CN109807562B - Electric arc additive manufacturing method for Al-Mg-Si alloy wire - Google Patents
Electric arc additive manufacturing method for Al-Mg-Si alloy wire Download PDFInfo
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Abstract
An Al-Mg-Si alloy wire electric arc additive manufacturing method comprises the following steps: step 1, performing electric arc additive forming by using cooling roller auxiliary; step 2, milling the side surface and the top surface of the additive body; step 3, performing friction stir processing on the additive body by using friction stir processing equipment, and simultaneously applying cooling rolling to the side wall of the additive body by using a cooling rolling device in the friction stir processing process; step 4, performing finish milling on the upper surface of the additive body for the next electric arc additive forming; and 5, circularly and repeatedly executing the steps until the final forming of the part is finished. The invention can completely break dendritic crystal growth and refine crystal grains in the process of Al-Mg-Si alloy additive forming, effectively repair defects such as air holes and cracks, and simultaneously prevent the additive body from overheating and microstructure coarsening caused by overheating by cooling in the process of wire electric arc additive manufacturing and modification, thereby greatly improving the mechanical properties, particularly the plasticity and the fatigue property of the additive body.
Description
Technical Field
The invention belongs to the technical field of metal additive manufacturing, and relates to an electric arc additive manufacturing method for a wire of an Al-Mg-Si alloy, in particular to an electric arc additive manufacturing method for a wire of an Al-Mg-Si alloy by using cooling rolling and stirring friction processing assistance.
Background
The Wire and Arc Additive manufacturing technology (WAAM) of metal Wire is an advanced manufacturing technology which adopts Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW) or Plasma Arc Welding (PAW) as a heat source, utilizes the principle of dispersion and accumulation, and adopts the addition of metal wires to build up a three-dimensional metal part layer by layer from a line-surface-body according to a three-dimensional digital model under the control of a program. Compared with the additive manufacturing technology taking laser and electron beams as heat sources, the method has the following advantages: 1) the deposition rate is high, the utilization rate of the wire is high, and the manufacturing cost is low; 2) materials with high laser reflectivity (such as aluminum alloy) can be formed; 3) the size of the manufactured part is not limited by the size of the equipment forming cylinder and the vacuum chamber, and the manufacture of large-size components is easy to realize.
The Al-Mg-Si alloy belongs to heat treatment strengthening medium-strength aluminum alloy, has the advantages of low density, high corrosion resistance, excellent formability and the like, and is an ideal material for manufacturing parts in high-speed trains, automobiles and ships. At present, the parts are usually manufactured by adopting a forging method, however, the forging process is complex, the production period is long, the material utilization rate is low, and the formed part has poor plastic shape, so that the research on the Al-Mg-Si alloy wire electric arc additive manufacturing technology which has high forming efficiency, low manufacturing cost and flexible manufacturing form has important practical significance. The weldability of a material often determines its suitability in the field of additive manufacturing technology, the better the weldability the more easily the material is subjected to melt-based metal additive manufacturing, and the more excellent the properties of the obtained additive component are. The Al-Mg-Si alloy has serious component segregation and high hot crack sensitivity in the solidification process, and easily has the defects of component segregation, welding cracks, air holes and the like during fusion welding, so that the Al-Mg-Si alloy is very challenging to be used for additive manufacturing based on fusion. Martin et al prepared an additive body with excellent properties by laser 3D printing using a Zr-containing 6061 aluminum alloy powder (see J.H.Martin.3D printing of high-strength aluminum alloys Nature, 2017, 549 (7672): 365.). However, the electric arc additive manufacturing technology of the Al-Mg-Si alloy wire is not reported at present. Therefore, the electric arc additive manufacturing technology of the Al-Mg-Si alloy wire is in need of breakthrough.
