CN114799224B - Laser additive manufacturing forming system and forming regulation and control method - Google Patents
Laser additive manufacturing forming system and forming regulation and control method Download PDFInfo
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- CN114799224B CN114799224B CN202210414391.6A CN202210414391A CN114799224B CN 114799224 B CN114799224 B CN 114799224B CN 202210414391 A CN202210414391 A CN 202210414391A CN 114799224 B CN114799224 B CN 114799224B
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 88
- 239000000654 additive Substances 0.000 title claims abstract description 84
- 230000000996 additive effect Effects 0.000 title claims abstract description 84
- 238000000034 method Methods 0.000 title claims abstract description 56
- 230000033228 biological regulation Effects 0.000 title abstract description 14
- 238000011065 in-situ storage Methods 0.000 claims abstract description 107
- 230000006698 induction Effects 0.000 claims abstract description 100
- 239000000843 powder Substances 0.000 claims abstract description 74
- 230000008569 process Effects 0.000 claims abstract description 26
- 239000007787 solid Substances 0.000 claims abstract description 14
- 229910000838 Al alloy Inorganic materials 0.000 claims description 41
- 230000001276 controlling effect Effects 0.000 claims description 30
- 238000012544 monitoring process Methods 0.000 claims description 14
- 239000011261 inert gas Substances 0.000 claims description 12
- 238000001035 drying Methods 0.000 claims description 10
- 230000001105 regulatory effect Effects 0.000 claims description 10
- 238000012545 processing Methods 0.000 claims description 9
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 8
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 8
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 8
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 8
- 229910052804 chromium Inorganic materials 0.000 claims description 8
- 239000011651 chromium Substances 0.000 claims description 8
- 229910052802 copper Inorganic materials 0.000 claims description 8
- 239000010949 copper Substances 0.000 claims description 8
- 238000003754 machining Methods 0.000 claims description 8
- 229910052749 magnesium Inorganic materials 0.000 claims description 8
- 239000011777 magnesium Substances 0.000 claims description 8
- 239000011701 zinc Substances 0.000 claims description 8
- 229910052725 zinc Inorganic materials 0.000 claims description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 6
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- 229910052760 oxygen Inorganic materials 0.000 claims description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 4
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- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/80—Data acquisition or data processing
- B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/90—Means for process control, e.g. cameras or sensors
-
- 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
-
- 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
-
- 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
- B33Y70/00—Materials specially adapted for additive manufacturing
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0408—Light metal alloys
- C22C1/0416—Aluminium-based alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/10—Alloys based on aluminium with zinc as the next major constituent
-
- 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
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Automation & Control Theory (AREA)
- Plasma & Fusion (AREA)
- Physics & Mathematics (AREA)
- Analytical Chemistry (AREA)
- Powder Metallurgy (AREA)
- Laser Beam Processing (AREA)
Abstract
The invention discloses a laser additive manufacturing forming system and a forming regulation method, wherein the system comprises laser additive manufacturing equipment, and the system comprises: the device comprises a laser, an in-situ magnetic field generator, an in-situ magnetic field control system and a power supply, wherein the in-situ magnetic field generator comprises a plurality of nonlinear magnetic field generating units, and each nonlinear magnetic field generating unit comprises a magnetic induction coil; computer design software for establishing three-dimensional solid geometric model, acquiring laser additive manufacturing process and leading into laser additive manufacturing equipment; the in-situ magnetic field generator, the in-situ magnetic field control system and the power supply form a closed loop, the in-situ magnetic field generator is used for generating an in-situ magnetic field to act on the built-in powder, the laser is used for generating laser to scan the powder laser, the in-situ magnetic field control system is used for controlling the power supply to generate current to activate or deactivate one or more nonlinear magnetic field generating units, and the magnetic induction intensities of the powder at different forming positions of the laser scanning in the process of forming the powder into the sample are controlled to be the same.
Description
Technical Field
The invention relates to the technical field of additive manufacturing, in particular to a laser additive manufacturing forming system and a forming regulation method.
Background
The aluminum alloy is widely applied to the industries of aerospace, ships, chemical industry, metal outer packaging and the like, and is applied to the aeronautical industry as early as the end of the 10 th year of the 20 th century, and has the characteristics of good plasticity after solution treatment, good heat treatment strengthening effect, high specific stiffness, good corrosion resistance, excellent low-temperature strength and the like, so far, the aluminum alloy is still widely applied to the aeronautical industry. However, the traditional process for manufacturing the aluminum alloy component has serious material loss, long manufacturing period and high cost, and can be completed by other processes such as welding when manufacturing complex parts. Therefore, an "additive" process with high precision and low material consumption rate is an urgent need in the manufacturing industry today.
