shaped linear cladding, and the inner layer uses welding wire B for linear filling cladding; the cladding method of the top slice is: using welding wire A for linear filling cladding .
  • the width of a single-pass cladding layer on the outer wall is 8-12mm.
  • each segment of additive weld bead is filled with a straight line
  • each segment of additive weld is filled along the X axis
  • each segment of additive weld is filled along the Y axis
  • each segment of additive weld is folded Linear fills in a straight line.
  • the left side wall, the right side wall, the front side wall, the rear side wall and the top surface of the parts made by this method all have an outer wall layer formed by welding wire A with a thickness of 8-12mm; if you want a thicker
  • the wall thickness can be cladding several more cladding layers.
  • this method uses parallel slices to plan the path filling.
  • the linear filling angle of the inner layer of the adjacent layer is 0-90°.
  • the selection of the metal wire is determined by the original product or the expected organizational performance requirements, such as strength and hardness, that is, what material the original product is made of or the expected organizational performance requirements, and the metal selected in the 3D printing process
  • the material of the wire is basically the same as that of the original product or meets the expected performance requirements.
  • the method of the present invention uses two different metal welding wires for braiding cladding, the outer wall layer is filled with a higher-cost metal welding wire A, and the inner layer is filled with a lower-cost metal welding wire B, thereby obtaining the parts
  • the strength and hardness of the outer layer are required, and the strength and hardness of the inner layer of the product are not so high.
  • 3D printed parts such as the central slot scraper sprocket of coal mining machinery, the crusher hammer of mining machinery, etc., this increase
  • the material method not only can effectively reduce the production cost of the product, but also can obtain bimetal products that meet the needs.
  • Figure 1 is a schematic diagram of the bottom surface of a printed workpiece
  • Figure 2 is a schematic diagram of the top surface of the printed workpiece
  • Figure 3 is a schematic diagram of the inner layer using a back-shaped straight line filling
  • Figure 4 is a schematic diagram of the inner layer in a broken line shape for linear filling
  • Figure 5 is a schematic diagram of the linear filling of each segment of the inner layer of the additive weld along the X-axis/Y-axis direction;
  • Fig. 6 is a schematic diagram when the inner layer is in a broken line shape for linear filling, and the filling angle of two adjacent inner layers is 90°;
  • Fig. 7 is a working principle diagram of the double-wire MIG/MAG welding machine in the method of the present invention.
  • Fig. 8 is a partial enlarged view of Fig. 7.
  • the method of the present invention uses a double-wire MIG/MAG welding machine as a heat source, and is driven by additive manufacturing software to control and drive two different wire metals in the double-wire welding machine to alternately cladding, thereby performing an arc additive manufacturing process.
  • each welding power source has its own independent control system and is equipped with an independently controlled wire feeder. There is a coordinated controller between the two welding power sources, which can obtain the perfect droplet transition coordination time between the two welding wires. There are continuously adjustable parameters on each welding power source. The power source characteristics can be adjusted according to the base material, filler metal and shielding gas, so as to obtain greater melting when surfacing welds with larger cross-sections or using greater welding speeds. Ratio.
  • the additive manufacturing software models the workpiece to be printed, and determines the height of each additive layer according to the material properties of the workpiece, and uses the arc additive manufacturing slicing software to slice the digital model of the part according to the determined layer height in the Z direction. , Obtain the two-dimensional contour map of the part model, use the offset algorithm or the parallel line scanning algorithm to generate the additive path corresponding to each point on each plane (each layer).
  • the invention adopts the bimetallic arc additive manufacturing method using MIG/MAG as the heat source.
  • the method adopts the twin-wire MIG/MAG welding machine as the heat source, and the welding wire A and the welding wire B in the bimetal welding wire are used as the deposited filler material, and the additive is used
  • the manufacturing software models the workpiece to be printed. According to the material properties of the workpiece, the additive layer height of each layer is determined.
  • the arc additive manufacturing slicing software is used to slice the digital model of the part according to the determined layer height in the Z direction.
  • the cladding method of each slice of the top layer is: the outer wall uses welding wire A for back-shaped linear cladding, and the inner layer uses welding wire B for linear filling cladding; the cladding method of the top slice is: using welding wire A for linear filling cladding .