Friction Stir Processing (FSP) technology is a technology developed on the basis of Friction Stir Welding (FSW) for modifying microstructure of materials and preparing new materials. The basic principle of the method is similar to that of FSW, a stirring pin rotating at a high speed is pressed into the material, the processed material is subjected to severe plastic deformation, mixing and crushing under the strong stirring action of a stirring head, and the densification, homogenization and refinement of the microstructure of the material are realized, so that the performance of the material is improved. At present, the FSP technology has achieved good effects in the preparation of fine-grained/ultra-fine-grained materials and surface/block composite materials, the modification of the microstructure of heterogeneous materials, the local hardening/defect repair of workpieces, and the like. The advantages are embodied in the following aspects: (1) the crystal grains are refined, and the material performance is improved. In the friction stir processing process, under the composite condition of large strain and high temperature, the uniformly refined equiaxial crystal grains are obtained by dynamic recrystallization in the stirring area, and the mechanical property of the material is further improved. (2) The defects of the tissue structure of the material are eliminated, and a uniform and compact tissue structure is obtained. The cast aluminum alloy is subjected to stirring friction processing, coarse second-phase particles and aluminum dendrites of the cast alloy are crushed, casting pores are closed, matrix grains are refined, and the mechanical properties, particularly the plasticity and the fatigue property of the material are obviously improved. T.S.Mahmoud modifies eutectic A390 Al-Si alloy by FSP Technology, and research shows that casting shrinkage can be reduced by FSP Technology, and that the eutectic A390 Al-Si alloy has obvious refining effect on alpha-Al and Si particles (see T.S.Mahmoud, Surface modification of A390hypereutectic Al-Si cast alloy processing. Surface & Coatings Technology, 2013, 228 (9): 209-220.). In addition, it has been reported that the FSP treatment of the weld of a fusion welded joint can eliminate weld defects such as dendrite segregation, porosity, thermal cracking and the like of the weld by dynamically recrystallizing the weld, thereby improving the overall performance of the joint (see G.K. Paddy. front vibration based welding and processing technologies-processes, parameters, microstructures and applications: A view. journal of Materials Science & Technology, 2018, 34 (9): 1-38.). (3) And the residual stress of the structure is reduced. The FSP belongs to a solid processing technology, the heat input is low, and the thermal deformation and residual stress of the processed material are small.
In conclusion, if interlayer stirring friction processing modification is combined in the wire electric arc additive manufacturing process, not only is the microstructure refinement in the additive body facilitated, but also the defects of air holes, cracks and the like can be eliminated, the microstructure with compact structure and uniform chemical components is obtained, meanwhile, the thermal deformation can be reduced, the residual stress is reduced, and the mechanical property of the additive body is improved. When the additive body is modified by using a stirring friction processing method, the action area of a stirring pin is limited, the metal on the side wall of the additive body is difficult to treat, and the metal on the side wall still retains the casting structure characteristics; in addition, in the subsequent electric arc additive manufacturing or friction stir processing modification process of the deposited metal of which the front layer is modified by friction stir processing, the microstructure can be coarsened under the action of multiple thermal cycles, so that the performance of the additive is reduced.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides an Al-Mg-Si alloy wire electric arc additive manufacturing method, which adopts the following technical scheme:
an Al-Mg-Si alloy wire electric arc additive manufacturing method comprises the following steps:
the method comprises the following steps of 1, drawing a part model by using three-dimensional drawing software, carrying out layered slicing processing on the part model by using slicing software to obtain layered slicing data, carrying out simulation on the layered slicing data by using simulation software and optimizing a forming path to generate a robot control code, introducing the robot control code into a welding robot, carrying out Al-Mg-Si alloy wire electric arc additive forming on a prepared substrate by using the welding robot, co-depositing for 2-4 layers to form multilayer deposited metal, and applying cooling rolling to the side wall of the multilayer deposited metal by using a cooling rolling device in the forming process, wherein the temperature of cooling water in the cooling rolling process is 5-25 ℃, the flow of the cooling water is 500-2000L/h, and the rolling stress borne by the multilayer deposited metal is 40-200 MPa;
step 5, circularly and repeatedly executing the steps until the multilayer deposited metal reaches a preset shape and size, and obtaining an additive body;
the cooling rolling device comprises a roller, a heat-conducting cylinder body and a heat-conducting outer ring, the heat-conducting outer ring is rotatably assembled on the outer wall of the heat-conducting cylinder body, an inner cavity is formed in the heat-conducting cylinder body, a cooling water inlet communicated with the inner cavity is formed in the upper surface of the heat-conducting cylinder body, a cooling water outlet communicated with the inner cavity is formed in the lower surface of the heat-conducting cylinder body, the roller is vertically fixedly assembled in the center of the upper surface of the heat-conducting cylinder body, and the roller and a welding gun of a welding robot or a stirring head of friction stir processing equipment synchronously act.