The laser additive manufacturing technology is an additive manufacturing technology which uses high-energy laser beams as heat sources, stacks powder layer by layer and forms a three-dimensional member by laser rapid fusion, and has remarkable advantages in the aspects of increasing the material utilization rate, manufacturing complex structures and reducing the cost. The laser additive manufacturing technology for manufacturing metal parts with complex shapes has higher dimensional accuracy than other traditional manufacturing technologies, has unique advantages in complex structures and thin-wall member forming, saves die design and production time, but has high crack sensitivity due to the inherent characteristics of high heat conductivity coefficient, high laser reflectivity, low melt fluidity and the like of part of high-strength aluminum alloy, so that the defects of cracks, pores and the like are easy to generate in the processing process of laser additive manufacturing.
Disclosure of Invention
The invention aims to: the laser additive manufacturing and forming system and the method for regulating and controlling the formability are provided for solving the problems that the powder is formed into coarse columnar crystals and easy to generate crack holes of a sample in the laser additive manufacturing and forming process.
The technical scheme is as follows: the invention provides a laser additive manufacturing forming system, comprising: a laser additive manufacturing apparatus comprising: the device comprises a laser, an in-situ magnetic field generator, an in-situ magnetic field control system and a power supply, wherein the in-situ magnetic field generator comprises a top cover and a plurality of nonlinear magnetic field generating units, and each nonlinear magnetic field generating unit is provided with a magnetic induction coil; computer design software for creating three-dimensional solid geometric model of the sample, for obtaining the machining process of laser additive manufacturing and leading into the laser additive manufacturing equipment; the in-situ magnetic field generator, the in-situ magnetic field control system and the power supply form a closed loop, powder is placed on the top cover, the in-situ magnetic field generator is used for generating an in-situ magnetic field and acting on the powder, the laser is used for generating laser to scan the powder, the in-situ magnetic field control system is used for controlling the power supply to generate current to activate or deactivate one or more nonlinear magnetic field generating units around the laser position, and controlling the magnetic induction intensity of the nonlinear magnetic field generating units, so that the powder is formed into a sample according to a processing procedure, a laser scanning path in the process of forming the sample is in a magnetic field range, and the magnetic induction intensity of different forming positions of laser scanning is the same.
Further, the in-situ magnetic field generator is arranged in an inert gas environment with oxygen content lower than 50ppm, and the radius r of the outer circle of the magnetic induction coil of each magnetic field generating unit is set 2 Radius r of inner ring 1 The calculated equivalent radius is: the center of a group of magnetic induction coils is taken as an origin, the magnetic induction coils are introduced with current I, coordinates (x, y, h) of any point in space are given, magnetic induction intensity generated at the point (x, y, h) is Bx, by and Bz, the forming height of a sample is h, and the permeability of an inert gas environment is mu 0 Calculating magnetic induction intensity B: />
Furthermore, the magnetic induction intensity B of the laser is the same under different sample forming heights h; the current I of the nonlinear magnetic field generating unit is 0-5A, and the magnetic induction intensity B of the nonlinear magnetic field generating unit is 0-1T.
Further, the in-situ magnetic field control system comprises: the system comprises a current control system, an information feedback system and a heat source tracking system which are connected in series, wherein the current control system is connected with a power supply, and an in-situ magnetic field generator is respectively connected with the power supply and the heat source tracking system; the heat source tracking system is used for tracking a heat source of the laser to determine the laser position and transmitting the laser position to the information feedback system; the information feedback system is used for confirming one or more nonlinear magnetic field generating units around the laser position and feeding back the nonlinear magnetic field generating units to the current control system; the current control system is used for controlling the power supply to transmit current to the confirmed nonlinear magnetic field generating unit so as to generate a magnetic field.
Further, the in-situ magnetic field control system further comprises: the magnetic field monitoring system is respectively connected with the current control system, the in-situ magnetic field generator and the heat source tracking system; the magnetic field monitoring system is used for monitoring the magnetic induction intensity of the laser position and transmitting the magnetic induction intensity information to the current control system; when the magnetic induction intensity is smaller than a set value, the current control system controls the power supply to increase the current so as to improve the magnetic induction intensity of the area, and when the magnetic induction intensity is larger than the set value, the current control system controls the power supply to decrease the current so as to reduce the magnetic induction intensity of the area.
