CN112621572A - Additive manufacturing method for high-strength aluminum alloy complex component - Google Patents
Additive manufacturing method for high-strength aluminum alloy complex component Download PDFInfo
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- CN112621572A CN112621572A CN202011489777.0A CN202011489777A CN112621572A CN 112621572 A CN112621572 A CN 112621572A CN 202011489777 A CN202011489777 A CN 202011489777A CN 112621572 A CN112621572 A CN 112621572A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
- B24C1/04—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for treating only selected parts of a surface, e.g. for carving stone or glass
- B24C1/045—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for treating only selected parts of a surface, e.g. for carving stone or glass for cutting
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Abstract
The invention discloses a high-strength aluminum alloy complex component additive manufacturing method, which comprises the following steps: preparing an abrasive material according to different abrasive particle sizes and distribution rules to obtain the prepared abrasive material, designing a clamp, placing the SLM aluminum alloy part to be processed on the clamp, fixing the SLM aluminum alloy part to be processed on the clamp, and placing the prepared abrasive material into the SLM aluminum alloy part to be processed to process the SLM aluminum alloy part to be processed. The formed part obtained by the high-strength aluminum alloy complex component additive manufacturing method has good surface quality, the SLM forming process is optimized, and the surface roughness of the formed part is reduced.
Description
Technical Field
The invention relates to the technical field of aluminum alloy additive manufacturing, in particular to a high-strength aluminum alloy complex component additive manufacturing method.
Background
The manufacturing technology is the support of the whole national economy development, and the society can be continuously advanced and developed only by the innovative manufacturing technology. With the rapid development of scientific technology, the manufacturing technology is also facing new reform and innovation. The additive manufacturing technology can complete the manufacturing of almost any geometric body with a geometric shape by adopting a technology of manufacturing a solid part by adopting a material layer-by-layer accumulation method through CAD data. The additive manufacturing technology is rapidly developing and is more and more emphasized by people. Additive manufacturing has many different forming modes, wherein the main forming mode of metal components is Selective Laser Melting forming (SLM) technology, which is a technology that metal powder is deposited and overlapped layer by layer to form a three-dimensional object, and a structural complex part can be formed rapidly and at low cost. When SLM takes shape, the requirement for shaping condition is higher, vacuum or inert gas protection is needed, shaping equipment is more complicated, and most industrial shaping equipment is used at present.
The formed part obtained by the existing aluminum alloy complex component additive manufacturing method has poor surface quality and high roughness, and the surface roughness can influence the matching property and the fatigue strength of parts, so that the improvement is urgently needed.
Disclosure of Invention
In view of the above disadvantages of the prior art, the present invention aims to provide an additive manufacturing method for a high-strength aluminum alloy complex component, which is used for solving the problems of poor surface quality and high roughness of the formed part obtained in the prior art, and the surface roughness affects the matching property and fatigue strength of the parts.
To achieve the above and other related objects, the present invention provides an additive manufacturing method for a high-strength aluminum alloy complex component, including:
preparing an abrasive according to different abrasive particle sizes and distribution rules to obtain the prepared abrasive;
designing a clamp;
placing an SLM aluminum alloy part to be processed on the clamp;
fixing the SLM aluminum alloy part to be processed on the clamp;
and putting the prepared grinding material into the SLM aluminum alloy part to be processed so as to process the SLM aluminum alloy part to be processed.
In an embodiment of the present invention, the step of placing the prepared abrasive into the SLM aluminum alloy part to be processed to process the SLM aluminum alloy part to be processed includes:
filling the prepared abrasive material at one end of the first hydraulic cylinder;
pushing the first hydraulic cylinder to extrude the prepared grinding material into the SLM aluminum alloy part to be processed;
and taking the SLM aluminum alloy part to be processed after being squeezed into the grinding material out of the first hydraulic cylinder, and outputting the SLM aluminum alloy part to the input end of the second hydraulic cylinder.
