CN113102861A - Electric arc additive manufacturing method with welding-following ultrasonic vibration and rolling characteristics - Google Patents
Electric arc additive manufacturing method with welding-following ultrasonic vibration and rolling characteristics Download PDFInfo
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- CN113102861A CN113102861A CN202110521112.1A CN202110521112A CN113102861A CN 113102861 A CN113102861 A CN 113102861A CN 202110521112 A CN202110521112 A CN 202110521112A CN 113102861 A CN113102861 A CN 113102861A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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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
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
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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
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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Abstract
The invention discloses an electric arc additive manufacturing method with welding ultrasonic vibration and rolling characteristics, which is characterized in that an ultrasonic vibration rolling roller capable of synchronously moving in the same direction along with an electric arc additive manufacturing welding gun is arranged behind the electric arc additive manufacturing welding gun, and during the electric arc additive manufacturing process, the ultrasonic vibration rolling roller synchronously moves in the same direction along with the electric arc additive manufacturing welding gun, and carries out ultrasonic vibration and rolling on an electric arc additive manufacturing layer in a thermoplastic stage, so that the electric arc additive manufacturing layer generates plastic deformation and promotes the cooling of the electric arc additive manufacturing layer, and meanwhile, the ultrasonic vibration is transmitted into an electric arc molten pool, so that the solidification process of the molten pool is subjected to short-distance ultrasonic vibration, and the structure and the performance of the electric arc additive manufacturing layer are improved by utilizing the combined action of the ultrasonic vibration and. The invention has the advantages that the rolling action can be carried out on the electric arc additive material stacking layer through the roller in the electric arc additive material manufacturing process, and meanwhile, the ultrasonic assistance is introduced, so that the ultrasonic action effect is improved, and the structure and the mechanical property of the electric arc additive material manufacturing material or part are improved.
Description
Technical Field
The invention relates to the field of additive manufacturing, in particular to an electric arc additive manufacturing method with ultrasonic vibration and rolling characteristics.
Background
In recent years, under the background of resource saving and efficient manufacturing, the additive manufacturing technology based on the 'addition' processing mode has a wide application prospect in the manufacturing of thin-walled parts with complex shapes. With the increasingly strict requirements on the performance, precision, manufacturing cost and period of compact metal parts in the key technical fields of aerospace, national defense and military industry, rail transit and the like, it is imperative to develop related research to break through and master the direct forming technology of metal parts. The electric arc additive manufacturing mostly adopts electric arcs such as metal inert gas welding (MIG), tungsten inert gas welding (TIG) and plasma welding (PA) as heat sources, wire materials are added, and metal parts are gradually formed from a line-surface-body according to a three-dimensional digital model under the control of a program, and the electric arc additive manufacturing is mainly characterized by high deposition efficiency and wire material utilization rate, short overall manufacturing period (the deposition rate can reach 1kg/h), low cost, and capability of in-situ composite manufacturing and forming of large-size parts (the capacity of manufacturing large-size parts up to lm)3The workpiece of (a). However, with the increase of the number of the stacked layers, the heat accumulation of the stacked layers is serious, the heat dissipation condition is not good, the problems of overheating of a molten pool, coarse grains of a solidified structure of a surfacing layer and the like are easy to occur, common fusion welding defects (such as air holes, inclusion, heat cracking and the like) can also occur, and high-performance additive manufacturing materials or parts are difficult to obtain.
In order to solve the above problems, two patents with publication numbers CN106363173A and CN111215843A disclose an apparatus for ultrasonic-assisted laser welding additive manufacturing and a method for using the same, and a method and an apparatus for manufacturing electric arc additive manufacturing hot rolling, respectively, although the blowhole defect is reduced to some extent, and the weld quality is improved. There still remains the problem of: the laser welding equipment has a complex structure, a process flow, complicated operation steps and high cost; the hot rolling equipment adopts multiple times of rolling after welding, and the rolling is not considered when the welding seam is in thermoplasticity, so that the problem of cooling the additive stacking layer cannot be solved.
Disclosure of Invention
Aiming at the defects of the prior art, the technical problems to be solved by the invention are as follows: the method can better introduce ultrasonic assistance in the electric arc additive manufacturing process, improve the ultrasonic action effect, effectively improve the structure and the performance of an electric arc additive manufacturing accumulation layer, and cool the electric arc additive manufacturing accumulation layer to a certain degree.
In order to solve the technical problems, the invention adopts the following technical scheme:
an electric arc additive manufacturing method with welding-following ultrasonic vibration and rolling characteristics is characterized in that, an ultrasonic vibration rolling roller which can synchronously move in the same direction along with the electric arc additive manufacturing welding gun is arranged behind the electric arc additive manufacturing welding gun, during the electric arc additive manufacturing process, the electric arc additive manufacturing welding gun firstly performs arc striking and translation, electric arc additive manufacturing is realized through welding material melting and solidification, the ultrasonic vibration rolling roller synchronously moves in the same direction along with the electric arc additive manufacturing welding gun, subjecting the arc additive manufacturing layer in the thermoplastic stage to ultrasonic vibration and rolling to plastically deform the arc additive manufacturing layer and promote cooling thereof, meanwhile, ultrasonic vibration is transmitted into an electric arc melting pool through the electric arc additive manufacturing layer and the substrate base metal through plane vibration combined from top to bottom and front and back, so that the solidification process of the melting pool is subjected to short-distance ultrasonic vibration, and the structure and the performance of the electric arc additive layer are improved by utilizing the comprehensive action of the ultrasonic vibration and the base metal.