In the step 1, the welding current used in the electric arc additive forming process is 60-280A, the welding voltage is 16.8-25.0V, the welding wire swing amplitude is 2.5-6.1 mm, the welding wire swing speed is 660-1500 mm/min, the forming speed is 150-400 mm/min, and the lifting height of each layer of welding gun is 0.8-2.6 mm.
The width of the multilayer deposited metal subjected to electric arc additive forming in the step 1 is 7-50 mm.
The multi-layer deposited metal in the step 1 is obtained by single-channel multi-layer deposition or multi-channel multi-layer deposition.
In the step 2, the milling amount of the side surface of the multilayer deposited metal is 0.1-0.5 mm, and the milling amount of the top surface is 0.3-2.2 mm.
And 3, the length of a pintle of a stirring head of the friction stir processing equipment is greater than the height of the multilayer deposited metal after washing and cutting, and the diameter of a shaft shoulder of the stirring head is slightly smaller than the width of the multilayer deposited metal after washing and cutting.
The diameter of a shaft shoulder of a stirring head adopted by the stirring friction processing equipment is 6-46 mm, the length of a stirring needle is 2-5 mm, the rotating speed of the stirring head is 400-2000 r/min, the advancing speed is 100-450 mm/min, and the inclination angle of the stirring head is 1.5-3 degrees.
The invention provides an auxiliary Al-Mg-Si alloy wire electric arc additive manufacturing method for cooling rolling and friction stir processing, wherein in the process of cooling rolling auxiliary electric arc additive forming of an Al-Mg-Si alloy, after 2-4 layers of Al-Mg-Si alloy are deposited, multilayer deposited metal is subjected to cooling rolling and friction stir processing modification;
the cooling rolling auxiliary electric arc additive forming means that in the process of depositing Al-Mg-Si alloy layer by electric arc, the side wall of the multilayer deposited metal is rolled and cooled by a cooling rolling device, so that the heat influence of the deposition process on the front layer metal is reduced, and the geometric dimension of the multilayer deposited metal can be controlled by rolling; in the process of cooling, rolling and friction stir processing modification of the deposited metal, a rolling device and a stirring head shaft shoulder are utilized to form a local cavity, so that a defect-free forged structure is formed by the multilayer deposited metal surrounded by the cavity under the action of a pressing roller and the stirring head, and meanwhile, the cooling device on the pressing roller can avoid the structure coarsening caused by overheating of a friction stir processing area and the front layer metal. Thereby obtaining the multi-layer deposited metal with excellent structure and further improving the mechanical property of the multi-layer deposited metal. In addition, the problem of poor dimensional accuracy and roughness of the additive manufacturing part can be solved.
Compared with the prior art, the method has obvious advantages in the aspects of improving the dimensional precision and the roughness of the component, and most importantly, the method can completely break dendritic crystal growth and grain refinement in the Al-Mg-Si alloy additive forming process, effectively repair defects such as air holes and cracks, and simultaneously prevent overheating and microstructure coarsening caused by overheating of multilayer deposited metal by cooling in the wire electric arc additive manufacturing and modification processes, thereby greatly improving the mechanical properties, particularly the plasticity and the fatigue property of the multilayer deposited metal. In addition, the cooling roller pressing device has higher flexibility, and is not only suitable for wire electric arc additive manufacturing of a straight-wall structural member, but also suitable for wire electric arc additive manufacturing of a curved-surface structural member.
Drawings
FIG. 1 is a schematic diagram of an electric arc additive forming process using chill roll assist according to the present invention;
FIG. 2 is a schematic cross-sectional view of a chill roll apparatus according to the present invention;
FIG. 3 is a schematic view of the milling of the side and top surfaces of a multilayer deposited metal of the present invention;
FIG. 4 is a schematic diagram of friction stir processing with the aid of chill roll application according to the present invention.
Wherein: a substrate 1; depositing a metal 2 in multiple layers; cooling the rolling device 3; a roller 31; a heat conductive cylinder 32; a heat conductive outer ring 33; an inner cavity 34; a cooling water inlet 35; a cooling water outlet 36; the balls 37; a stirring head 4; a welding gun 5; a milling cutter 6.
