CN112139636A - Magnesium alloy activation TIG electric arc additive manufacturing system and method - Google Patents
Magnesium alloy activation TIG electric arc additive manufacturing system and method Download PDFInfo
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- CN112139636A CN112139636A CN202010916800.3A CN202010916800A CN112139636A CN 112139636 A CN112139636 A CN 112139636A CN 202010916800 A CN202010916800 A CN 202010916800A CN 112139636 A CN112139636 A CN 112139636A
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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
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
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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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/003—Cooling means
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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
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
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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
- B23K9/32—Accessories
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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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/08—Non-ferrous metals or alloys
- B23K2103/15—Magnesium or alloys thereof
Abstract
The invention belongs to the field of electric arc additive manufacturing, and particularly relates to a magnesium alloy activation TIG electric arc additive manufacturing system and method. Selecting a pulse alternating current working mode for the TIG welding machine, coating a layer of active agent doped with a nano enhanced phase on a designated position by using a brush before arc striking, moving a welding robot after arc striking, controlling the TIG arc form by using the active agent, and stacking the magnesium alloy welding wire along an additive track; raising a welding gun by one layer height in the height direction, reducing the temperature of the topmost layer of the magnesium alloy additive part to 50-60 ℃, coating a layer of active agent on the additive position of the next layer by using a brush, and melting and accumulating the next layer after the welding gun arcs; and finishing the deposition stacking of the workpieces. According to the invention, the active agent is used for changing the TIG arc form, increasing the additive melting depth and improving the interlayer fusion of the magnesium alloy arc additive; meanwhile, the nano reinforcing phase independently exists in the magnesium alloy matrix, so that the effects of refining crystal grains, reducing the precipitation of a second phase and improving the mechanical property of the additive component can be achieved.
Description
Technical Field
The invention belongs to the field of electric arc additive manufacturing, and particularly relates to a magnesium alloy activation TIG electric arc additive manufacturing system and method.
Background
In recent years, more and more industries propose a development direction for reducing energy consumption and improving effective load, which is not necessary to reduce the weight of materials. Magnesium alloys have a small density, a high specific strength, a good heat conductivity, and good absorption of vibration and impact, and are the lightest structural materials, and therefore, they are ideal materials for lightweight design. However, the crystal structure of the magnesium alloy is Hexagonal Close Packing (HCP), and the crystal has poor plastic deformability and limited deformation, which results in poor cold workability at room temperature. Compared with the traditional material reduction and equal-material manufacturing technology, the additive manufacturing has the advantages of unlimited shape, short forming period and the like, so the industry starts to pay attention to the magnesium alloy additive manufacturing technology.
The prior magnesium alloy additive manufacturing technology mainly comprises selective laser melting, rapid investment casting and electric arc additive manufacturing. In the existing research on laser additive manufacturing of magnesium alloy, the research on laser process parameters is focused on laser process parameters, several process parameters are determined by controlling a variable method, one or more other process parameters are changed, and the research on the several process parameters is achieved by observing phenomena in the processing process and researching the performance of a formed sample. The main problems of the magnesium alloy manufactured by the laser additive are that the magnesium alloy has large reflectivity to laser and the additive energy utilization rate is low. The traditional meaning of rapid investment casting does not belong to the field of additive manufacturing, but in recent years, some manufacturers introduce additive manufacturing technology in the investment manufacturing link, so that the manufacturing period is greatly shortened. The investment casting and the antigravity casting technology are combined, and the method is hopeful to be applied to the precise forming of large, complex and thin-wall magnesium alloy components, greatly reduces the machining allowance, and improves the surface quality and the dimensional precision of the components.
Compared with the former two additive methods, the magnesium alloy electric arc additive still is in a starting stage, but the electric arc additive has the advantages of high efficiency, low cost and the like. Compared with selective laser melting, the electric arc additive adopts wire materials as additive filling materials, and compared with magnesium alloy powder adopted by laser additive, the electric arc additive is safer, and the magnesium alloy powder is easy to generate dust explosion under the condition of improper treatment. Compared with the rapid investment casting, the electric arc additive manufacturing can be carried out point by point layer by layer, the material components of each layer are more uniform, and the material structure capable of additive manufacturing is not limited.