Thus, the technical scheme provided by the invention organically combines ultrasonic vibration and rolling on a steel roller capable of synchronously moving along with a welding gun in the same direction, and the roller performs ultrasonic vibration and rolling when the arc additive stacking layer is just solidified and is still in a thermoplastic state, so that the arc additive stacking layer generates plastic deformation. The beneficial effects are two: firstly, the ultrasonic vibration and rolling are coupled, so that the plasticity of the material can be greatly improved, the material can obtain larger plastic deformation modification, and the improvement effect of the tissue performance is better; and secondly, when the electric arc additive material stacking layer is still in a thermoplastic state, ultrasonic vibration rolling is carried out, so that the waste heat is utilized, the method is more energy-saving and simple and feasible compared with a subsequent reheating rolling method, and the electric arc additive material stacking layer is subjected to certain forced cooling by utilizing a roller, so that the interlayer waiting time of electric arc additive material manufacturing is reduced, and the efficiency is improved.
Further, the ultrasonic vibration rolling roller is made of steel, and the side surface of the ultrasonic vibration rolling roller is in an inwards concave arc shape adapting to the cross section shape of the electric arc additive manufacturing layer.
Therefore, the function of the inner arc-shaped pressing surface of the steel roller is to increase the contact area with the additive layer, so that more ultrasonic energy is transmitted to a molten pool, and meanwhile, the cooling effect of the roller on the electric arc additive manufacturing layer is increased. In practice, the diameter of the roller can be 20mm-50 mm.
Further, the ultrasonic vibration rolling roller realizes ultrasonic rolling on the electric arc additive manufacturing layer, the average downward pressure is 0.5-2.5KN, and the ultrasonic vibration power is 50-250W.
The ultrasonic rolling effect can be better guaranteed within the parameter range. In practice, the roller and the welding gun are arranged adjacent to each other by 5-15 mm.
Further, the method is realized by the following electric arc additive and ultrasonic rolling combined manufacturing equipment, electric arc vibration material disk and supersound roll and jointly make equipment, including an electric arc vibration material disk manufacturing welder, electric arc vibration material disk manufacturing welder installs on the holder that an entirety set up along the level and soldered connection one end down, still install a gyro wheel rolling device on the holder, gyro wheel rolling device includes a pressure device, pressure device's flexible arm sets up and flexible arm lower extreme installation steel ultrasonic vibration rolls the gyro wheel vertically downwards, ultrasonic vibration rolls the setting of gyro wheel side surface towards electric arc vibration material disk manufacturing welder direction and for adapting to electric arc vibration material disk manufacturing layer cross sectional shape's indent arc, gyro wheel rolling device still includes an ultrasonic vibrator for the gyro wheel, ultrasonic vibrator for the gyro wheel is relative fixed connection and provides ultrasonic vibration for it with pressure device.
The roller rolling device can keep the roller to apply pressure to the electric arc additive manufacturing layer by the aid of the pressing device, and meanwhile, ultrasonic vibration can be applied by the aid of the ultrasonic vibrator for the roller, so that an ultrasonic rolling effect is achieved. The roller rolling device and the electric arc additive manufacturing welding gun are arranged on the same retainer, so that synchronous follow-up can be better guaranteed.
Further, the electric arc additive manufacturing welding gun is installed on a welding gun installation sleeve, and the welding gun installation sleeve is vertically and rotatably installed on the retainer through a welding gun installation sleeve rotation adjusting handle.
Loosening the welding gun mounting sleeve and rotating the adjusting handle can rotate and adjust the inclination angle of the welding gun mounting sleeve in the vertical direction, further can realize the adjustment of the angle of the welding gun as required, and screwing the welding gun mounting sleeve after the welding gun mounting sleeve is adjusted in place and rotating the adjusting handle can realize fixation. The structure that the regulation fastening is realized specifically to the adjustment handle that relates to in the scheme belongs to ripe prior art, can set up a bolt and pass welder mounting sleeve and cooperate with the screw that corresponds on the holder and realize on the adjustment handle, and concrete structure does not detailed here.
Furthermore, the electric arc additive manufacturing welding gun can be installed on the welding gun installation sleeve in an axially sliding mode, and a welding gun fastening bolt is further arranged on the welding gun installation sleeve in a penetrating and screwed mode to achieve fixing of the electric arc additive manufacturing welding gun.
Therefore, the height of the welding gun can be conveniently adjusted after the inclination adjustment, so that the welding gun can keep enough depth of a molten pool and adjust the relative position matched with the stirring pin.
Furthermore, the holder is the rectangular shape of width unanimity from top to bottom, and the gyro wheel rolling machine is established a sliding sleeve on the holder including the ground cover of horizontal slip, still runs through ground to connect soon on the sliding sleeve to be provided with the sliding sleeve bolt for the fastening and realize the fixed of sliding sleeve, biasing means fixed mounting is at the sliding sleeve lower extreme, ultrasonic vibrator fixed mounting is in the slide cartridge upper end for the gyro wheel.
In this way, the relative distance between the roller and the welding gun can be better adjusted as desired.
Furthermore, during the electric arc additive manufacturing, a stirring pin with reciprocating ultrasonic vibration characteristics is inserted into an additive manufacturing molten pool and moves synchronously with the molten pool, and ultrasonic vibration and stirring are directly carried out on the solidification process of molten pool metal, so that the solidification structure and the mechanical property of the molten pool metal are improved.
Thus, when the electric arc additive manufacturing is carried out, a stirring pin in a vibration state is further inserted into the molten pool, ultrasonic vibration is introduced into the molten pool through stirring, the cavitation effect and the vibration effect of the ultrasonic vibration can be better utilized, welding pores are reduced, crystal grains are refined, the bonding strength of the edge of the molten pool in a welding area and a non-welding area in the crystallization process is improved, and the metal solidification structure and the mechanical property of the molten pool are improved. Compared with other ultrasonic vibration modes, such as loading on a substrate base metal or loading through an electric arc, the ultrasonic vibration loading mode provided by the invention has the advantages that the ultrasonic vibration on the molten pool is more direct, the mechanical stirring effect is good, and the improvement effect on the metal solidification structure and the mechanical property of the molten pool is better.
Preferably, the stirring pin is made of metal tungsten or tungsten alloy.