Detailed Description
It should be noted that all the directional indicators (such as up, down, left, right, front, and rear … …) in the embodiment of the present invention are only used to explain the relative position relationship between the components, the movement situation, etc. in a specific posture (as shown in the drawing), and if the specific posture is changed, the directional indicator is changed accordingly.
Example 1
As shown in fig. 1 to 4, the present embodiment provides
The 6061 aluminum alloy wire electric arc additive manufacturing method for the straight wall comprises the following steps:
Meanwhile, in the forming process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; the side wall of the multilayer deposited metal 2 is rolled and cooled by the cooling rolling device 3, which is beneficial to reducing the thermal influence of the deposition process on the front layer metal, and secondly, the geometric dimension of the multilayer deposited metal 2 can be controlled by the rolling action, the temperature of cooling water in the cooling rolling process is 10 ℃, the flow of the cooling water is 1500L/h, and the rolling stress of the multilayer deposited metal is 50 MPa.
2, milling the side surfaces and the top surfaces of the multilayer deposited metal 2 by using a milling cutter 6 of a milling robot; on one hand, in order to control the dimensional accuracy of the multilayer deposited metal 2 and on the other hand, a flat surface can be provided for the subsequent friction stir processing procedure to prevent the generation of friction stir processing defects, the milling amount of the two side surfaces of the multilayer deposited metal 2 is 0.2mm, the milling amount of the top surface is 1.5mm, and the milling amount, the feeding speed and other process parameters are set according to the accuracy required by the final part dimension in the milling process;
meanwhile, in the stirring friction processing process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; a rolling device and a shaft shoulder of a stirring head 4 are utilized to form a local cavity, so that a defect-free forged structure is formed by the multilayer deposited metal 2 surrounded by the cavity under the action of rolling and the stirring head 4, meanwhile, cooling water introduced into a cooling rolling device 3 can avoid a friction stir processing area and a thousand layers of metal from overheating to coarsen the structure, the temperature of the cooling water in the cooling rolling process is 10 ℃, the flow of the cooling water is 1500L/h, and the rolling stress borne by the multilayer deposited metal is 100 MPa.
and 5, circularly and repeatedly executing the steps until the multilayer deposited metal 2 reaches the preset shape and size, so as to obtain the additive body.
The cooling and rolling device 3 comprises a roller 31, a heat-conducting cylinder 32 and a heat-conducting outer ring 33, the heat-conducting outer ring 33 is rotatably assembled on the outer wall of the heat-conducting cylinder 32 through a ball 37, an inner cavity 34 is formed in the heat-conducting cylinder 32, a cooling water inlet 35 communicated with the inner cavity 34 is formed in the upper surface of the heat-conducting cylinder 32, a cooling water outlet 36 communicated with the inner cavity 34 is formed in the lower surface of the heat-conducting cylinder 32, the roller 31 is vertically and fixedly assembled in the center of the upper surface of the heat-conducting cylinder 32, and the roller 31 and a welding gun 5 of a welding robot or a stirring head 4 of a friction stir processing device synchronously act.
The heat-conducting cylinder 32 and the heat-conducting outer ring 33 can be made of metal material with good heat conductivity.
The area structure processed by the stirring friction processing consists of fine equiaxial grains, the defects of air holes, liquefied cracks and the like which are easily formed in the electric arc additive manufacturing process of common wire materials are eliminated, and the mechanical property of a formed body is improved. Table 1 shows comparative data of mechanical properties of 6061 aluminum alloy thin-wall formed by cooling, rolling, friction stir processing, auxiliary arc additive forming, common arc additive forming, and forging.
TABLE 1
Example 2
The embodiment provides
The 6082 aluminum alloy wire electric arc additive manufacturing method for the straight wall comprises the following steps:
step 1, performing electric arc additive forming by using cooling rolling assistance: drawing a straight wall model with the size of 350mm (length) × 100mm (height) × 42mm (width) by using three-dimensional drawing software, carrying out layered slicing processing on a part model by using slicing software to obtain layered slicing data, carrying out simulation on the layered slicing data by using simulation software and optimizing a forming path to generate a robot control code (or a numerical control code), introducing the robot control code into a welding robot, using the welding robot and an electric arc generated by an MIG (metal inert gas) welding machine as a heat source, carrying out electric arc additive forming on 6082 aluminum alloy wire materials on a T-shaped substrate 1 prepared in advance to form a plurality of layers of deposited metals 2, and co-depositing 2 layers, wherein the width of the formed plurality of layers of deposited metals 2 is 42mm, and the plurality of layers of deposited metals are obtained by multi-channel multi-layer deposition; the welding current used in the electric arc additive forming process is 200A, the welding voltage is 23.8V, the forming speed is 232mm/min, the lifting height is 1.5mm, the welding wire swing amplitude is 3mm, and the swing speed is 980 mm/min.