The whole magnesium alloy electric arc additive manufacturing technology is still in a starting stage and has more problems. In the thesis of influence of current on forming and structure performance of AZ31 magnesium alloy in electric arc additive manufacturing (DOI: 10.16410/j. issn1000-8365.2018.10.037), Schhan super et al performed magnesium alloy TIG electric arc additive manufacturing experiments and studied the influence of the magnitude of current on the quality of electric arc additive forming of AZ31 magnesium alloy. The electric arc additive manufacturing technology can realize the rapid forming of the magnesium alloy, the problems that the energy utilization rate of the magnesium alloy is low, the dust of the magnesium alloy is flammable and explosive and the like which are difficult to solve when the magnesium alloy is melted in a laser selection area do not exist, but the problem that the melting depth of a magnesium alloy coating layer is shallow exists, which is mainly because the heat dissipation performance of the magnesium alloy is good, the heat is rapidly transferred on a substrate, and the heat loss is serious. The shallow penetration has an influence on the mechanical properties of the magnesium alloy additive component. The melting depth can be increased to a certain extent by adopting large current for additive manufacturing, but the grain size of the magnesium alloy additive manufacturing component is increased, and the mechanical property of the material is also adversely affected by the large grain size. In order to solve these problems, an arc additive manufacturing method capable of increasing the penetration depth and refining the crystal grains is required.
In addition, in recent years, a metal matrix composite material reinforced with particles using a magnesium alloy as a matrix has been gaining increasing attention in the industry. Lower density than the corresponding aluminum matrix composite. The preparation process is similar to that of the particle reinforced aluminum matrix composite. Mainly comprises the processes of stirring and compounding, powder metallurgy, pressure infiltration and jet codeposition.
Disclosure of Invention
The invention aims to provide a magnesium alloy activation TIG arc additive manufacturing system and a method.
The technical solution for realizing the purpose of the invention is as follows: a magnesium alloy activation TIG electric arc additive manufacturing system comprises a wire feeder, an alternating current TIG welding machine, a magnesium alloy substrate, a workbench, a TIG welding gun and an industrial robot; the device also comprises a cooling device, an active agent coating mechanism and an infrared temperature sensor;
the cooling device is used for cooling the topmost layer of the magnesium alloy additive part;
the active agent coating mechanism is used for coating a layer of active agent doped with a nano enhanced phase on a region to be additively processed;
the infrared temperature sensor is used for detecting the temperature of the topmost additive layer.
Further, the cooling device is a water cooling device, and the water cooling device is arranged below the magnesium alloy substrate;
the active agent coating mechanism is a brush.
Before starting arc, coating a layer of active agent doped with nano enhanced phase on a to-be-added area, after starting arc, moving a welding robot according to a planned track, and controlling a TIG arc form through the active agent; reducing the temperature of the topmost layer of the additive to 50-60 ℃, coating a layer of active agent doped with a nano enhanced phase on the additive position of the next layer, and performing fusion accumulation on the next layer after the arc of a welding gun; and repeating the steps to finish the additive manufacturing of the workpiece.
The method specifically comprises the following steps:
s1: cleaning the surface of the substrate by using a grinding machine, cleaning the substrate by using acetone to remove oil stains, and opening a protective gas cylinder;
s2: mixing the nanometer reinforcing phase into an active agent, wherein the liquid of the active agent adopts absolute ethyl alcohol, the absolute ethyl alcohol is filled with active agent particles and the nanometer reinforcing phase with required amount according to the performance requirement of the material increase structural part, and the component ratio of the active agent particles to the nanometer reinforcing phase is m1：m2＝α：β；
S3: slicing and layering the three-dimensional solid part model drawing, and then guiding the sliced and layered three-dimensional solid part model drawing into a control system, wherein the control system calculates and generates a walking track of the welding robot according to slicing and layering;
s4: cooling the material increase structural part by using a water cooling device below the material increase substrate, and detecting that the temperature of the topmost layer of the material increase structural part is reduced to 50-60 ℃ by using an infrared temperature sensor;
s5: coating the active agent on the surface of the walking track of the welding robot by using a brush, wherein the coating density is gamma mg/cm2Starting a welding robot, setting a TIG welding machine to be in a pulse alternating current working mode, pre-feeding gas for 1S, moving the welding robot according to a preset track after the welding robot starts to arc, changing the arc shape by an active agent, accumulating the molten magnesium alloy welding wire at a specified position, and simultaneously controlling a wire feeding mechanism to feed the welding wire into a molten area according to a specified speed by a control system;
s6: raising the welding gun by one layer height in the height direction, and then performing fusion stacking of the next layer according to the step S5;
s7: repeating the step S6, completing the deposition and stacking of the magnesium alloy additive component, stopping the movement of the welding gun, and simultaneously performing arc quenching and stopping the wire feeding of the wire feeding mechanism;
s8: after the completion of step S7, the gas supply was stopped after a delay of 1S by the shielding gas, and after the welding torch was moved to the safe position, the magnesium alloy activated TIG arc additive manufacturing was completed.