In this way, it is better ensured that the pin does not react with the bath metal.
Preferably, the vibration direction of the stirring pin is along the self axial direction.
Therefore, the stirring pin acts on the molten pool and only drives liquid metal in the molten pool to do high-frequency reciprocating vibration within a certain area range, and the stirring pin generates a stirring-like effect (actually not stirring in the conventional sense) on the molten pool by means of vibration so as to reduce welding pores, improve the bonding compactness of welding materials at a molecular level, further improve the mechanical property of a welding area and improve the welding effect.
The optimized vibration frequency of the stirring needle is 20-100KHZ, and the amplitude is 0.2-1 mm. The vibration within the range can better ensure that the vibration has a good effect on metal crystallization, avoid the influence of overlarge vibration on crystallization and reduce the welding quality.
Alternatively, the electric arc additive manufacturing welding gun is arranged along the direction perpendicular to the plane of the product where the molten pool is located during welding, and the stirring pin is inserted into the position below the middle part of the molten pool from the front or the rear of the moving direction of the electric arc additive manufacturing welding gun to realize ultrasonic vibration.
Therefore, the welding gun is arranged along the direction vertical to the plane of the product during the conventional electric arc additive manufacturing process, so that the mode can be implemented by directly adding the stirring pin to introduce ultrasonic vibration on the basis of the control process of the conventional electric arc additive manufacturing process, the control program of the electric arc additive manufacturing welding gun is not required to be adjusted, and the implementation and the application are convenient.
Alternatively, the electric arc additive manufacturing welding gun is arranged in a mode that the upper end of the electric arc additive manufacturing welding gun is obliquely arranged in front of the advancing direction of the electric arc additive manufacturing welding gun during welding, and the stirring pin is arranged behind the electric arc additive manufacturing welding gun and vertically inserted downwards to the middle of the additive manufacturing molten pool to realize ultrasonic vibration.
Therefore, the upper end of the electric arc additive manufacturing welding gun is inclined along the advancing direction, the upper end of the electric arc additive manufacturing welding gun can be used for preheating a region to be processed in front of a molten pool better, meanwhile, a space which is vertically arranged along the middle position of the molten pool can be set for the stirring needle, after the stirring needle is vertically arranged in the middle position of the molten pool, the ultrasonic vibration of the stirring needle can be uniformly transmitted to the whole molten pool, the influence on the metal crystal fusion effect caused by the fact that the ultrasonic vibration is not uniformly transmitted in the molten pool is avoided, and the product forming quality is.
After the step of directly carrying out ultrasonic vibration stirring on the molten pool by adopting a stirring pin is added in the method, the method can be realized by adopting the following equipment, namely on the basis of the electric arc additive and ultrasonic rolling combined manufacturing equipment, a vibration stirring device is also arranged on a holding frame, the vibration stirring device comprises an ultrasonic vibrator for a stirring pin, the lower end of the ultrasonic vibrator for the stirring pin is downwards provided with the stirring pin, and the ultrasonic vibrator for the stirring pin can provide axial vibration for the stirring pin.
Like this, welder and vibration agitating unit install on same holder, can guarantee better that the stirring needle follows welder and realizes the vibration stirring in step.
Furthermore, the ultrasonic vibrator for the stirring pin is vertically arranged on a vibrator mounting sleeve, the vibrator mounting sleeve is vertically and rotatably arranged on a sliding sleeve through a vibration adjusting handle of the vibrator mounting sleeve, and the sliding sleeve is horizontally and slidably arranged on the retainer.
Like this, can conveniently adjust the inclination of pin mixer as required, make it form the perpendicular to molten bath direction and arrange, perhaps slope arrangement also can be convenient for adjust pin mixer for welder's fore-and-aft distance, make its lower extreme can be located molten bath middle part position better. The adjustment structure of the vibration adjustment handle of the vibrator mounting sleeve can be consistent with the rotation adjustment handle of the welding gun mounting sleeve, and is not detailed here.
Furthermore, the retainer is in a strip shape with the same vertical width, the sliding sleeve can be sleeved and mounted on the retainer in a horizontally sliding manner, and the sliding sleeve is further penetratingly and rotatably provided with a bolt for fastening the sliding sleeve to fix the sliding sleeve.
Therefore, the front and back positions of the stirring pin can be adjusted and fixed more conveniently.
Further, the ultrasonic vibrator for the stirring pin is mounted on the vibrator mounting sleeve through a vibration eliminating spring.
Therefore, the vibration eliminating spring acts between the ultrasonic vibrator for the stirring pin and the vibrator mounting sleeve, and the ultrasonic vibration can be prevented from being transmitted to the retainer through the vibrator mounting sleeve, so that the vibration of the welding gun is avoided. The welding gun can be kept to work stably.
Further, the ultrasonic vibrator for the pin is an ultrasonic vibrator for a pneumatic pin.
Therefore, the ultrasonic vibration retainer has the advantages of stable effect, convenience in control and implementation and small adverse effect of ultrasonic vibration on the retainer. And the pneumatic ultrasonic vibration source has higher tolerance degree on heat and high temperature, and is more suitable for the high-temperature working condition of electric arc additive manufacturing.
Further, the retainer is fixedly installed on a mechanical arm of the special electric arc additive manufacturing robot.
Therefore, automatic arc additive manufacturing of the product is conveniently realized through robot computer control.
Furthermore, the lower end of the stirring pin is provided with a circle of horizontal convex bulges.
Therefore, when the stirring pin vibrates up and down along the axial direction, the bulge can play a great vibration amplification role on a molten pool, and the ultrasonic vibration effect is improved. In specific implementation, the convex distance of the bulge is not too large, the convex distance can be generally controlled within three times of the diameter of the stirring pin, and the specific size can be obtained according to experimental verification.
Further, the bulges are uniformly arranged in the circumferential direction, and the upper surface and the lower surface of each bulge are respectively provided with reversely symmetrical inclined surfaces or spiral blade surfaces.