Meanwhile, in the forming process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; the side wall of the multilayer deposited metal 2 is rolled and cooled by the cooling rolling device 3, which is beneficial to reducing the thermal influence of the deposition process on the front layer metal, and secondly, the geometric dimension of the multilayer deposited metal 2 can be controlled by the rolling action, the temperature of cooling water in the cooling rolling process is 10 ℃, the flow of the cooling water is 1500L/h, and the rolling stress of the multilayer deposited metal is 150 MPa.
2, milling the side surfaces and the top surfaces of the multilayer deposited metal 2 by using a milling cutter 6 of a milling robot; on one hand, in order to control the dimensional accuracy of the multilayer deposited metal 2 and on the other hand, a flat surface can be provided for the subsequent friction stir processing procedure to prevent the generation of friction stir processing defects, the milling amount of the two side surfaces of the multilayer deposited metal 2 is 0.3mm, the milling amount of the top surface is 2.2mm, and the milling amount, the feeding speed and other process parameters are set according to the accuracy required by the final part dimension in the milling process;
meanwhile, in the stirring friction processing process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; a rolling device and a shaft shoulder of a stirring head 4 are utilized to form a local cavity, so that a defect-free forged structure is formed by the multilayer deposited metal 2 surrounded by the cavity under the action of rolling and the stirring head 4, meanwhile, cooling water introduced into a cooling rolling device 3 can avoid a friction stir processing area and a thousand layers of metal from overheating to coarsen the structure, the temperature of the cooling water in the cooling rolling process is 10 ℃, the flow of the cooling water is 1500L/h, and the rolling stress borne by the multilayer deposited metal is 300 MPa.
And 4, carrying out finish milling on the upper surface of the multilayer deposited metal 2 by 0.5mm by using a milling cutter 6 of a milling robot or a milling machine tool to flatten the processed surface for the next electric arc additive forming step.
And 5, circularly and repeatedly executing the steps until the multilayer deposited metal 2 reaches the preset shape and size.
The cooling and rolling device 3 comprises a roller 31, a heat-conducting cylinder 32 and a heat-conducting outer ring 33, the heat-conducting outer ring 33 is rotatably assembled on the outer wall of the heat-conducting cylinder 32 through a ball 37, an inner cavity 34 is formed in the heat-conducting cylinder 32, a cooling water inlet 35 communicated with the inner cavity 34 is formed in the upper surface of the heat-conducting cylinder 32, a cooling water outlet 36 communicated with the inner cavity 34 is formed in the lower surface of the heat-conducting cylinder 32, the roller 31 is vertically and fixedly assembled in the center of the upper surface of the heat-conducting cylinder 32, and the roller 31 and a welding gun 5 of a welding robot or a stirring head 4 of a friction stir processing device synchronously act.
The heat-conducting cylinder 32 and the heat-conducting outer ring 33 can be made of metal material with good heat conductivity.
The area structure processed by cooling rolling and stirring friction processing consists of fine equiaxial grains, and the defects of air holes, liquefied cracks and the like which are easily formed in the electric arc additive manufacturing process of common wire materials are eliminated, so that the mechanical property of a formed body is improved. Table 2 shows the comparison data of mechanical properties of 6082 aluminum alloy thin-wall formed by cooling, rolling, friction stir processing, auxiliary arc additive forming, common arc additive forming, and forging.