  • the left side wall, right side wall, front side wall, back side wall and top surface of the parts produced by the method of the present invention all have a thickness of 8-12 mm, and an outer wall layer formed by welding wire A cladding ;
  • each segment of the additive weld bead is filled with a straight line, as shown in Figure 3. It can also be linearly filled along the X axis for each segment of the additive weld or linearly filled along the Y axis for each segment of the additive weld. As shown in Figure 5, the additive weld bead can also be linearly filled in the shape of a broken line, as shown in Figure 4.
  • the linear filling angle of the layers is 0-90°, as shown in Fig. 6, the linear filling angle of the inner layer of adjacent layers is 90°.
  • the present invention uses bimetallic wire welding as the heat source for arc additive manufacturing.
  • Two sets of independent power sources and wire feeders respectively control two different types of metal wires (wire A and wire B).
  • the difference between arc twin wire welding is double
  • the welding wire A and the welding wire B of the metal arc additive manufacturing are not cladding at the same time. Instead, the slicing path generated by the additive manufacturing software is used for linear alternate braiding cladding.
  • the ratio of the two metals in the unit area or unit length of the bimetallic additive can be adjusted.
  • Adopting the inner layer filling method shown in Figure 5 of the present invention for bimetallic arc additive manufacturing includes the following steps: firstly, the substrate or workpiece (for the workpiece to be repaired) is cleaned, and the outer layer adopts a high wear resistance core with a diameter of 1.6.
  • Slag welding wire welding wire A
  • first layer current 180A welding speed 12mm/s
  • inner layer uses ER316 welding wire (welding wire B) with a diameter of 1.2, first layer current 160A, welding speed 12mm/s, during which the current can be adjusted according to actual conditions ;
  • the welding current and welding speed parameters of welding wire A and welding wire B are gradually reduced, and the welding current is stable at about 160A and 150A.