Therefore, along with the reciprocating vibration of the stirring needle along the axial direction, the upper surface and the lower surface of the bulge can form an action effect of pushing the molten metal outwards in a reciprocating and whirling mode in the circumferential direction during reciprocating motion, further generate reciprocating vibration along the circumferential direction while generating vibration along the axial direction for the molten metal, wherein the vibration along the axial direction can better act on the bottom of a molten pool, the vibration along the circumferential direction can better act on the peripheral wall of the molten pool, the double vibration forms a composite high-frequency vibration effect on the molten pool of the molten metal, the bonding property of the molten pool to the metal on the peripheral wall is greatly improved, the metal crystal structure can be better refined, the influence of the vibration on the metal crystal fusion effect is improved, and the forming quality of a product is improved.
Therefore, the scheme of the invention further introduces ultrasonic vibration stirring in the electric arc additive manufacturing, on one hand, the growing columnar crystals can be broken up, so that the crystal grains are refined and homogenized, on the other hand, the gas overflow in a molten pool can be promoted, the porosity is reduced, and the comprehensive effect of the two greatly improves the mechanical property of the electric arc additive manufacturing material or parts.
In conclusion, the invention has the advantages that the rolling action can be carried out on the electric arc additive material stacking layer through the roller in the electric arc additive material manufacturing process, and meanwhile, the ultrasonic assistance is introduced, so that the ultrasonic action effect is improved, and the structure and the mechanical property of the electric arc additive material manufacturing material or part are improved.
Drawings
Fig. 1 is a schematic structural diagram of an electric arc additive and ultrasonic rolling combined manufacturing apparatus used in one embodiment of the present invention.
Fig. 2 is a schematic structural view of the ultrasonic vibration roller shown in fig. 1.
Fig. 3 is a schematic structural diagram of an arc additive and ultrasonic rolling combined manufacturing apparatus used in the second embodiment of the present invention.
Fig. 4 is a schematic structural view of the lower end projection of the single stirring pin in fig. 3.
Detailed Description
The present invention will be described in further detail with reference to specific embodiments.
The first embodiment is as follows: an electric arc additive manufacturing method with welding ultrasonic vibration and rolling characteristics is characterized in that, an ultrasonic vibration rolling roller which can synchronously move in the same direction along with the electric arc additive manufacturing welding gun is arranged behind the electric arc additive manufacturing welding gun, during the electric arc additive manufacturing process, the electric arc additive manufacturing welding gun firstly performs arc striking and translation, electric arc additive manufacturing is realized through welding material melting and solidification, the ultrasonic vibration rolling roller synchronously moves in the same direction along with the electric arc additive manufacturing welding gun, subjecting the arc additive manufacturing layer in the thermoplastic stage to ultrasonic vibration and rolling to plastically deform the arc additive manufacturing layer and promote cooling thereof, meanwhile, ultrasonic vibration is transmitted into an electric arc melting pool through the electric arc additive manufacturing layer and the substrate base metal through plane vibration combined from top to bottom and front and back, so that the solidification process of the melting pool is subjected to short-distance ultrasonic vibration, and the structure and the performance of the electric arc additive layer are improved by utilizing the comprehensive action of the ultrasonic vibration and the base metal.
Therefore, the scheme organically combines the ultrasonic vibration and the rolling on the steel roller which can synchronously move along with the welding gun in the same direction, and the roller performs the ultrasonic vibration and the rolling when the electric arc additive stacking layer is just solidified and is still in a thermoplastic state, so that the electric arc additive stacking layer generates plastic deformation. The beneficial effects are two: firstly, the ultrasonic vibration and rolling are coupled, so that the plasticity of the material can be greatly improved, the material can obtain larger plastic deformation modification, and the improvement effect of the tissue performance is better; and secondly, when the electric arc additive material stacking layer is still in a thermoplastic state, ultrasonic vibration rolling is carried out, so that the waste heat is utilized, the method is more energy-saving and simple and feasible compared with a subsequent reheating rolling method, and the electric arc additive material stacking layer is subjected to certain forced cooling by utilizing a roller, so that the interlayer waiting time of electric arc additive material manufacturing is reduced, and the efficiency is improved.
Wherein, referring to fig. 2, the ultrasonic vibration rolling roller is made of steel and the side surface of the ultrasonic vibration rolling roller is in an inward concave arc shape adapting to the cross section shape of the electric arc additive manufacturing layer.
Therefore, the function of the inner arc-shaped pressing surface of the steel roller is to increase the contact area with the additive layer, so that more ultrasonic energy is transmitted to a molten pool, and meanwhile, the cooling effect of the roller on the electric arc additive manufacturing layer is increased. In practice, the diameter of the roller can be 20mm-50 mm.
The ultrasonic vibration rolling roller realizes ultrasonic rolling on the electric arc additive manufacturing layer, the average lower pressure is 0.5-2.5KN, and the ultrasonic vibration power is 50-250W.
The ultrasonic rolling effect can be better guaranteed within the parameter range. In practice, the roller and the welding gun are arranged adjacent to each other by 5-15 mm.
The embodiment is realized by means of the electric arc additive and ultrasonic rolling combined manufacturing equipment shown in figures 1-2, the electric arc additive material and ultrasonic rolling combined manufacturing equipment comprises an electric arc additive material manufacturing welding gun 1, wherein the electric arc additive material manufacturing welding gun 1 is installed on a holder 4 which is horizontally arranged on the whole, one end of a welding head is downward, a roller rolling device is further installed on the holder, the roller rolling device comprises a pressure applying device 13, a telescopic arm 14 of the pressure applying device 13 is vertically downward arranged, a steel ultrasonic vibration rolling roller 15 is installed at the lower end of the telescopic arm, the side surface of the ultrasonic vibration rolling roller 15 faces the electric arc additive material manufacturing welding gun direction and is in an inwards concave arc shape suitable for the cross section shape of an electric arc additive material manufacturing layer, the roller rolling device further comprises an ultrasonic vibrator 16 for a roller, and the ultrasonic vibrator 16 for the roller and the pressure applying device are relatively and fixedly connected and provide ultrasonic vibration for the roller.