Further, the component ratio of the active agent particles to the nano reinforcing phase is m 1: m2 ═ α: beta is 0.5-2;
the coating density is 2-6 mg/cm 2.
Further, the alternating current of the welding machine is 80-140A, and the frequency of the alternating current is 400 Hz;
the pulse frequency of the welding machine is 5-20 Hz, the ratio of the pulse peak value is 30-60%, and the ratio of the base value current to the peak value current is 30-60%.
Further, the wire feeding speed of the wire feeder is 1-3 m/min, and the material increase speed of the welding gun is 2-7 mm/s.
Further, the shielding gas used in the arc additive manufacturing process is argon.
Further, the active agent particles used are oxides, chlorides and fluorides, preferably TiO2, CaO, SiO2, ZrO2 and NaCl.
Furthermore, the adopted nano reinforcing phase is SiC particles with the particle size of 50-200 nm, graphene sheets with the thickness of 10-20 nm or carbon fibers with the diameter of 50-200 nm.
Compared with the prior art, the invention has the remarkable advantages that:
1. the magnesium alloy activation TIG electric arc additive manufacturing method of the invention utilizes the activator to change the electric arc form, increase the melting depth of the melting pool and improve the interlayer fusion of the magnesium alloy additive component.
2. The magnesium alloy activation TIG electric arc additive manufacturing method has the advantages that the range of the selected active agents is wide, the proper active agent components are selected, and the alloy elements burnt in the additive process can be supplemented.
3. The magnesium alloy activation TIG electric arc additive manufacturing method provided by the invention utilizes the nanometer reinforcing phase as a nucleation core, and plays a role in refining crystal grains and inhibiting the precipitation of a second phase.
4. The magnesium alloy activation TIG electric arc additive manufacturing method provided by the invention utilizes metal liquid flow driving and electromagnetic force to stir the nano enhanced phase, so that the nano enhanced phase is uniformly distributed in the magnesium alloy additive component.
5. According to the magnesium alloy activation TIG electric arc additive manufacturing method, a water cooling device is used for rapidly cooling after additive manufacturing of each layer is finished, and the temperature of an additive component is controlled. On the other hand, the forming quality of the additive component is ensured, if the interlayer temperature is too high, the magnesium alloy is easy to collapse at the edge of the component, and the forming quality is reduced.
Drawings
Fig. 1 is a schematic view of a magnesium alloy activation TIG arc additive manufacturing device.
FIG. 2 is a schematic diagram of a magnesium alloy activation TIG arc additive manufacturing device coating active agent.
Description of reference numerals:
1-wire feeder, 2-alternating current TIG welding machine, 3-magnesium alloy welding wire, 4-magnesium alloy substrate, 5-water cooling device, 6-workbench, 7-TIG welding gun, 8-industrial robot, 9-protective gas cylinder, 10-brush, 11-infrared temperature sensor and 12-material increasing component.
Detailed Description
The present invention is described in further detail below with reference to the attached drawing figures.
The device shown in figure 1 is used for additive manufacturing, and the active TIG electric arc additive manufacturing equipment comprises a wire feeder 1, an alternating current TIG welding machine 2, a water cooling device 5, a workbench 6, a TIG welding gun 7, an industrial robot 8, a protective gas cylinder 9, a brush 10 and an infrared temperature sensor 11. The components of the magnesium alloy welding wire 3, namely the material for electric arc additive manufacturing, can be adjusted according to the performance requirements of the additive structural part, and the additive substrate is selected from the materials with the same components as the welding wire.
Send a machine 1 to place and link to each other with industrial robot 8 on exchanging TIG welding machine 2 power, can control wire feed speed, and the blast pipe that protective gas bottle 9 set up on through industrial robot 8 links to each other with TIG welder 7 of the terminal centre gripping of robot, for the vibration material disk process provides the shielding gas, prevents that the magnesium alloy molten drop from by the oxidation, and the shielding gas of adoption is argon gas.