  • Adjust the heat input according to the actual situation set the waiting time between layers, initially set 50s, and can be adjusted.
  • the printing time is 90min, and it will be cooled to room temperature naturally after printing.

Abstract

一种采用MIG、MAG作为热源的双金属增材制造方法，该方法采用双丝MIG、MAG作为热源，双金属焊丝中的焊丝A和焊丝B作为熔敷的填充材料，利用增材制造软件对待打印的工件进行建模，根据工件的材料性能，确定每层增材层高，用电弧增材制造切片软件对零件进行分层切片。除顶层外，每层切片的熔覆方式为：外壁采用焊丝A进行回字型直线熔覆，内层采用焊丝B进行直线填充熔覆；顶层切片的熔覆方式为：采用焊丝A进行直线填充熔覆。采用两种不同的金属焊丝进行编织熔覆，得到对零件外层的强度和硬度有要求、对产品内层的强度和硬度需求不那么高的3D打印零件，不仅能够有效降低产品的制备成本，也能得到满足需要的双金属产品。

Description

一种采用MIG/MAG作为热源的双金属电弧增材制造方法 技术领域
本发明涉及一种采用MIG/MAG作为热源的双金属电弧增材制造方法，属于定向能量沉积系统装备的技术领域。
 背景技术
增材制造（Additive Manufacturing，AM）俗称3D打印，融合了计算机辅助设计、材料加工与成型技术、以数字模型文件为基础，通过软件与数控系统将专用的金属材料、非金属材料以及医用生物材料，按照挤压、烧结、熔融、光固化、喷射等方式逐层堆积，制造出实体物品的制造技术。
增材制造技术常在模具制造、工业设计等领域被用于制造模型，后逐渐用于一些产品的直接制造，已经有使用这种技术打印而成的零部件。该技术在珠宝、鞋类、工业设计、建筑、工程和施工（AEC）、汽车，航空航天、牙科和医疗产业、教育、地理信息系统、土木工程、枪支以及其他领域都有所应用。
电弧增材制造技术（Wire Arc Additive Manufacture，WAAM）是一种利用逐层熔覆原理，采用熔化极惰性气体保护焊接（MIG）、钨极惰性气体保护焊接（TIG）以及等离子体焊接电源（PA）等焊机产生的电弧为热源，通过丝材的添加，在软件程序的控制下，根据三维数字模型由线-面-体逐渐成形出金属零件的先进数字化制造技术。
 技术问题
本发明所要解决的技术问题是提供一种采用MIG/MAG作为热源的双金属电弧增材制造方法，该方法能够打印出对零件外层的强度和硬度有要求的，但对产品内层的强度和硬度需求不那么高的零件，如矿山机械设备的零件：破碎机锤，中部槽刮板机的链轮等对零件表面有特殊性能要求的，因此可有效降低产品的制备成本。
 技术解决方案
为解决上述技术问题，本发明所采用的技术方案为：
一种采用MIG/MAG作为热源的双金属电弧增材制造方法，该方法采用双丝MIG/MAG焊机作为热源，双金属焊丝中的焊丝A和焊丝B作为熔敷的填充材料，利用增材制造软件对待打印的工件进行建模，根据该工件的材料性能，确定每层增材层高，用电弧增材制造切片软件在Z方向上对零件数模按照确定层高进行分层切片，除顶层外每层切片的熔覆方式为：外壁采用焊丝A进行回字型直线熔覆，内层采用焊丝B进行直线填充熔覆；顶层切片的熔覆方式为：采用焊丝A进行直线填充熔覆。
其中，外壁的单道熔覆层宽度为8~12mm。
其中，内层的填充方式有：每段增材焊道呈回字型直线填充、每段增材焊道沿X轴方向进行直线填充、每段增材焊道沿Y轴方向进行直线填充或每段增材焊道呈折线形进行直线填充。
其中，该方法制得的零件左侧壁、右侧壁、前侧壁、后侧壁以及顶面均具有厚度为8~12mm，由焊丝A熔覆形成的外壁层；如果想要更厚的壁厚，可以多熔覆几道熔覆层。
其中，该方法采用平行切片规划路径的方式填充，除顶层外每层切片的单位面积为S，S=X%焊丝A+(1-X%)%焊丝B。
其中，当内层的直线填充方式采用每段增材焊道呈折线形进行直线填充时，相邻层的内层的直线填充夹角为0~90°。
本发明方法中，金属丝材的选择根据原产品决定或者预期的组织性能要求，如强度、硬度，即原产品采用什么样的材质制成或者预期的组织性能要求，3D打印过程中选用的金属丝材的材质与原产品的材质成分基本相同或和符合预期的性能要求相同。
 有益效果
相比于现有技术，本发明技术方案具有的有益效果为：
本发明方法为采用两种不同的金属焊丝进行编织熔覆，外壁层采用成本较高的金属焊丝A进行填充熔覆，内层采用成本较低的金属焊丝B进行填充熔覆，从而得到对零件外层的强度和硬度有要求、对产品内层的强度和硬度需求不那么高的3D打印零件，如煤矿机械的中部槽刮板机链轮、矿山机械的破碎机锤等产品，这样的增材方法不仅能够有效降低产品的制备成本，也能得到满足需要的双金属产品。
 附图说明
图1为打印工件底面的示意图；
图2为打印工件顶面的示意图；
图3为内层采用回字型直线填充的示意图；
图4为内层呈折线形进行直线填充的示意图；
图5为内层每段增材焊道沿X轴/Y轴方向进行直线填充的示意图；
图6为内层呈折线形进行直线填充时，相邻两层的内层的填充夹角为90°时的示意图；
图7为本发明方法中双丝MIG/MAG焊机的工作原理图；
图8为图7的局部放大图。