The roller rolling device can keep the roller to apply pressure to the electric arc additive manufacturing layer by the aid of the pressing device, and meanwhile, ultrasonic vibration can be applied by the aid of the ultrasonic vibrator for the roller, so that an ultrasonic rolling effect is achieved. The roller rolling device and the electric arc additive manufacturing welding gun are arranged on the same retainer, so that synchronous follow-up can be better guaranteed. When the pressure applying device is implemented, the pressure applying device can be realized by adopting an electric push rod, so that the pressure can be conveniently and accurately controlled.
The electric arc additive manufacturing welding gun 1 is installed on a welding gun installation sleeve 5, and the welding gun installation sleeve 5 is vertically and rotatably installed on the retainer 4 through a welding gun installation sleeve rotation adjusting handle 6.
Loosening the welding gun mounting sleeve and rotating the adjusting handle can rotate and adjust the inclination angle of the welding gun mounting sleeve in the vertical direction, further can realize the adjustment of the angle of the welding gun as required, and screwing the welding gun mounting sleeve after the welding gun mounting sleeve is adjusted in place and rotating the adjusting handle can realize fixation. The structure that the regulation fastening is realized specifically to the adjustment handle that relates to in the scheme belongs to ripe prior art, can set up a bolt and pass welder mounting sleeve and cooperate with the screw that corresponds on the holder and realize on the adjustment handle, and concrete structure does not detailed here.
The electric arc additive manufacturing welding gun 1 is mounted on the welding gun mounting sleeve 5 in an axially sliding manner, and a welding gun fastening bolt 10 is further penetratingly screwed on the welding gun mounting sleeve to fix the electric arc additive manufacturing welding gun.
Therefore, the height of the welding gun can be conveniently adjusted after the inclination adjustment, so that the welding gun can keep enough depth of a molten pool and adjust the relative position matched with the stirring pin.
Wherein, the holder 4 is the rectangular shape of width unanimity from top to bottom, and the gyro wheel rolling device includes that the cover establishes a sliding sleeve 17 on the holder with horizontal slip, still runs through on the sliding sleeve 17 and connects soon to be provided with sliding sleeve fastening bolt 18 and realize the fixed to the sliding sleeve, pressure applying device fixed mounting is at sliding sleeve 17 lower extreme, ultrasonic vibrator fixed mounting is in the slide cartridge upper end for the gyro wheel.
In this way, the relative distance between the roller and the welding gun can be better adjusted as desired.
The holder 4 is fixedly mounted on a mechanical arm of the electric arc additive manufacturing special robot (the electric arc additive manufacturing special robot is a mature existing product, and can control a traveling path of a welding gun through computer programming to realize additive welding manufacturing, so that the holder is not shown in the figure).
The second embodiment is as follows: in the present embodiment, a step of performing ultrasonic vibration stirring on the molten pool by using the stirring pin 2 is added on the basis of the first embodiment, that is, in the process of performing the arc additive manufacturing of the first embodiment, the stirring pin with the reciprocating ultrasonic vibration characteristic is inserted into the additive manufacturing molten pool and moves synchronously with the molten pool, and ultrasonic vibration and stirring are directly performed on the solidification process of the molten pool metal, so that the solidification structure and the mechanical property are improved.
Therefore, a stirring pin in a vibration state is further inserted into the molten pool, ultrasonic vibration is introduced into the molten pool through stirring, the cavitation effect and the vibration effect of the ultrasonic vibration can be better utilized, welding pores are reduced, crystal grains are refined, the bonding strength of the edge of the molten pool in a welding area and a non-welding area in the crystallization process is improved, and the metal solidification structure and the mechanical property of the molten pool are improved. Compared with other ultrasonic vibration modes, such as loading on a substrate base metal or loading through an electric arc, the ultrasonic vibration loading mode provided by the invention has the advantages that the ultrasonic vibration on the molten pool is more direct, the mechanical stirring effect is good, and the improvement effect on the metal solidification structure and the mechanical property of the molten pool is better.
Wherein, the stirring pin adopts metal tungsten or tungsten alloy.
In this way, it is better ensured that the pin does not react with the bath metal.
Wherein, the vibrating direction of the stirring pin is along the self-axial direction.
Therefore, the stirring pin acts on the molten pool and only drives liquid metal in the molten pool to do high-frequency reciprocating vibration within a certain area range, and the stirring pin generates a stirring-like effect (actually not stirring in the conventional sense) on the molten pool by means of vibration so as to reduce welding pores, improve the bonding compactness of welding materials at a molecular level, further improve the mechanical property of a welding area and improve the welding effect.
Wherein the vibration frequency of the stirring needle is 20-100KHZ, and the amplitude is 0.2-1 mm. The vibration within the range can better ensure that the vibration has a good effect on metal crystallization, avoid the influence of overlarge vibration on crystallization and reduce the welding quality.
Alternatively, the electric arc additive manufacturing welding gun is arranged along the direction perpendicular to the plane of the product where the molten pool is located during welding, and the stirring pin is inserted into the position below the middle part of the molten pool from the front or the rear of the moving direction of the electric arc additive manufacturing welding gun to realize ultrasonic vibration.
Therefore, the welding gun is arranged along the direction vertical to the plane of the product during the conventional electric arc additive manufacturing process, so that the mode can be implemented by directly adding the stirring pin to introduce ultrasonic vibration on the basis of the control process of the conventional electric arc additive manufacturing process, the control program of the electric arc additive manufacturing welding gun is not required to be adjusted, and the implementation and the application are convenient.