TABLE 2
Example 3
The embodiment provides
The 6061 aluminum alloy wire electric arc additive manufacturing method for the straight wall comprises the following steps:
step 1, performing electric arc additive forming by using cooling rolling assistance: drawing a straight wall model with the size of 350mm (length) × 100mm (height) × 7mm (width) by using three-dimensional drawing software, carrying out layered slicing processing on a part model by using slicing software to obtain layered slicing data, carrying out simulation on the layered slicing data by using simulation software and optimizing a forming path to generate a robot control code (or a numerical control code), introducing the robot control code into a welding robot, carrying out electric arc additive forming on 6061 aluminum alloy wire material on a T-shaped substrate 1 prepared in advance by using the welding robot and an electric arc generated by an MIG (metal inert gas welding) welder as a heat source, co-depositing 2-4 layers to form multilayer deposited metal 2, wherein the width of the formed multilayer deposited metal 2 is 7mm, and the multilayer deposited metal 2 is obtained by single-pass multilayer deposition; the welding current used in the electric arc additive forming process is 60A, the welding voltage is 16.8V, the forming speed is 150mm/min, the lifting height of each layer of welding gun is 0.8mm, the welding wire swing amplitude is 2.5mm, and the welding wire swing speed is 660 mm/min.
Meanwhile, in the forming process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; the side wall of the multilayer deposited metal 2 is rolled and cooled by the cooling rolling device 3, which is beneficial to reducing the thermal influence of the deposition process on the front layer metal, and secondly, the geometric dimension of the multilayer deposited metal 2 can be controlled by the rolling action, the temperature of cooling water in the cooling rolling process is 25 ℃, the flow of the cooling water is 2000L/h, and the rolling stress of the multilayer deposited metal is 60 MPa.
2, milling the side surfaces and the top surfaces of the multilayer deposited metal 2 by using a milling cutter 6 of a milling robot; on one hand, in order to control the dimensional accuracy of the multilayer deposited metal 2 and on the other hand, a flat surface can be provided for the subsequent friction stir processing procedure to prevent the generation of friction stir processing defects, the milling amount of the two side surfaces of the multilayer deposited metal 2 is 0.3mm, the milling amount of the top surface is 0.5mm, and the milling amount, the feeding speed and other process parameters are set according to the accuracy required by the final part dimension in the milling process;
meanwhile, in the stirring friction processing process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; a rolling device and a shaft shoulder of a stirring head 4 are utilized to form a local cavity, so that a defect-free forged structure is formed by the multilayer deposited metal 2 surrounded by the cavity under the action of rolling and the stirring head 4, meanwhile, cooling water introduced into a cooling rolling device 3 can avoid a friction stir processing area and a thousand layers of metal from overheating to coarsen the structure, the temperature of the cooling water in the cooling rolling process is 5 ℃, the flow of the cooling water is 500L/h, and the rolling stress borne by the multilayer deposited metal is 150 MPa.
and 5, circularly and repeatedly executing the steps until the multilayer deposited metal 2 reaches the preset shape and size, so as to obtain the additive body.
The cooling and rolling device 3 comprises a roller 31, a heat-conducting cylinder 32 and a heat-conducting outer ring 33, the heat-conducting outer ring 33 is rotatably assembled on the outer wall of the heat-conducting cylinder 32 through a ball 37, an inner cavity 34 is formed in the heat-conducting cylinder 32, a cooling water inlet 35 communicated with the inner cavity 34 is formed in the upper surface of the heat-conducting cylinder 32, a cooling water outlet 36 communicated with the inner cavity 34 is formed in the lower surface of the heat-conducting cylinder 32, the roller 31 is vertically and fixedly assembled in the center of the upper surface of the heat-conducting cylinder 32, and the roller 31 and a welding gun 5 of a welding robot or a stirring head 4 of a friction stir processing device synchronously act.
The heat-conducting cylinder 32 and the heat-conducting outer ring 33 can be made of metal material with good heat conductivity.
Example 4
The embodiment provides
The 6082 aluminum alloy wire electric arc additive manufacturing method for the straight wall comprises the following steps:
step 1, performing electric arc additive forming by using cooling rolling assistance: drawing a straight wall model with the dimension of 350mm (length) × 100mm (height) × 50mm (width) by using three-dimensional drawing software, carrying out layered slicing processing on a part model by using slicing software to obtain layered slicing data, carrying out simulation on the layered slicing data by using simulation software and optimizing a forming path to generate a robot control code (or a numerical control code), introducing the robot control code into a welding robot, carrying out electric arc additive forming on 6082 aluminum alloy wire electric arc on a T-shaped substrate 1 prepared in advance by using the welding robot and an electric arc generated by an MIG (metal inert gas welding) welder as a heat source to form a plurality of layers of deposited metal 2, and co-depositing 2 layers of the deposited metal 2, wherein the width of the formed plurality of layers of deposited metal 2 is 50mm, and the plurality of layers of deposited metal are obtained by multi-channel multi-layer deposition; the welding current used in the electric arc additive forming process is 280A, the welding voltage is 25.0V, the forming speed is 400mm/min, the lifting height is 2.5mm, the welding wire swing amplitude is 6mm, and the swing speed is 600 mm/min.