In an embodiment of the present invention, the abrasive material is selected from aluminum alloy powder.
In one embodiment of the invention, a physical vapor deposition process is adopted to deposit rare earth alloy on the surface of the aluminum alloy powder to obtain the aluminum alloy powder with the surface being a rare earth coating, and the powder is vibrated and stirred in the deposition process; drying the aluminum alloy powder with the rare earth deposition coating under the conditions of negative pressure and inert protective atmosphere; an aluminum alloy member is prepared.
In an embodiment of the present invention, the conditions of the physical vapor deposition process are: the working gas is Ar, the reaction gas is oxygen, the flow ratio of the working gas and the reaction gas is 10-45mL/min, the deposition temperature is 120-350 ℃, the pressure is 0.8-2.2MPa, the bias voltage is 200-300V, the deposition rate is 3-7 mu m/h, and the mass of the deposition layer accounts for 0.6-5 wt% of the whole powder.
In an embodiment of the present invention, the rare earth coating uses scandium and zirconium as main elements, and a mass ratio of scandium to zirconium is 2.2: 1.5, the scandium and the zirconium account for 0.4 to 1.3wt percent of the mass of the whole aluminum alloy powder, and the non-main element content in the rare earth coating accounts for 7 to 9wt percent of the mass of the whole coating.
In an embodiment of the present invention, the drying temperature is 382-422K, and the drying time is 5-10 h.
In one embodiment of the present invention, the aluminum alloy member is prepared using a laser additive manufacturing process.
In one embodiment of the present invention, the laser selects the melting parameters as follows: the laser power is 50-80W, the scanning speed is 80-3000 mm/s, the layer thickness is 15-38 μm, the substrate temperature is 28-260 ℃, and the scanning interval is 68-134 μm.
In an embodiment of the present invention, the scanning strategy of the laser is a reciprocating unidirectional scanning, and the angles are changed layer by layer.
As described above, the additive manufacturing method for the high-strength aluminum alloy complex component of the invention has the following beneficial effects:
the formed part obtained by the high-strength aluminum alloy complex component additive manufacturing method has good surface quality, the SLM forming process is optimized, and the surface roughness of the formed part is reduced.
The additive manufacturing method for the high-strength aluminum alloy complex component can improve the processing efficiency and the processing precision on the premise of prolonging the service life of the adopted abrasive flow as much as possible.
The additive manufacturing method for the high-strength aluminum alloy complex component has the advantages of high material utilization rate, basically no material waste, short preparation period and low energy consumption.
Drawings
Fig. 1 is a working schematic diagram of an additive manufacturing method for a high-strength aluminum alloy complex component according to an embodiment of the present application.
Fig. 2 is a flowchart of an operation in step S5 of the method for manufacturing the high-strength aluminum alloy complex component in fig. 1 according to an embodiment of the present disclosure.
Detailed Description
The embodiments of the present invention are described below with reference to specific embodiments, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention. It is to be noted that the features in the following embodiments and examples may be combined with each other without conflict.
It should be noted that the drawings provided in the following embodiments are only for illustrating the basic idea of the present invention, and the drawings only show the components related to the present invention rather than the number, shape and size of the components in actual implementation, and the type, quantity and proportion of the components in actual implementation may be changed freely, and the layout of the components may be more complicated.