Alternatively, the electric arc additive manufacturing welding gun is arranged in a mode that the upper end of the electric arc additive manufacturing welding gun is obliquely arranged in front of the advancing direction of the electric arc additive manufacturing welding gun during welding, and the stirring pin is arranged behind the electric arc additive manufacturing welding gun and vertically inserted downwards to the middle of the additive manufacturing molten pool to realize ultrasonic vibration.
Therefore, the upper end of the electric arc additive manufacturing welding gun is inclined along the advancing direction, the upper end of the electric arc additive manufacturing welding gun can be used for preheating a region to be processed in front of a molten pool better, meanwhile, a space which is vertically arranged along the middle position of the molten pool can be set for the stirring needle, after the stirring needle is vertically arranged in the middle position of the molten pool, the ultrasonic vibration of the stirring needle can be uniformly transmitted to the whole molten pool, the influence on the metal crystal fusion effect caused by the fact that the ultrasonic vibration is not uniformly transmitted in the molten pool is avoided, and the product forming quality is.
In the second embodiment, after the step of directly performing ultrasonic vibration stirring on the molten pool by using a stirring pin is added, the method can be implemented by using the equipment shown in fig. 3-4, that is, on the basis of the electric arc additive and ultrasonic rolling combined manufacturing equipment, a vibration stirring device is additionally installed on the holder, the vibration stirring device comprises an ultrasonic vibrator 3 for a stirring pin, a stirring pin 2 is downward arranged at the lower end of the ultrasonic vibrator 3 for a stirring pin, and the ultrasonic vibrator 3 for a stirring pin can provide axial vibration for the stirring pin 2.
Like this, welder and vibration agitating unit install on same holder, can guarantee better that the stirring needle follows welder and realizes the vibration stirring in step.
The ultrasonic vibrator 3 for the stirring needle is vertically arranged on a vibrator mounting sleeve 7, the vibrator mounting sleeve 7 is vertically and rotatably arranged on a sliding sleeve 8 through a vibrator mounting sleeve vibration adjusting handle 9, and the sliding sleeve is horizontally and slidably arranged on the retainer.
Like this, can conveniently adjust the inclination of pin mixer as required, make it form the perpendicular to molten bath direction and arrange, perhaps slope arrangement also can be convenient for adjust pin mixer for welder's fore-and-aft distance, make its lower extreme can be located molten bath middle part position better. The adjustment structure of the vibration adjustment handle of the vibrator mounting sleeve can be consistent with the rotation adjustment handle of the welding gun mounting sleeve, and is not detailed here.
The retainer 4 is a strip shape with the same width from top to bottom, the sliding sleeve 8 can be sleeved and installed on the retainer in a horizontally sliding manner, and the sliding sleeve 8 is further penetratingly screwed with a sliding sleeve fastening bolt 11 to fix the sliding sleeve 8.
Therefore, the front and back positions of the stirring pin can be adjusted and fixed more conveniently.
Wherein, the ultrasonic vibrator 3 for the stirring pin is installed on the vibrator installing sleeve through a vibration eliminating spring.
Therefore, the vibration eliminating spring acts between the ultrasonic vibrator for the stirring pin and the vibrator mounting sleeve, and the ultrasonic vibration can be prevented from being transmitted to the retainer through the vibrator mounting sleeve, so that the vibration of the welding gun is avoided. The welding gun can be kept to work stably.
Wherein the ultrasonic vibrator 3 for a pin is an ultrasonic vibrator for a pneumatic pin.
Therefore, the ultrasonic vibration retainer has the advantages of stable effect, convenience in control and implementation and small adverse effect of ultrasonic vibration on the retainer. And the pneumatic ultrasonic vibration source has higher tolerance degree on heat and high temperature, and is more suitable for the high-temperature working condition of electric arc additive manufacturing.
The holder 4 is fixedly mounted on a mechanical arm of the electric arc additive manufacturing special robot (the electric arc additive manufacturing special robot is a mature existing product, and can control a traveling path of a welding gun through computer programming to realize additive welding manufacturing, so that the holder is not shown in the figure).
Therefore, automatic arc additive manufacturing of the product is conveniently realized through robot computer control.
Wherein, the lower end of the stirring pin 2 is provided with a circle of horizontal convex protrusions 12.
Therefore, when the stirring pin vibrates up and down along the axial direction, the bulge can play a great vibration amplification role on a molten pool, and the ultrasonic vibration effect is improved. In specific implementation, the convex distance of the bulge is not too large, the convex distance can be generally controlled within three times of the diameter of the stirring pin, and the specific size can be obtained according to experimental verification.
The bulges are uniformly distributed in the circumferential direction, and the upper surface and the lower surface of each bulge are respectively provided with reversely symmetrical inclined surfaces or spiral blade surfaces.
Therefore, along with the reciprocating vibration of the stirring needle along the axial direction, the upper surface and the lower surface of the bulge can form an action effect of pushing the molten metal outwards in a reciprocating and whirling mode in the circumferential direction during reciprocating motion, further generate reciprocating vibration along the circumferential direction while generating vibration along the axial direction for the molten metal, wherein the vibration along the axial direction can better act on the bottom of a molten pool, the vibration along the circumferential direction can better act on the peripheral wall of the molten pool, the double vibration forms a composite high-frequency vibration effect on the molten pool of the molten metal, the bonding property of the molten pool to the metal on the peripheral wall is greatly improved, the metal crystal structure can be better refined, the influence of the vibration on the metal crystal fusion effect is improved, and the forming quality of a product is improved.
In order to further verify the effect, the applicant further performs multiple sets of comparative experiment verification, and the parameters in each experimental example are kept consistent: the geometric dimension of the substrate is 100 multiplied by 50 multiplied by 10mm, a MIG (metal-inert gas welding) welding machine is adopted, and the process parameters of electric arc additive manufacturing are as follows: the welding current is 80A, the voltage is 19.8V, the diameter of a welding wire is 1.6mm, the wire feeding speed is 120cm/min, the welding speed (the moving speed of a welding gun) is 200mm/min, the protective gas is argon with the concentration of 99.99 percent, and the gas flow is 15L/min. 4 passes of arc additive manufacturing of the accumulation layer are totally performed, the interval of each pass is two minutes, 3 samples are welded in each embodiment, the three positions of the front, middle and rear of each sample are tested, and the average value is obtained after the performance is tested.