Meanwhile, in the forming process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; the side wall of the multilayer deposited metal 2 is rolled and cooled by the cooling rolling device 3, which is beneficial to reducing the thermal influence of the deposition process on the front layer metal, and secondly, the geometric dimension of the multilayer deposited metal 2 can be controlled by the rolling action, the temperature of cooling water in the cooling rolling process is 10 ℃, the flow of the cooling water is 1500L/h, and the rolling stress of the multilayer deposited metal is 200 MPa.
2, milling the side surfaces and the top surfaces of the multilayer deposited metal 2 by using a milling cutter 6 of a milling robot; on one hand, in order to control the dimensional accuracy of the multilayer deposited metal 2 and on the other hand, a flat surface can be provided for the subsequent friction stir processing procedure to prevent the generation of friction stir processing defects, the milling amount of the two side surfaces of the multilayer deposited metal 2 is 0.5mm, the milling amount of the top surface is 2mm, and the milling amount, the feeding speed and other process parameters are set according to the accuracy required by the final part dimension in the milling process;
meanwhile, in the stirring friction processing process, a cooling rolling device 3 is used for applying cooling rolling to the side wall of the multilayer deposited metal 2; a rolling device and a shaft shoulder of a stirring head 4 are utilized to form a local cavity, so that a defect-free forged structure is formed by the multilayer deposited metal 2 surrounded by the cavity under the action of rolling and the stirring head 4, meanwhile, cooling water introduced into a cooling rolling device 3 can avoid the structure coarsening caused by the overheating of a friction stir processing area and a thousand layers of metal, the temperature of the cooling water in the cooling rolling process is 10 ℃, the flow of the cooling water is 1500L/h, and the rolling stress borne by the multilayer deposited metal is 400 MPa.
And 4, carrying out finish milling on the upper surface of the multilayer deposited metal 2 by 0.5mm by using a milling cutter 6 of a milling robot or a milling machine tool to flatten the processed surface for the next electric arc additive forming step.
And 5, circularly and repeatedly executing the steps until the multilayer deposited metal 2 reaches the preset shape and size.
The cooling and rolling device 3 comprises a roller 31, a heat-conducting cylinder 32 and a heat-conducting outer ring 33, the heat-conducting outer ring 33 is rotatably assembled on the outer wall of the heat-conducting cylinder 32 through a ball 37, an inner cavity 34 is formed in the heat-conducting cylinder 32, a cooling water inlet 35 communicated with the inner cavity 34 is formed in the upper surface of the heat-conducting cylinder 32, a cooling water outlet 36 communicated with the inner cavity 34 is formed in the lower surface of the heat-conducting cylinder 32, the roller 31 is vertically and fixedly assembled in the center of the upper surface of the heat-conducting cylinder 32, and the roller 31 and a welding gun 5 of a welding robot or a stirring head 4 of a friction stir processing device synchronously act.
The heat-conducting cylinder 32 and the heat-conducting outer ring 33 can be made of metal material with good heat conductivity.
The invention has the advantages that in the wire electric arc additive manufacturing and the stirring friction modification process, the cooling rolling device is used for cooling to prevent the multilayer deposited metal from overheating and coarsening the microstructure caused by overheating, the mechanical property of the multilayer deposited metal is greatly improved, and the purpose of controlling the geometric dimension of the multilayer deposited metal is realized by the cooling rolling device.
The above examples are only for illustrating the technical solutions of the present invention and not for limiting the same, and although the present invention is described in detail with reference to the above examples, those of ordinary skill in the art should understand that: similar technical approaches can be derived from the solutions given in the figures and examples, as described above. For the method of utilizing MIG, TIG or PAW welder to generate electric arc as heat source, adopting Al-Mg-Si alloy wires with different diameters and different alloy element contents as filling metal, during the additive forming process, the method of interlayer cooling rolling and friction stir processing can be utilized to eliminate the defects of pores, liquefied phases, cracks and the like of deposited metal, and refine the structure, thereby improving the performance.