Referring to fig. 1, fig. 1 is a schematic diagram illustrating an operation of a method for manufacturing a high-strength aluminum alloy complex component by additive manufacturing according to an embodiment of the present disclosure. The invention provides a high-strength aluminum alloy complex component additive manufacturing method which is applied to the technical field of aluminum alloy additive manufacturing, wherein the high-strength aluminum alloy has low laser absorption rate, high thermal conductivity and high forming difficulty, is easy to oxidize, contains a large amount of alloy elements easy to burn and damage, has a strong hot cracking tendency, and is far behind other alloy materials in the additive manufacturing and forming technology at present. Typical high strength aluminum-copper alloys have a severe tendency to crack, indicating poor roughness. The abrasive particle flow can remove the burr structure of the flow channel in the SLM forming workpiece. However, the smaller abrasive particles can only realize micro-cutting, and cannot realize efficient and large-scale removal processing on the surface of the SLM aluminum alloy structure. Therefore, how to optimize the particle size of the abrasive particles and the distribution and density of the abrasive particles in the polymer medium determines whether the abrasive particles can effectively process the burr surface with larger roughness to realize real surface polishing, and further reduces the roughness of the burr surface from 10-50 μm to 1-3 μm or below.
The main research content of the additive manufacturing method of the high-strength aluminum alloy complex component comprises the following steps: the aluminum-copper alloy has wide solidification temperature range, and the solidification mode is mainly pasty or spongy network solidification under the rapid cooling condition of additive manufacturing, so that the aluminum-copper alloy is easy to generate hot cracking. On the premise of not influencing the mechanical property of the high-strength aluminum alloy, the invention aims to reduce the solidification temperature range of the alloy, reduce the absolute shrinkage amount in the solidification period and reduce the hot cracking tendency of the high-strength aluminum alloy by properly adjusting the chemical components of elements such as Cu, Mg, Zn and the like in the alloy and adding micro-alloying means such as rare earth elements and the like capable of reducing the effective crystallization temperature range. And (3) measuring the thermal cracking tendency coefficient (Hcs) of the designed high-strength aluminum alloy with different alloy components by using a constraint rod die thermal cracking evaluation method, comprehensively considering the mechanical properties of the high-strength aluminum alloy, and finally obtaining the high-strength aluminum alloy component with small thermal cracking tendency for additive manufacturing. Analysis and research on the influence of high-strength aluminum alloy forming process factors on forming precision and forming mechanism show that laser power, laser scanning speed, powder laying thickness and preheating temperature are main process factors influencing laser sintering forming performance. Under certain powder laying conditions, the influence relation of the four parameters on the laser sintering molding performance is researched by adopting an orthogonal experimental design method, the density and the mechanical property of the molded part are used as main performance indexes, and the optimal technological parameter matching is obtained by analyzing the experimental result. And designing a proper clamp and a proper sealing device according to the size and the structural form of the SLM forming aluminum alloy part. The corresponding reasonable anchor clamps of structural design according to SLM shaping aluminum alloy part, this anchor clamps possess two basic conditions simultaneously. Firstly, possess the joint strength and the sealing characteristic of anchor clamps and two upper and lower pneumatic cylinders, secondly possess and be favorable to that the grit stream smoothly passes through the interior runner structure of treating polishing of SLM shaping aluminum alloy part. The clamp is designed in an earlier stage aiming at the size of the existing hydraulic cylinder and the surface to be machined of the SLM forming workpiece, and then the clamp is reasonably arranged. On the basis of the existing upper and lower hydraulic cylinders, a clamp is designed and manufactured, parts are fixed in the clamp, and the output ports of the hydraulic cylinders are butted by flanges and sealing rings. And connecting the hydraulic cylinder to a hydraulic system, and performing trial operation machining. The working pressure of the hydraulic cylinder is determined by the input power of the hydraulic system and the load (i.e. the viscous flow resistance of the abrasive flow of the part to be machined). The process of reciprocating motion of the abrasive flow with adjustable processing speed can be realized within a certain range by adopting hydraulic cylinders with different input powers. And (4) predicting the removal degree of the abrasive materials with different shapes and structures on the surface of the aluminum alloy according to theoretical design to prepare or select the type. For greater roughness, larger abrasive particles and higher abrasive concentrations are used. However, the range and concentration of the abrasive particles still need to be selected according to specific requirements. The effective acting force of the abrasive flow on the surface of the SLM aluminum alloy structure mainly comes from the positive pressure and the impact speed of the burr wall surface. Wherein the positive pressure of the abrasive flow is derived from the expansion pressure transmitted from the larger cylinder to the flow channel in the work piece by the pressure in the hydraulic cylinder. In addition, the impact velocity is determined according to the continuous medium flow relationship, namely, the motion velocity of the abrasive flow is in inverse proportion to the cross-sectional area. Therefore, when the abrasive flow channel of the hydraulic cylinder suddenly changes to the aperture of the tiny inner cavity of the processed workpiece, the speed is greatly improved. However, the pressure of the hydraulic cylinder and the size of the hydraulic cylinder need to be designed reasonably to remove the burr structure with the corresponding size by the aid of the large positive pressure of the abrasive.