Comparative example 1: the welding wire is AZ31 magnesium alloy, and ultrasonic vibration and rolling are not added during electric arc additive manufacturing. The experimental results are as follows: the average tensile strength was 222.34 MPa.
Comparative example 2: the welding wire is ER5356 aluminum alloy, and ultrasonic vibration and rolling are not added during electric arc additive manufacturing. The experimental results are as follows: the average tensile strength was 251.4 MPa.
Experimental example 1: the test was conducted using the apparatus and procedure of embodiment one, and the wire was AZ31 magnesium alloy. The distance between the roller and the welding gun is 5 mm. When the electric arc additive manufacturing is carried out, follow-up ultrasonic vibration and rolling compaction are applied to each thermal additive stacking layer, the ultrasonic vibration power is 100W, and the downward pressure of roller compaction is 2.4 KN.
The experimental results are as follows: the average tensile strength of the arc additive manufacturing deposition layer is 228.14MPa, and compared with the comparative example 1, the structure of the additive manufacturing deposition layer is denser and the crystal grains are finer.
Experimental example 2: the test was conducted using the apparatus and procedure of embodiment one, and the wire was AZ31 magnesium alloy. The distance between the roller and the welding gun is 10 mm. When the electric arc additive manufacturing is carried out, follow-up ultrasonic vibration and rolling compaction are applied to each hot additive stacking layer, the ultrasonic vibration power is 175W, and the downward pressure of the roller compaction is 1.6 KN.
The experimental results are as follows: the average tensile strength of the arc additive manufacturing deposition layer is 235.41MPa, and compared with the comparative example 1, the structure of the additive manufacturing deposition layer is denser and the crystal grains are finer.
Experimental example 3: the test was conducted using the apparatus and procedure of embodiment one, and the wire was AZ31 magnesium alloy. The roller is 15mm away from the welding gun. When the electric arc additive manufacturing is carried out, follow-up ultrasonic vibration and rolling compaction are applied to each thermal additive stacking layer, the ultrasonic vibration power is 250W, and the downward pressure of the roller compaction is 0.8 KN.
The experimental results are as follows: the average tensile strength of the arc additive manufacturing deposition layer is 230.14MPa, and compared with the comparative example 1, the structure of the additive manufacturing deposition layer is denser and the crystal grains are finer.
Experimental example 4: the test was conducted using the apparatus and procedure of embodiment two, with the wire being AZ31 magnesium alloy. The roller is 15mm away from the welding gun. When the electric arc additive manufacturing is carried out, follow-up ultrasonic vibration and rolling compaction are applied to each thermal additive stacking layer, the ultrasonic vibration power is 250W, and the downward pressure of the roller compaction is 0.8 KN.
The experimental results are as follows: the average tensile strength of the arc additive manufacturing deposition layer is 237.55MPa, and compared with the comparative example 1, the structure of the additive manufacturing deposition layer is denser and the crystal grains are finer.
Experimental example 5: the experiment was carried out using the apparatus and procedure of the first embodiment, and the wire was an ER5356 aluminum alloy wire. The distance between the roller and the welding gun is 5 mm. When the electric arc additive manufacturing is carried out, follow-up ultrasonic vibration and rolling compaction are applied to each thermal additive stacking layer, the ultrasonic vibration power is 50W, and the downward pressure of the roller rolling compaction is 2.4 KN.
The experimental results are as follows: the average tensile strength of the arc additive manufacturing deposition layer is 269.05MPa, and compared with the comparative example 2, the structure of the additive manufacturing deposition layer is denser and the crystal grains are finer.
Experimental example 6: the experiment was carried out using the apparatus and procedure of embodiment one, and the wire was an ER5356 alloy wire. The distance between the roller and the welding gun is 10 mm. When the electric arc additive manufacturing is carried out, follow-up ultrasonic vibration and rolling compaction are applied to each thermal additive stacking layer, the ultrasonic vibration power is 125W, and the downward pressure of the roller compaction is 1.6 KN.
The experimental results are as follows: the average tensile strength of the arc additive manufacturing deposition layer is 266.30MPa, and compared with the comparative example 2, the structure of the additive manufacturing deposition layer is denser and the crystal grains are finer.
Experimental example 7: the experiment was carried out using the apparatus and procedure of the first embodiment, and the wire was an ER5356 aluminum alloy wire. The roller is 15mm away from the welding gun. When the electric arc additive manufacturing is carried out, follow-up ultrasonic vibration and rolling compaction are applied to each thermal additive stacking layer, the ultrasonic vibration power is 200W, and the downward pressure of roller compaction is 0.8 KN.
The experimental results are as follows: the average tensile strength of the arc additive manufacturing deposition layer is 264.37MPa, and compared with the comparative example 2, the structure of the additive manufacturing deposition layer is denser and the crystal grains are finer.
Experimental example 8: the experiment is carried out by adopting the equipment and the steps of the second embodiment, and the welding wire is an ER5356 aluminum alloy welding wire. The roller is 15mm away from the welding gun. When the electric arc additive manufacturing is carried out, follow-up ultrasonic vibration and rolling compaction are applied to each thermal additive stacking layer, the ultrasonic vibration power is 200W, and the downward pressure of roller compaction is 0.8 KN.
The experimental results are as follows: the average tensile strength of the arc additive manufacturing deposition layer is 273.42MPa, and compared with the comparative example 2, the structure of the additive manufacturing deposition layer is denser and the crystal grains are finer.