The infrared temperature sensor 11 is a handheld device, and a worker aligns the sensor 11 with the uppermost layer of the additive component to acquire real-time temperature information. The water cooling device 5 is arranged below the magnesium alloy substrate 4, and takes away heat through the circulating flow of cooling liquid in the water pipe, so that the additive component is rapidly cooled. The brush 10 is a hand-held device and is operated as shown in figure 2, with the active agent applied to the area where the next layer of additive track is expected to pass, and the amount of the active agent applied can be adjusted by the operator based on the properties of the additive structure.
The active agent is coated on the surface of the component to contract the TIG electric arc, so that the energy density of the electric arc is increased, the electric arc force is increased, the additive melting depth is increased, and the interlayer fusion of the magnesium alloy additive component is improved; the nano reinforcing phase is doped in the active agent, and is finally and uniformly dispersed in the molten pool under the combined action of metal liquid flow driving and electromagnetic force stirring in the molten pool. The nanometer reinforcing phase can become a nucleation core, and plays a role in refining crystal grains and inhibiting the precipitation of a second phase, so that the mechanical property of the magnesium alloy welding joint is greatly improved.
Example 1
Selecting a welding wire of AZ31 magnesium alloy, wherein the diameter of the welding wire is 1.2 mm; a5 mm thick AZ31B magnesium alloy substrate is taken as an example for additive straight wall. The method comprises the following specific steps:
s1: cleaning the surface of the substrate by using a grinding machine, cleaning the substrate by using acetone to remove oil stains, and opening a protective gas cylinder, wherein the flow of protective gas is 20L/min;
s2: determining additive process parameters, wherein the wire feeding speed is set to be 1.2m/min and the welding speed is set to be 5mm/s in the example;
s3: setting the alternating current of the welding machine to be 120A and the alternating current frequency to be 400 Hz;
s4: setting the pulse frequency of a welding machine to be 5Hz, the pulse peak value ratio to be 30 percent, and the ratio of the base value current to the peak value current to be 40 percent;
s5: mixing the nano reinforcing phase into active agent, using absolute ethyl alcohol as active agent liquid, and using ZrO as active agent granules2The nano reinforcing phase is nano SiC particles. ZrO by using absolute ethyl alcohol2And uniformly mixing with the nano SiC particles. ZrO (ZrO)2Taking 40g of particles, and taking 60g of nano SiC particles;
s6: slicing and layering the three-dimensional solid part model drawing, and then guiding the sliced and layered three-dimensional solid part model drawing into a control system, wherein the control system calculates and generates a walking track of the welding robot according to slicing and layering;
s7: coating the active agent on the surface of the walking track of the welding robot by using a brush, wherein the coating density is 5mg/cm2Starting a welding robot, setting a TIG welding machine to be in a pulse alternating current working mode, pre-feeding gas 1S, linearly moving the welding robot along the X direction according to a preset track after the welding robot arcs, changing the shape of an electric arc by an active agent, and extinguishing the arc at the tail end of a welding line after one-pass material increase is completed;
s8: translating the welding gun in the Y-axis direction by 10mm, waiting for a water cooling device to rapidly cool the additive component, and determining that the temperature of the topmost layer of the additive component is reduced to 60 ℃ by using an infrared temperature sensor;
s9: repeating the step S8, completing the deposition and stacking of the magnesium alloy additive component, stopping the movement of the welding gun, and simultaneously performing arc quenching and stopping the wire feeding of the wire feeding mechanism;
s10: after the completion of step S9, the gas supply was stopped after a delay of 1S by the shielding gas, and after the welding torch was moved to the safe position, the magnesium alloy activated TIG arc additive manufacturing was completed.
Claims (10)
1. A magnesium alloy activation TIG electric arc additive manufacturing system comprises a wire feeder (1), an alternating current TIG welding machine (2), a magnesium alloy substrate (4), a workbench (6), a TIG welding gun (7) and an industrial robot (8); the device is characterized by also comprising a cooling device, an active agent coating mechanism and an infrared temperature sensor (11);
the cooling device is used for cooling the topmost layer of the magnesium alloy additive part;
the active agent coating mechanism is used for coating a layer of active agent doped with a nano enhanced phase on a region to be additively processed;
the infrared temperature sensor (11) is used for detecting the temperature of the topmost additive layer.
2. The system according to claim 1, wherein the cooling device is a water cooling device (5), and the water cooling device (5) is arranged below the magnesium alloy substrate (4);
the active agent coating mechanism is a brush.