The laser additive manufacturing and forming system utilizes an in-situ magnetic field generator, an in-situ magnetic field regulation and control system and a power supply to form a closed loop, and utilizes the in-situ magnetic field generator to enable powder to be in a controllable magnetic field range in the process of forming the powder into a sample according to a processing procedure; the in-situ magnetic field control system is provided with a magnetic field monitoring system, a signal feedback system and a current control system, and the in-situ magnetic induction intensity of powder in the melting and solidifying area is controlled by controlling the output current of a power supply, so that the magnetic induction intensity of a laser additive manufacturing sample in different spatial positions is ensured to be the same, and the laser additive manufacturing forming sample is a sample three-dimensional entity with uniform microstructure and high compactness; the invention can effectively reduce the defect number in the high crack sensitivity aluminum alloy sample manufactured by laser additive, refine the microstructure state and improve the forming effect and mechanical property.
The invention also provides a method for regulating and controlling the formability of laser additive manufacturing, which comprises the following steps:
s1: drying the powder in a drying box;
s2: providing laser additive manufacturing and forming equipment, wherein the equipment comprises a laser, an in-situ magnetic field generator, an in-situ magnetic field regulation and control system and a power supply; the in-situ magnetic field generator comprises a top cover and a plurality of nonlinear magnetic field generating units, wherein each nonlinear magnetic field generating unit is provided with a magnetic induction coil;
s3: establishing a three-dimensional solid geometric model of the sample, obtaining a machining procedure of laser additive manufacturing, and introducing the machining procedure into laser additive manufacturing equipment;
s4: setting the magnetic induction intensity of an in-situ magnetic field generator on a top cover, and starting an in-situ magnetic field regulation and control system to enable a laser scanning path to be in a magnetic field range in the process of forming the powder into a sample according to a processing procedure, wherein the magnetic induction intensity of different forming positions of laser scanning is the same;
s5: and (5) carrying out post-treatment on the sample.
Further, the powder in the step S1 is an aluminum alloy mixture powder containing aluminum, zinc, magnesium, copper and chromium, wherein the content of zinc is 5.6 wt%, the content of magnesium is 2.5 wt%, the content of copper is 1.6 wt%, and the content of chromium is 0.30 wt%; the particle size of the aluminum alloy mixture powder is in the range of 20-63 μm.
Further, in the step of planning the laser scanning path in step S3, the laser process parameters are set as follows: the laser power is 375-425W, the scanning speed is 800-1200 mm/s, the scanning interval is 60 mu m, the powder layer thickness is 30 mu m, an island-shaped scanning strategy is adopted, the island size is 4.8mm, and the laser filling direction rotation between adjacent layers is 37 degrees.
Further, step S4 comprises the step of exposing the in-situ magnetic field generator to an inert gas atmosphere having an oxygen content of less than 50ppm prior to sample formation; the current of the nonlinear magnetic field generating unit is 0-5A, and the magnetic induction intensity B of the nonlinear magnetic field generating unit is set to be 0-1T.
Further, after the sample is formed and the top cover is cooled in the step S4, the top cover is disassembled, and the sample and the top cover are separated by utilizing a linear cutting technology so as to obtain the sample; post-treatment of the sample includes grinding, polishing and corroding the sample.
The beneficial effects are that: the method for regulating and controlling the formability of the laser additive manufacturing comprises the steps of adding an in-situ magnetic field generator, an in-situ magnetic field regulating and controlling system and a power supply to form a closed loop system, controlling an in-situ magnetic field generating device by utilizing an in-situ magnetic field control system, wherein a magnetic field monitoring system, a signal feedback system and a current control system are arranged in the in-situ magnetic field control system, and ensuring that the magnetic induction intensity of different forming positions is kept unchanged in the laser additive manufacturing and forming process of forming powder into a sample according to a processing procedure by controlling the output current of the power supply so as to ensure that the powder is manufactured and formed into a sample three-dimensional entity with uniform microstructure and high compactness by laser additive manufacturing; the invention can effectively reduce the defect number in the high crack sensitivity aluminum alloy sample manufactured by laser additive, refine the microstructure state and improve the forming effect and mechanical property.
Drawings
FIG. 1a is a schematic diagram of a laser additive manufacturing forming system according to the present invention;
FIG. 1b is a schematic diagram of an assembly of an in-situ magnetic field generator;
FIG. 2 is a schematic diagram of an in-situ magnetic field generator, an in-situ magnetic field regulation system, and a power supply of the present invention forming a closed loop;
FIG. 3 is a schematic diagram illustrating the operation of an array of distributed nonlinear magnetic field generating units;
FIG. 4 is a magnetic induction intensity distribution of a single nonlinear magnetic field generating unit;
FIG. 5 is a longitudinal cross-sectional optical image of a grain refined aluminum alloy block sample treated with an applied electrostatic magnetic field prepared in example 1;
FIG. 6 is a longitudinal cross-sectional optical image of a grain refined aluminum alloy block sample treated with an applied electrostatic magnetic field prepared in comparative example 1;
FIG. 7 is a longitudinal cross-sectional optical image of a laser powder bed molten aluminum alloy sample prepared in comparative example 2;
FIG. 8 is a graph showing the microhardness comparison of three groups of aluminum alloys of example 1 and comparative example 2.