 本发明的实施方式
根据下述实施例，可以更好地理解本发明。然而，本领域的技术人员容易理解，实施例所描述的内容仅用于说明本发明，而不应当也不会限制权利要求书中所详细描述的本发明。
本发明方法采用双丝MIG/MAG焊机作为热源，通过增材制造软件控制驱动，让双丝焊机里面两种不同的丝材金属交替熔覆，从而进行电弧增材的制造过程。
在双丝焊中，每个焊接电源有其独立的控制系统，并配有独立控制的送丝机。两个焊接电源之间有一个协同控制器，可以得到两根焊丝之间完美的熔滴过渡配合时间。每个焊接电源上都有持续可调参数，可根据母材，填充金属和保护气体来调节电源特性，以在堆焊更大截面的焊缝或者使用更大的焊接速度时获得更大的熔敷率。
增材制造软件对待打印的工件进行建模，根据该工件的材料性能，确定每层增材层高，用电弧增材制造切片软件在Z方向上对零件数模按照确定层高进行分层切片，得到零件模型的二维轮廓图，使用偏置算法或平行线扫描算法生成每个平面（每层）上对应每个点的增材路径。
本发明采用MIG/MAG作为热源的双金属电弧增材制造方法，该方法采用双丝MIG/MAG焊机作为热源，双金属焊丝中的焊丝A和焊丝B作为熔敷的填充材料，利用增材制造软件对待打印的工件进行建模，根据该工件的材料性能，确定每层增材层高，用电弧增材制造切片软件在Z方向上对零件数模按照确定层高进行分层切片，除顶层外每层切片的熔覆方式为：外壁采用焊丝A进行回字型直线熔覆，内层采用焊丝B进行直线填充熔覆；顶层切片的熔覆方式为：采用焊丝A进行直线填充熔覆。
如图1~2所示，本发明方法制得的零件左侧壁、右侧壁、前侧壁、后侧壁以及顶面均具有厚度为8~12mm，由焊丝A熔覆形成的外壁层；
其中，外壁的厚度一般为12~18mm，外壁的单道熔覆层宽度为8~12mm，即外壁每道增材焊道熔覆的宽度为8~12mm，因此一般外壁需要回字形增材两道。内层的填充方式有：每段增材焊道呈回字型直线填充，如图3所示，也可以每段增材焊道沿X轴方向进行直线填充或每段增材焊道沿Y轴方向进行直线填充，如图5所示，也可以增材焊道呈折线形进行直线填充，如图4所示；当内层的直线填充方式采用每段增材焊道呈折线形进行直线填充时，相邻层的内层的直线填充夹角为0~90°，如图6所示，相邻层的内层的直线填充夹角为90°。
本发明方法采用平行切片规划路径的方式填充，除顶层外每层切片的单位面积为S，S=X%焊丝A+(1-X%)%焊丝B。
本发明利用双金属丝焊作为电弧增材制造的热源，两套独立的电源和送丝机分别控制两种不同种类金属的丝材（焊丝A和焊丝B），区别电弧双丝焊接的是双金属电弧增材制造的焊丝A和焊丝B并不是同时熔覆，而是根据增材制造软件生成的切片路径进行直线交替编织熔覆。双金属增材在单位面积或者单位长度上，两种金属的占比是可以调整。
采用本发明图5所示的内层填充方式进行双金属电弧增材制造，包括如下步骤：首先对基板或者工件（针对待修补的工件）进行清理，外层采用直径1.6高耐磨药芯低渣焊丝（焊丝A），首层电流180A，焊接速度12mm/s，内层采用直径1.2的ER316焊丝（焊丝B），首层电流160A，焊接速度12mm/s，期间可根据实际情况调节电流大小；焊丝A和焊丝B的焊接电流和焊接速度参数逐渐降低，焊接电流稳定在160A和150A左右，根据实际情况调整热输入，层与层之间设置等待时间，初步设置50s，可调整。打印体积为110mm*85mm*57mm的产品，打印时间为90min，打印完毕后自然冷却至室温。

Claims (6)

  1. 一种采用MIG/MAG作为热源的双金属电弧增材制造方法，其特征在于：该方法采用双丝MIG/MAG焊机作为热源，双金属焊丝中的焊丝A和焊丝B作为熔敷的填充材料，利用增材制造软件对待打印的工件进行建模，根据该工件的材料性能，确定每层增材层高，用电弧增材制造切片软件在Z方向上对零件数模按照确定层高进行分层切片，除顶层外每层切片的熔覆方式为：外壁采用焊丝A进行回字型直线熔覆，内层采用焊丝B进行直线填充熔覆；顶层切片的熔覆方式为：采用焊丝A进行直线填充熔覆。
  2. 根据权利要求1所述的采用MIG/MAG作为热源的双金属电弧增材制造方法，其特征在于：外壁的单道熔覆层宽度为8~12mm。
  3. 根据权利要求1所述的采用MIG/MAG作为热源的双金属电弧增材制造方法，其特征在于：内层的填充方式有：每段增材焊道呈回字型直线填充、每段增材焊道沿X轴方向进行直线填充、每段增材焊道沿Y轴方向进行直线填充或每段增材焊道呈折线形进行直线填充。
  4. 根据权利要求1所述的采用MIG/MAG作为热源的双金属电弧增材制造方法，其特征在于：该方法制得的零件左侧壁、右侧壁、前侧壁、后侧壁以及顶面均具有厚度为8~12mm，由焊丝A熔覆形成的外壁层。
  5. 根据权利要求1所述的采用MIG/MAG作为热源的双金属电弧增材制造方法，其特征在于：该方法采用平行切片规划路径的方式填充，除顶层外每层切片的单位面积为S，S=X%焊丝A+(1-X%)%焊丝B。
  6. 根据权利要求3所述的采用MIG/MAG作为热源的双金属电弧增材制造方法，其特征在于：当内层的直线填充方式采用每段增材焊道呈折线形进行直线填充时，相邻层的内层的直线填充夹角为0~90°。
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