3. A method of additive manufacturing using the system of any of claims 1-2, wherein prior to arcing, a layer of nanoenhanced phase doped active agent is applied to the area to be additized, and after arcing, the welding robot moves in a planned trajectory, controlling the TIG arc morphology via the active agent; reducing the temperature of the topmost layer of the additive to 50-60 ℃, coating a layer of active agent doped with a nano enhanced phase on the additive position of the next layer, and performing fusion accumulation on the next layer after the arc of a welding gun; and repeating the steps to finish the additive manufacturing of the workpiece.
4. The method according to claim 3, characterized in that it comprises in particular the steps of:
s1: cleaning the surface of the substrate by using a grinding machine, cleaning the substrate by using acetone to remove oil stains, and opening a protective gas cylinder;
s2: mixing the nanometer reinforcing phase into an active agent, wherein the liquid of the active agent adopts absolute ethyl alcohol, the absolute ethyl alcohol is filled with active agent particles and the nanometer reinforcing phase with required amount according to the performance requirement of the material increase structural part, and the component ratio of the active agent particles to the nanometer reinforcing phase is m1：m2＝α：β；
S3: slicing and layering the three-dimensional solid part model drawing, and then guiding the sliced and layered three-dimensional solid part model drawing into a control system, wherein the control system calculates and generates a walking track of the welding robot according to slicing and layering;
s4: cooling the material increase structural part by using a water cooling device below the material increase substrate, and detecting that the temperature of the topmost layer of the material increase structural part is reduced to 50-60 ℃ by using an infrared temperature sensor;
s5: coating the active agent on the surface of the walking track of the welding robot by using a brush, wherein the coating density is gamma mg/cm2Starting a welding robot, setting a TIG welding machine to be in a pulse alternating current working mode, pre-feeding gas for 1S, moving the welding robot according to a preset track after the welding robot starts to arc, changing the arc shape by an active agent, accumulating the molten magnesium alloy welding wire at a specified position, and simultaneously controlling a wire feeding mechanism to feed the welding wire into a molten area according to a specified speed by a control system;
s6: raising the welding gun by one layer height in the height direction, and then performing fusion stacking of the next layer according to the step S5;
s7: repeating the step S6, completing the deposition and stacking of the magnesium alloy additive component, stopping the movement of the welding gun, and simultaneously performing arc quenching and stopping the wire feeding of the wire feeding mechanism;
s8: after the completion of step S7, the gas supply was stopped after a delay of 1S by the shielding gas, and after the welding torch was moved to the safe position, the magnesium alloy activated TIG arc additive manufacturing was completed.
5. The method of claim 4, wherein the active agent particles are present in a compositional ratio m to the nanoreinforcement phase1：m2＝α：β＝0.5～2；
The application density is 2-6 mg ═ gammacm2。
6. The method according to claim 4, wherein the alternating current of the welding machine is 80-140A, and the frequency of the alternating current is 400 Hz;
the pulse frequency of the welding machine is 5-20 Hz, the ratio of the pulse peak value is 30-60%, and the ratio of the base value current to the peak value current is 30-60%.
7. The method according to claim 4, wherein the wire feeding speed of the wire feeder is 1-3 m/min, and the welding gun additive speed is 2-7 mm/s.
8. The method of claim 4, wherein the shielding gas used in the arc additive manufacturing process is argon.
9. A method according to claim 4, characterized in that the active agent particles used are oxides, chlorides and fluorides, preferably TiO2，CaO，SiO2，ZrO2And NaCl.
10. The method according to claim 4, wherein the nano reinforcing phase is SiC particles with the particle size of 50-200 nm, graphene sheets with the thickness of 10-20 nm or carbon fibers with the diameter of 50-200 nm.
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| CN113695571A (en) * | 2021-07-09 | 2021-11-26 | 中北大学 | Electric arc additive manufacturing method of continuous carbon fiber reinforced magnesium-based composite material |
| CN114083084A (en) * | 2021-11-24 | 2022-02-25 | 吉林大学 | Method for manufacturing magnesium alloy component by current-assisted arc additive manufacturing |
| CN114083085A (en) * | 2021-11-24 | 2022-02-25 | 吉林大学 | Method for manufacturing magnesium alloy component by electric pulse synchronous treatment and electric arc additive manufacturing |
| CN115121980A (en) * | 2022-05-17 | 2022-09-30 | 南京工业大学 | Low-stress additive manufacturing method for arc fuse stirring composite thin-wall complex structure |
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Application publication date: 20201229 |