Detailed Description
The technical scheme provided by the invention is described in detail below with reference to the accompanying drawings.
As shown in fig. 1 to 8, the laser additive manufacturing forming system provided by the present invention includes: laser additive manufacturing equipment and computer design software; the laser additive manufacturing equipment comprises a laser 1, an in-situ magnetic field generator 5, an in-situ magnetic field control system 6 and a power supply 7, wherein the in-situ magnetic field generator 5 comprises a top cover 9 and a nonlinear magnetic field generating unit array 11, powder 3 is arranged on the top cover 9, the nonlinear magnetic field generating unit array 11 comprises a plurality of nonlinear magnetic field generating units 110, and the nonlinear magnetic field generating units 110 comprise magnetic induction coils; the in-situ magnetic field control system 6 includes: a current control system 13, an information feedback system 14, a heat source tracking system 15 and a magnetic field monitoring system 16.
The laser additive manufacturing equipment is improved based on SLM-150 equipment, and replaces a conventional substrate of the existing laser additive manufacturing equipment by using an in-situ magnetic field generator 5, wherein the laser additive manufacturing equipment further comprises a laser powder bed 4, a forming chamber, a forming cylinder, a powder cylinder, an automatic powder spreading system, a protective atmosphere device, a computer control circuit system and a cooling circulation system. The automatic powder spreading system comprises a powder spreading device 8, wherein the powder 3 is positioned in the powder bed 4, the powder spreading device 8 is used for spreading the powder 3, and the laser 1, preferably YLR-500 type optical fiber laser, is used for generating laser 2 so as to perform laser scanning on the powder 3.
In the application, the powder 3 is dry aluminum alloy powder, the aluminum alloy powder is obtained by drying treatment through a drying box, and a formed metal powder sample is an aluminum alloy sample; the aluminum alloy powder is a mixture of aluminum, zinc, magnesium, copper and chromium, wherein the content of zinc is 5.6 wt%, the content of magnesium is 2.5 wt%, the content of copper is 1.6 wt%, and the content of chromium is 0.30 wt%; the grain size of the aluminum alloy powder is 20-63 mu m.
In this application, the in-situ magnetic field generator 5 is fixedly arranged in a forming cylinder of a forming area, so that a sample is formed on the top cover 9; the external dimensions of the in-situ magnetic field generator 5 are selected as follows: the length 150mm, the width 150mm, the height 4mm, as shown in fig. 2, the in-situ magnetic field generator 5 further comprises a magnetic field shielding bottom plate 10, and the top cover 9 and the magnetic field shielding bottom plate 10 are mounted together by 4 screws 12, the nonlinear magnetic field generating unit array 11 is located between the top cover 9 and the magnetic field shielding bottom plate 10, wherein the top cover 9 is an aluminum alloy top cover, the magnetic field shielding bottom plate 10 is a nickel-based magnetic field shielding bottom plate, and the magnetic induction coils in the nonlinear magnetic field generating units 110 are controllable magnetic induction coils so as to meet nonlinear requirements.
The computer design software comprises computer aided design software and Materialise Magics software, the computer aided design software is used for establishing a three-dimensional solid geometric model of a sample, the Materialise Magics software is used for obtaining the machining procedure of laser additive manufacturing of the three-dimensional solid geometric model, and the machining procedure is led into the laser additive manufacturing equipment.
The in-situ magnetic field generator 5, the in-situ magnetic field control system 6 and the power supply 7 form a closed loop, the in-situ magnetic field generator 5 is used for generating an in-situ magnetic field in the vertical direction and acting on the powder 3, the power supply 7 is a direct current power supply, the in-situ magnetic field control system 6 is used for controlling the current generated by the power supply 7 to activate or deactivate one or more nonlinear magnetic field generating units 110 near the laser position and controlling the magnitude of the magnetic induction intensity of the nonlinear magnetic field generating units 110 so that the laser scanning path is always in the magnetic field range and the magnetic induction intensity of different forming positions of the laser scanning, namely different horizontal positions and vertical positions, is the same, so that the powder 3 is formed into a sample. The sample formed by laser additive manufacturing is a three-dimensional solid aluminum alloy sample with uniform microstructure and high compactness.
The forming cylinder of the laser additive manufacturing equipment is sealed by a sealing device, vacuumized and filled with inert gas so that the oxygen content in the forming cavity is lower than 50ppm, and the in-situ magnetic field generator 5 is in an inert gas environment.