Claims (5)
1. An electric arc additive manufacturing method for a wire of an Al-Mg-Si alloy is characterized by comprising the following steps:
the method comprises the following steps of 1, drawing a part model by using three-dimensional drawing software, carrying out layered slicing processing on the part model by using slicing software to obtain layered slicing data, carrying out simulation on the layered slicing data by using simulation software to generate a robot control code, introducing the robot control code into a welding robot, carrying out Al-Mg-Si alloy wire electric arc additive forming on a substrate prepared in advance by using the welding robot, co-depositing 2-4 layers to form a multilayer deposited metal, applying cooling rolling on the side wall of the multilayer deposited metal by using a cooling rolling device in the forming process to help to reduce the heat influence of the depositing process on the front layer metal, wherein the temperature of cooling water in the cooling rolling process is 5-25 ℃, the flow of the cooling water is 500-2000L/h, and the rolling stress of the multilayer deposited metal is 40-200 MPa;
step 2, milling the side surfaces and the top surfaces of the multilayer deposited metal;
step 3, performing friction stir processing on the milled multilayer deposited metal by using friction stir processing equipment, applying cooling rolling to the side wall of the multilayer deposited metal by using a cooling rolling device in the friction stir processing process, forming a local cavity by using the cooling rolling device and a stirring head shaft shoulder of the friction stir processing equipment, wherein the temperature of cooling water in the cooling rolling process is 5-25 ℃, the flow rate of the cooling water is 500-2000L/h, and the rolling stress borne by the multilayer deposited metal is 50-400 MPa; the length of a pintle of a stirring head of the stirring friction processing equipment is greater than the height of the multilayer deposited metal after washing and cutting, and the diameter of a shaft shoulder of the stirring head is smaller than the width of the multilayer deposited metal after washing and cutting; the diameter of a shaft shoulder of a stirring head adopted by the stirring friction processing equipment is 6-46 mm, the length of a stirring needle is 2-5 mm, the rotating speed of the stirring head is 400-2000 r/min, the advancing speed is 100-450 mm/min, and the inclination angle of the stirring head is 1.5-3 degrees;
step 4, performing finish milling on the upper surface of the multilayer deposited metal to enable the processed surface to be flat for the next electric arc additive forming;
step 5, circularly and repeatedly executing the steps until the multilayer deposited metal reaches a preset shape and size, and obtaining an additive body;
the cooling rolling device comprises a roller, a heat-conducting cylinder body and a heat-conducting outer ring, the heat-conducting outer ring is rotatably assembled on the outer wall of the heat-conducting cylinder body, an inner cavity is formed in the heat-conducting cylinder body, a cooling water inlet communicated with the inner cavity is formed in the upper surface of the heat-conducting cylinder body, a cooling water outlet communicated with the inner cavity is formed in the lower surface of the heat-conducting cylinder body, the roller is vertically fixedly assembled in the center of the upper surface of the heat-conducting cylinder body, and the roller and a welding gun of a welding robot or a stirring head of friction stir processing equipment synchronously act.
2. The electric arc additive manufacturing method for the Al-Mg-Si alloy wire according to claim 1, wherein the width of the multi-layer deposited metal subjected to electric arc additive forming in the step 1 is 7-50 mm.
3. The electric arc additive manufacturing method for Al-Mg-Si alloy wires according to claim 1, wherein the multi-layer deposited metal in step 1 is obtained by single-pass multi-layer deposition or multi-pass multi-layer deposition.
4. The electric arc additive manufacturing method for the wire of the Al-Mg-Si alloy according to claim 1, wherein the welding current used in the electric arc additive forming process in the step 1 is 60-280A, the welding voltage is 16.8-25.0V, the swing amplitude of the welding wire is 2.5-6.1 mm, the swing speed of the welding wire is 660-1500 mm/min, the forming speed is 150-400 mm/min, and the lifting height of each layer of welding gun is 0.8-2.6 mm.
5. The electric arc additive manufacturing method for the Al-Mg-Si alloy wire according to claim 1, wherein the milling amount of the side surface of the multi-layer deposited metal in the step 2 is 0.1-0.5 mm, and the milling amount of the top surface is 0.3-2.2 mm.
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