As shown in fig. 1, the additive manufacturing method for the high-strength aluminum alloy complex component includes: and step S1, preparing the abrasive according to different abrasive particle sizes and distribution rules to obtain the prepared abrasive. And step S2, designing a clamp. And step S3, placing the SLM aluminum alloy part to be machined on the clamp. And S4, fixing the SLM aluminum alloy part to be machined on the clamp. And S5, putting the prepared grinding material into the SLM aluminum alloy part to be processed so as to process the SLM aluminum alloy part to be processed. Specifically, the proper abrasive is prepared according to the particle size and distribution rule of different abrasive particles predicted by theoretical calculation. Reasonable in design's anchor clamps adopt suitable sealing washer to assemble, will wait to process SLM aluminum alloy part and place suitable position, fix to leave abrasive flow channel import and export. At first, only need pack the abrasive material in one end pneumatic cylinder, through once promoting, extrude the part with the abrasive material, and then enter into another pneumatic cylinder from another export, through the reciprocating motion of a period of several rounds, can realize the abrasive flow polishing to the work piece. The project will develop basic research for two different SLM aluminum alloy parts as shown in the following figures. And judging and verifying by comparing the abrasive flow processing effects under different experimental process parameters, and further performing parameter optimization.
Referring to fig. 2, fig. 2 is a flowchart illustrating a step S5 of the method for manufacturing a high-strength aluminum alloy complex component in fig. 1 according to an embodiment of the present disclosure. The step S5 of putting the prepared abrasive material into the SLM aluminum alloy part to be processed to process the SLM aluminum alloy part to be processed includes: and step S51, filling the prepared abrasive material at one end of the first hydraulic cylinder. And S52, pushing the first hydraulic cylinder, and extruding the prepared abrasive into the SLM aluminum alloy part to be processed. And step S53, taking out the SLM aluminum alloy part to be processed after being squeezed into the grinding material from the first hydraulic cylinder, and outputting the SLM aluminum alloy part to be processed to the input end of the second hydraulic cylinder. Specifically, in order to obtain better process parameters, stress analysis and removal mechanism analysis are carried out aiming at the interaction between the abrasive flow and the runner burr structure of the inner cavity of the SLM aluminum alloy part. Then, modeling simulation is carried out on the removal process by adopting multi-physical-field coupling software, and abrasive particle parameters, working pressure, flow rate and other parameters suitable for removing burrs of the SLM aluminum alloy part are searched in a parameter scanning calculation mode.