Outer circle radius r of magnetic induction coil of each nonlinear magnetic field generating unit 110 is set 2 Radius r of inner ring 1 The calculated equivalent radius is:
the nonlinear magnetic field generating unit 110 has magnetic induction coils, and is configured to supply a current I to a group of centers of the magnetic induction coils as an origin, and to generate magnetic induction intensities Bx, by, bz at arbitrary point coordinates (x, y, h) in a space, a sample forming height h, and a permeability in an inert gas atmosphere μ at the point 0 Calculating magnetic induction intensity B:
as shown in fig. 3, fig. 3 is a schematic diagram illustrating the operation of the nonlinear magnetic field generating units distributed in an array, and fig. 4 is a magnetic induction intensity distribution of the single nonlinear magnetic field generating unit 110; square cells 110a represent activated nonlinear magnetic field generating cells 110, square cells 110b represent deactivated nonlinear magnetic field generating cells 110, arrows represent laser scanning directions, and circular areas 110c represent laser spot areas. In the application, the magnetic induction intensity B of the laser under different sample forming heights h is required to be the same; the magnetic induction intensity B at the position can be controlled to be 0-1T only by controlling the current I of the magnetic induction coil to be 0-5A.
The in-situ magnetic field generator 5 enables the powder 3 to be in a controllable magnetic field range in the melting and solidification process; and the magnetic induction intensity B is in an inverse proportion state with the square of the sample forming height h through the design, the formed sample is prevented from being too high so as to ensure that a molten pool is completely under the set magnetic induction intensity, and further ensure that the processed aluminum alloy sample has good forming performance and mechanical property.
The current control system 13, the signal feedback system 14 and the heat source tracking system 15 of the in-situ magnetic field control system 6 are connected in series, and the magnetic field monitoring system 16 is respectively connected with the current control system 13, the in-situ magnetic field generator 5 and the heat source tracking system 15; the current control system 13 is connected with the power supply 7, the in-situ magnetic field generating device 5 is respectively connected with the heat source tracking system 15 and the magnetic field monitoring system 16, and the in-situ magnetic field generating device 5 is connected with the power supply 7, so that the in-situ magnetic field generating device 5, the in-situ magnetic field control system 6 and the power supply 7 form a closed loop system.
The heat source tracking system 15 is configured to track the heat source of the laser 2 to determine the scanning position of the laser 2, and transmit the laser position to the information feedback system 14; the information feedback system 14 is used for confirming one or more nonlinear magnetic field generating units 110 near the laser position and feeding back the information of the nonlinear magnetic field generating units 110 to the current control system 13; the current control system 13 is used for controlling the power supply 7 to transmit current to the confirmed nonlinear magnetic field generating unit 110 to generate a magnetic field. As the laser 2 moves, the in-situ magnetic field control system 6 is used to activate or deactivate one or more nonlinear magnetic field generating units 110 near the laser scanning location to ensure that the laser scanning path is always within the magnetic field range.
The magnetic field monitoring system 16 is used for monitoring the magnetic induction intensity of the laser position in the space region and transmitting the magnetic induction intensity information to the current control system 13; when the magnetic induction intensity is smaller than the set value, the current control system 13 controls the power supply 7 to increase the current to increase the magnetic induction intensity of the area, and when the magnetic induction intensity is larger than the set value, the current control system 13 controls the power supply 7 to decrease the current to decrease the magnetic induction intensity of the area. Thereby realizing the control of the in-situ magnetic induction intensity of the powder 3 in the melting and solidifying area by using the in-situ magnetic field control system 6.
In the laser additive manufacturing and forming process, the laser power is 375-425W, the laser scanning speed is 800-1200 mm/s, the scanning interval is 60 mu m, the powder spreading thickness is 30 mu m, and the island scanning strategy is adopted, so that the island size is 4.8 mu m. The in-situ magnetic field regulation system 6 is utilized to regulate the magnetic induction intensity to be 0-1T, so that the sample manufactured and formed by laser additive is a three-dimensional solid aluminum alloy sample with uniform microstructure and high density.