Therefore, it can be known from the above experimental examples that under the same parameter conditions, the strength performance of the product obtained in the second embodiment is greater than that of the product obtained in the first embodiment. Therefore, the method can effectively improve the tensile strength of the product obtained by the electric arc additive manufacturing.
Claims (10)
1. An electric arc additive manufacturing method with welding-following ultrasonic vibration and rolling characteristics is characterized in that, an ultrasonic vibration rolling roller which can synchronously move in the same direction along with the electric arc additive manufacturing welding gun is arranged behind the electric arc additive manufacturing welding gun, during the electric arc additive manufacturing process, the electric arc additive manufacturing welding gun firstly performs arc striking and translation, electric arc additive manufacturing is realized through welding material melting and solidification, the ultrasonic vibration rolling roller synchronously moves in the same direction along with the electric arc additive manufacturing welding gun, subjecting the arc additive manufacturing layer in the thermoplastic stage to ultrasonic vibration and rolling to plastically deform the arc additive manufacturing layer and promote cooling thereof, meanwhile, ultrasonic vibration is transmitted into an electric arc melting pool through the electric arc additive manufacturing layer and the substrate base metal through plane vibration combined from top to bottom and front and back, so that the solidification process of the melting pool is subjected to short-distance ultrasonic vibration, and the structure and the performance of the electric arc additive layer are improved by utilizing the comprehensive action of the ultrasonic vibration and the base metal.
2. The method of claim 1, wherein the ultrasonically vibrating roller is a steel ultrasonically vibrating roller and the side surface is concave curved to conform to a cross-sectional shape of the arc additive manufacturing layer.
3. The arc additive manufacturing method with the weld-follow ultrasonic vibration and compaction characteristics according to claim 1, wherein the ultrasonic vibration compaction roller achieves ultrasonic compaction of the arc additive manufacturing layer with an average downforce of 0.5-2.5KN and an ultrasonic vibration power of 50-250W.
4. The method for manufacturing the arc additive with the welding-following ultrasonic vibration and rolling characteristics as claimed in claim 1, wherein in the process of arc additive manufacturing, a stirring pin with the reciprocating ultrasonic vibration characteristics is simultaneously inserted into an additive manufacturing molten pool and moves synchronously with the molten pool, and ultrasonic vibration and stirring are directly carried out on the solidification process of molten pool metal to improve the solidification structure and mechanical properties of the molten pool metal; the vibration direction of the stirring pin is along the self axial direction.
5. The electric arc additive manufacturing method having the welding-following ultrasonic vibration and rolling characteristics according to claim 1, which is implemented by means of an electric arc additive and ultrasonic rolling combined manufacturing apparatus comprising an electric arc additive manufacturing welding gun installed on a holder horizontally disposed as a whole with one end of a welding head downward, a roller rolling device installed on the holder, the roller rolling device comprising a pressing means with a telescopic arm vertically disposed downward and a steel ultrasonic vibration rolling roller installed at a lower end of the telescopic arm, a side surface of the ultrasonic vibration rolling roller being disposed toward the electric arc additive manufacturing welding gun and being concave-curved to adapt to a cross-sectional shape of the electric arc additive manufacturing layer, the roller rolling device further comprising an ultrasonic vibrator for a roller, the roller is relatively fixedly connected with the pressing device by the ultrasonic vibrator and provides ultrasonic vibration for the roller.
6. The arc additive manufacturing method with the weld-following ultrasonic vibration and crush features of claim 5, wherein the arc additive manufacturing welding gun is mounted on a welding gun mounting sleeve, and the welding gun mounting sleeve is vertically rotatably mounted on the holder by a welding gun mounting sleeve rotation adjusting handle;
the electric arc additive manufacturing welding gun can be installed on the welding gun installation sleeve in an axially sliding mode, and a welding gun fastening bolt is further arranged on the welding gun installation sleeve in a penetrating and screwed mode to fix the electric arc additive manufacturing welding gun.
7. The method for manufacturing an arc additive having ultrasonic vibration and rolling characteristics along with welding according to claim 5, wherein the holder is in a strip shape with a uniform width, the roller rolling device comprises a sliding sleeve horizontally slidably sleeved on the holder, a bolt for fastening the sliding sleeve is further screwed on the sliding sleeve in a penetrating manner to fix the sliding sleeve, the pressure applying device is fixedly installed at the lower end of the sliding sleeve, and the roller is fixedly installed at the upper end of the sliding sleeve by an ultrasonic vibrator.
8. The arc additive manufacturing method having the welding-following ultrasonic vibration and crushing characteristics as claimed in claim 5, wherein a vibration stirring device is further installed on the holder, the vibration stirring device comprises an ultrasonic vibrator for the pin, a pin is provided downward at a lower end of the ultrasonic vibrator for the pin, and the ultrasonic vibrator for the pin can provide the pin with vibration in an axial direction.
9. The arc additive manufacturing method with weld-following ultrasonic vibration and crush features of claim 8, wherein the said stirring pin is vertically mounted with an ultrasonic vibrator on a vibrator mounting sleeve, the vibrator mounting sleeve is vertically rotatably mounted on a sliding sleeve by a vibrator mounting sleeve vibration adjusting handle, the sliding sleeve is horizontally slidably mounted on the holder;
the retainer is in a strip shape with the same upper and lower width, the sliding sleeve can be sleeved and mounted on the retainer in a horizontally sliding manner, and the sliding sleeve is also penetratingly and spirally connected with a bolt for fastening the sliding sleeve to fix the sliding sleeve;
the ultrasonic vibrator for the stirring pin is arranged on the vibrator mounting sleeve through a vibration absorption spring.
10. The arc additive manufacturing method with welding-following ultrasonic vibration and grinding characteristics as claimed in claim 8, wherein the lower end of the stirring pin is provided with a circle of horizontal convex protrusions;
the bulges are uniformly arranged in the circumferential direction, and the upper surface and the lower surface of each bulge are respectively provided with an inclined plane or a spiral blade surface which are in reverse symmetry.
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