As shown in FIG. 1, the abrasive material is aluminum alloy powder. Depositing rare earth alloy on the surface of the aluminum alloy powder by adopting a physical vapor deposition process to obtain the aluminum alloy powder with the surface being a rare earth coating, and vibrating and stirring the powder in the deposition process; drying the aluminum alloy powder with the rare earth deposition coating under the conditions of negative pressure and inert protective atmosphere; an aluminum alloy member is prepared. The physical vapor deposition process conditions are as follows: the working gas is Ar, the reaction gas is oxygen, the flow ratio of the working gas and the reaction gas is 10-45mL/min, the deposition temperature is 120-350 ℃, the pressure is 0.8-2.2MPa, the bias voltage is 200-300V, the deposition rate is 3-7 mu m/h, and the mass of the deposition layer accounts for 0.6-5 wt% of the whole powder. The rare earth coating takes scandium and zirconium as main elements, and the mass ratio of scandium to zirconium is 2.2: 1.5, the scandium and the zirconium account for 0.4 to 1.3wt percent of the mass of the whole aluminum alloy powder, the non-main element content in the rare earth coating accounts for 7 to 9wt percent of the mass of the whole coating, the drying temperature is 482 and 422K, and the drying time is 5 to 10 hours. And preparing the aluminum alloy member by adopting a laser additive manufacturing process. The laser selection melting parameters are as follows: the laser power is 50-80W, the scanning speed is 80-3000 mm/s, the layer thickness is 15-38 μm, the substrate temperature is 28-260 ℃, and the scanning interval is 68-134 μm. The scanning strategy of the laser is reciprocating one-way scanning, and the angles are converted layer by layer.
As shown in fig. 1, example 1: the grinding material is selected from aluminum alloy powder, a physical vapor deposition process is adopted to deposit rare earth alloy on the surface of the aluminum alloy powder, the aluminum alloy powder with the surface being a rare earth coating is obtained, and the powder is vibrated and stirred in the deposition process; drying the aluminum alloy powder with the rare earth deposition coating under the conditions of negative pressure and inert protective atmosphere; an aluminum alloy member is prepared. The physical vapor deposition process conditions are as follows: the working gas is Ar, the reaction gas is oxygen, the flow ratio of the working gas to the reaction gas is 15mL/min, the deposition temperature is 150 ℃, the pressure is 2.2MPa, the bias voltage is 200-V, the deposition rate is 3.3 mu m/h, and the mass of a deposition layer accounts for 0.8 wt% of the whole powder. The rare earth coating takes scandium and zirconium as main elements, the mass ratio of scandium to zirconium is 2.2, scandium and zirconium account for 0.4 wt% of the mass of the whole aluminum alloy powder, the content of non-main elements in the rare earth coating accounts for 7 wt% of the mass of the whole coating, the drying temperature is 380K, and the drying time is 6 h. And preparing the aluminum alloy member by adopting a laser additive manufacturing process. The laser selection melting parameters are as follows: the laser power was 60W, the scanning speed was 850mm/s, the layer thickness was 17 μm, the substrate temperature was 150 ℃ and the scanning pitch was 122 μm. The scanning strategy of the laser is reciprocating one-way scanning, and the angles are converted layer by layer.
In conclusion, the formed part obtained by the additive manufacturing method for the high-strength aluminum alloy complex component has good surface quality, the SLM forming process is optimized, and the surface roughness of the formed part is reduced.
The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.
Claims (10)
1. A high-strength aluminum alloy complex component additive manufacturing method is characterized by comprising the following steps:
preparing an abrasive according to different abrasive particle sizes and distribution rules to obtain the prepared abrasive;
designing a clamp;
placing an SLM aluminum alloy part to be processed on the clamp;
fixing the SLM aluminum alloy part to be processed on the clamp;
and putting the prepared grinding material into the SLM aluminum alloy part to be processed so as to process the SLM aluminum alloy part to be processed.
2. The additive manufacturing method for the high-strength aluminum alloy complex component as claimed in claim 1, wherein the method comprises the following steps: the step of placing the prepared abrasive material into the SLM aluminum alloy part to be processed so as to process the SLM aluminum alloy part to be processed comprises the following steps:
filling the prepared abrasive material at one end of the first hydraulic cylinder;
pushing the first hydraulic cylinder to extrude the prepared grinding material into the SLM aluminum alloy part to be processed;
and taking the SLM aluminum alloy part to be processed after being squeezed into the grinding material out of the first hydraulic cylinder, and outputting the SLM aluminum alloy part to the input end of the second hydraulic cylinder.