The laser additive manufacturing and forming system utilizes an in-situ magnetic field generator 5, an in-situ magnetic field regulating and controlling system 6 and a power supply 7 to form a closed loop, and utilizes the in-situ magnetic field generator 5 to enable the powder 3 to be in a controllable magnetic field range in the melting and solidification process; the in-situ magnetic field control system 6 is provided with a magnetic field monitoring system 16, a signal feedback system 14 and a current control system 13, and the in-situ magnetic induction intensity of the powder 3 in the melting and solidifying area is controlled by controlling the current output by the power supply 7, and the in-situ magnetic field generator 5 is controlled by utilizing the in-situ magnetic field control system 6, so that the magnetic induction intensity of a laser additive manufacturing sample at different spatial positions is ensured to be the same, namely, the magnetic induction intensity of each position in the laser additive manufacturing and forming process is kept unchanged, the defect number in the laser additive manufacturing high-crack-sensitivity aluminum alloy can be effectively reduced, the microstructure state is thinned, the forming effect and the mechanical property are improved, and the laser additive manufacturing and forming aluminum alloy sample is a three-dimensional solid sample with uniform microstructure and high compactness. The intelligent regulation function is realized by using the in-situ magnetic field generator 5, so that the magnetic induction intensity of the melt under different sample forming heights h is the same, and the magnetic field is generated by adding the in-situ magnetic field generator 5, so that on one hand, the flow speed of a molten pool marangoni flow is reduced, the flow speed of the molten pool marangoni flow is stabilized, on the other hand, the columnar dendrite is broken by the magnetic field, the columnar dendrite is converted into equiaxial crystals, the defects that the high-crack-sensitivity aluminum alloy sample is extremely easy to generate pore cracks and the like in the forming process are avoided, the laser powder bed fusion forming of the high-strength forged aluminum alloy with the advantages of equiaxial crystal grains, no cracks and high forming degree is realized, and the adaptability of the aluminum alloy to the laser additive manufacturing process is greatly improved. The forming effect and the mechanical property are obviously improved.
In an embodiment 1 of the present application, the present invention further provides a method for adjusting and controlling formability of laser additive manufacturing, including the following steps:
s1: drying the powder 3 in a drying box;
the powder 3 in the step S1 is aluminum alloy powder, and the aluminum alloy powder is a mixture of aluminum, zinc, magnesium, copper and chromium, wherein the content of zinc is 5.6 wt%, the content of magnesium is 2.5 wt%, the content of copper is 1.6 wt%, and the content of chromium is 0.30 wt%; the grain size of the aluminum alloy powder is 20-63 mu m.
In this step S1, the powder 3 was kept dry by drying in a drying oven at 80℃for 8 hours.
S2: providing laser additive manufacturing equipment, wherein the laser additive manufacturing equipment comprises a laser 1, an in-situ magnetic field generator 5, an in-situ magnetic field regulation and control system 6 and a power supply 7; the in-situ magnetic field generator 5 comprises a top cover 9 and a plurality of nonlinear magnetic field generating units 110, wherein each nonlinear magnetic field generating unit 110 comprises a magnetic induction coil; laying the powder 3 on the top cover 9;
s3: establishing a three-dimensional solid geometric model of a sample by using computer design software, acquiring a processing procedure of the three-dimensional solid geometric model and guiding the processing procedure into laser additive manufacturing equipment;
in the step of planning the scanning path of the laser in step S3, the laser process parameters are set as follows: the laser power is 375-425W, the scanning speed is 800-1200 mm/s, the scanning interval is 60 mu m, the powder spreading layer thickness is 30 mu m, an island-shaped scanning strategy is adopted, and the island size is 4.8mm; preferably, the laser power is 425W, the scanning speed is 800mm/s, the scanning interval is 60 mu m, the powder spreading layer thickness is 30 mu m, the island-shaped scanning strategy is adopted, the island size is 4.8mm, and the laser filling direction rotation between adjacent layers is 37 degrees.
S4: placing the dried powder 3 in laser additive manufacturing equipment, setting the magnetic induction intensity of an in-situ magnetic field generator 5, and starting an in-situ magnetic field regulation and control system 6 to make the magnetic induction intensity of different forming positions in the process of forming the powder 3 into a sample identical;
before the sample is formed in the step S4, sealing a forming cylinder of laser additive manufacturing equipment through a sealing device, vacuumizing, and introducing inert gas to ensure that the oxygen content in a forming cavity is lower than 50ppm; wherein the inert gas is high-purity argon gas used as a protective atmosphere.
In this step S4, the outer circle radius of the magnetic induction coil of each nonlinear magnetic field generating unit 110 is setr 2 Radius r of inner ring 1 The calculated equivalent radius is:
the nonlinear magnetic field generating unit 110 has magnetic induction coils, and is configured to supply a current I to a group of centers of the magnetic induction coils as an origin, and to generate magnetic induction intensities Bx, by, bz at arbitrary point coordinates (x, y, h) in a space, a sample forming height h, and a permeability in an inert gas atmosphere μ at the point 0 Calculating magnetic induction intensity B:
the magnetic induction intensity B of the laser under different sample forming heights h is the same; the current I of the magnetic induction coil is controlled to be 0-5A, so that the magnetic induction intensity B of the position is controlled to be 0-1T. Furthermore, the magnetic induction intensity of the optimal laser additive manufacturing in the sample forming process is 0.5T-0.7T, so that the magnetic induction intensity B at the position is set to be 0.5-0.7T, and the laser additive manufacturing is used for manufacturing the three-dimensional solid sample with uniform formed microstructure and high compactness.
In this step S4, in a preferred embodiment 1, the magnetic induction is set to 0.7T. In another preferred embodiment 2, the magnetic induction is set to 0.5T.
In the step S4, since the magnetic induction B is inversely proportional to the square of the sample forming height h, the sample forming height h should be avoided from being too high to ensure that the molten pool is completely under the set magnetic induction, thereby ensuring that the processed aluminum alloy sample has good forming performance and mechanical properties.
S5: and (5) carrying out post-treatment on the sample.
In the step S4, after the sample is formed and after the top cover 9 is cooled, the top cover 9 of the in-situ magnetic field generator 5 is disassembled, and the sample and the top cover 9 are separated by using a wire cutting technique to obtain the sample; the sample is an aluminum alloy sample with the advantages of equiaxed grains, high forming degree and few defects; the formed aluminum alloy block sample is polished, polished and corroded according to the standard metallographic sample preparation method, and is observed under a light microscope as shown in fig. 5.
Comparative example 1 and example 2 have similar effects on grain refinement and defect suppression under the action of the optimal magnetic induction intensity range.
In the existing comparative example 1, the basic steps of comparative example 1 are the same as those of the present example, except that the in-situ magnetic field control system 6 is not started, the dried powder is directly subjected to laser additive manufacturing preparation, after the sample is prepared in comparative example 1, the aluminum alloy sample is polished, polished and corroded according to the standard metallographic sample preparation method, and the longitudinal section of the block sample is observed under a light mirror as shown in fig. 6. In comparative example 1, a large number of cracks and voids were found in the sample under the action of no applied magnetic field, and the microstructure exhibited coarse columnar crystals. The optical micrographs of longitudinal sections of the samples prepared in comparative examples 1 and 1 show that the laser additive manufacturing formation under the action of the in-situ magnetic field can significantly reduce the number of defects, and the mechanical properties of example 1 in fig. 8 are significantly improved.
In the existing comparative example 2, the basic procedure of comparative example 2 was the same as that of the present example except that comparative example 2 was set to 1T magnetic induction, whereas the present example was set to 0.7T magnetic induction, and then laser additive manufacturing preparation was performed on the dried powder, and after the sample was prepared in comparative example 2, an aluminum alloy sample was polished and polished according to the standard metallographic sample preparation method, and the longitudinal section of the block sample was observed under a mirror as shown in fig. 7. The optical micrographs of longitudinal sections of the samples obtained in comparative examples 1 and 2 revealed that in comparative example 2, the magnetic field induction strength was enhanced beyond the optimum range, and that the sample forming quality was improved, but the mechanical properties in FIG. 8 did not reach the level of example 1.
The method for regulating and controlling the formability of the laser additive manufacturing provided by the invention utilizes an in-situ magnetic field generator 5, an in-situ magnetic field regulating and controlling system 6 and a power supply 7 to form a closed loop, and utilizes the in-situ magnetic field generator 5 to ensure that the melting and solidification processes of the powder 3 are all carried out in a controllable magnetic field range; by adding an in-situ magnetic field, the flow speed of a molten pool marangoni flow is reduced, so that the molten pool marangoni flow is stable, the columnar dendrites are broken by the magnetic field, the columnar dendrites are transformed into equiaxial crystals, the problems that the high-crack-sensitivity aluminum alloy is extremely easy to generate defects such as pore cracks and the like in the forming process are solved, the laser powder bed melting forming of the high-strength forged aluminum alloy with equiaxial crystal grains, no cracks and high forming degree is realized, and the adaptability of the aluminum alloy to a laser additive manufacturing process is greatly improved; the intelligent regulation function of the in-situ magnetic field regulation system 6 is adopted to achieve the purpose of controlling the magnetic induction intensity due to the fact that the magnetic induction intensity self-attenuation effect is different in different horizontal positions and vertical positions, and the in-situ magnetic induction intensity of the powder 3 in a melting solidification area is controlled by controlling the output current of the power supply 7, so that the magnetic induction intensity of a laser additive manufacturing sample in different space positions is guaranteed to be identical in the laser additive manufacturing forming process, and the phenomenon of tissue non-uniformity caused by the influence of the different magnetic induction intensities on the sample in the forming process is avoided, so that the laser additive manufacturing forming aluminum alloy sample is a three-dimensional solid sample with uniform microstructure and high compactness; the invention can effectively reduce the defect number in the high crack sensitivity aluminum alloy manufactured by laser additive, refine the microstructure state and improve the forming effect and mechanical property.