3. The additive manufacturing method for the high-strength aluminum alloy complex component as claimed in claim 1, wherein the method comprises the following steps: the grinding material is aluminum alloy powder.
4. The additive manufacturing method for the high-strength aluminum alloy complex component according to claim 3, wherein the method comprises the following steps: depositing rare earth alloy on the surface of the aluminum alloy powder by adopting a physical vapor deposition process to obtain the aluminum alloy powder with the surface being a rare earth coating, and vibrating and stirring the powder in the deposition process; drying the aluminum alloy powder with the rare earth deposition coating under the conditions of negative pressure and inert protective atmosphere; an aluminum alloy member is prepared.
5. The additive manufacturing method for the high-strength aluminum alloy complex component according to claim 4, wherein the method comprises the following steps: the physical vapor deposition process conditions are as follows: the working gas is Ar, the reaction gas is oxygen, the flow ratio of the working gas and the reaction gas is 10-45mL/min, the deposition temperature is 120-350 ℃, the pressure is 0.8-2.2MPa, the bias voltage is 200-300V, the deposition rate is 3-7 mu m/h, and the mass of the deposition layer accounts for 0.6-5 wt% of the whole powder.
6. The additive manufacturing method for the high-strength aluminum alloy complex component according to claim 4, wherein the method comprises the following steps: the rare earth coating takes scandium and zirconium as main elements, and the mass ratio of scandium to zirconium is 2.2: 1.5, the scandium and the zirconium account for 0.4 to 1.3wt percent of the mass of the whole aluminum alloy powder, and the non-main element content in the rare earth coating accounts for 7 to 9wt percent of the mass of the whole coating.
7. The additive manufacturing method for the high-strength aluminum alloy complex component according to claim 4, wherein the method comprises the following steps: the drying temperature is 382-422K, and the drying time is 5-10 h.
8. The additive manufacturing method for the high-strength aluminum alloy complex component according to claim 4, wherein the method comprises the following steps: and preparing the aluminum alloy member by adopting a laser additive manufacturing process.
9. The additive manufacturing method for the high-strength aluminum alloy complex component according to claim 8, wherein the method comprises the following steps: the laser selection melting parameters are as follows: the laser power is 50-80W, the scanning speed is 80-3000 mm/s, the layer thickness is 15-38 μm, the substrate temperature is 28-260 ℃, and the scanning interval is 68-134 μm.
10. The additive manufacturing method for the high-strength aluminum alloy complex component according to claim 9, wherein the method comprises the following steps: the scanning strategy of the laser is reciprocating one-way scanning, and the angles are converted layer by layer.
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| CN109454237A (en) * | 2018-12-20 | 2019-03-12 | 广东省新材料研究所 | Remove the device and method of increasing material manufacturing porous metals bore area residual metal powder |
| CN111604817A (en) * | 2020-06-01 | 2020-09-01 | 吉林大学 | Abrasive flow precision finishing method and device |
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|---|---|---|---|---|
| EP1100620A1 (en) * | 1998-07-17 | 2001-05-23 | Reiner Weichert | Method and device for milling and mixing solid materials in an ultra-fine manner |
| WO2002020218A2 (en) * | 2000-09-08 | 2002-03-14 | 3M Innovative Properties Company | Abrasive sheet, method of manufacturing the same and method to abrade a fiber optic connector |
| CN106271902A (en) * | 2016-09-27 | 2017-01-04 | 飞而康快速制造科技有限责任公司 | A kind of material that increases manufactures aluminium alloy pipeline accessory inner surface finishing method |
| CN106583720A (en) * | 2016-11-28 | 2017-04-26 | 南通金源智能技术有限公司 | 3D printing manufacturing method for aluminum base graphene alloy thin-walled vane |
| CN109365803A (en) * | 2018-12-20 | 2019-02-22 | 哈尔滨工业大学 | A kind of aluminum alloy complex component increasing material manufacturing method that powder surface rare earth is modified |
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Application publication date: 20210409 |