Claims (9)
1. A laser additive manufacturing forming system, comprising:
a laser additive manufacturing apparatus comprising: the device comprises a laser (1), an in-situ magnetic field generator (5), an in-situ magnetic field control system (6) and a power supply (7), wherein the in-situ magnetic field generator (5) comprises a top cover (9) and a nonlinear magnetic field generating unit array (11), the nonlinear magnetic field generating unit array (11) comprises a plurality of nonlinear magnetic field generating units (110), and each nonlinear magnetic field generating unit is provided with a magnetic induction coil;
computer design software for creating three-dimensional solid geometric model of the sample, for obtaining the machining process of laser additive manufacturing and leading into the laser additive manufacturing equipment; wherein,,
the in-situ magnetic field generator (5), the in-situ magnetic field control system (6) and the power supply (7) form a closed loop, the powder (3) is placed on the top cover (9), the in-situ magnetic field generator (5) is used for generating an in-situ magnetic field and acting on the powder (3), the laser (1) is used for generating laser (2) to perform laser scanning on the powder (3), the in-situ magnetic field control system (6) is used for controlling the power supply (7) to generate current so as to activate or deactivate one or more nonlinear magnetic field generating units (110) around the laser position in the nonlinear magnetic field generating unit array (11), and is used for controlling the magnitude of the magnetic induction intensity of the nonlinear magnetic field generating units (110) so that the laser scanning path of the powder (3) in the process of forming the sample according to the processing procedure is in the magnetic field range, and the magnetic induction intensity of the laser scanning at different forming positions is the same;
the in-situ magnetic field control system (6) comprises: the system comprises a current control system (13), an information feedback system (14) and a heat source tracking system (15) which are connected in series, wherein the current control system (13) is connected with a power supply (7), and an in-situ magnetic field generator (5) is respectively connected with the power supply (7) and the heat source tracking system (15);
the heat source tracking system (15) is used for tracking the heat source of the laser (2) to determine the laser position and transmitting the laser position to the information feedback system (14); an information feedback system (14) for confirming one or more nonlinear magnetic field generating units (110) around the laser position and feeding back to the current control system (13); the current control system (13) is used for controlling the power supply (7) to transmit current to the confirmed nonlinear magnetic field generating unit (110) so as to generate a magnetic field.
2. The laser additive manufacturing forming system of claim 1, wherein the in-situ magnetic field generator (5) is in an inert gas environment with an oxygen content of less than 50ppm, and the magnetic induction coil outer circle radius r of each magnetic field generating unit (110) is set 2 Inner ringRadius r 1 The calculated equivalent radius is:the center of a group of magnetic induction coils is taken as an origin, the magnetic induction coils are introduced with current I, coordinates (x, y, h) of any point in space are given, magnetic induction intensity generated at the point (x, y, h) is Bx, by and Bz, the forming height of a sample is h, and the permeability of an inert gas environment is mu 0 Calculating magnetic induction intensity B:
3. the laser additive manufacturing forming system of claim 2, wherein the magnetic induction B experienced by the laser at different sample forming heights h is the same; the current I of the nonlinear magnetic field generating unit (110) is 0-5A, and the magnetic induction intensity B of the nonlinear magnetic field generating unit (110) is 0-1T.
4. The laser additive manufacturing shaping system of claim 1, wherein the in-situ magnetic field control system (6) further comprises: the magnetic field monitoring system (16) is respectively connected with the current control system (13), the in-situ magnetic field generator (5) and the heat source tracking system (15); the magnetic field monitoring system (16) is used for monitoring the magnetic induction intensity of the laser position and transmitting the magnetic induction intensity information to the current control system (13); when the magnetic induction intensity is smaller than a set value, the current control system (13) controls the power supply (7) to increase the current so as to increase the magnetic induction intensity of the area, and when the magnetic induction intensity is larger than the set value, the current control system (13) controls the power supply (7) to decrease the current so as to decrease the magnetic induction intensity of the area.
5. A method of regulating laser additive manufacturing formability using the laser additive manufacturing forming system of claim 1, comprising the steps of:
s1: drying the powder (3) in a drying box;
s2: providing laser additive manufacturing and forming equipment, wherein the laser additive manufacturing and forming equipment comprises a laser (1), an in-situ magnetic field generator (5), an in-situ magnetic field regulating and controlling system (6) and a power supply (7); the in-situ magnetic field generator (5) comprises a top cover (9) and a plurality of nonlinear magnetic field generating units (110), and each nonlinear magnetic field generating unit (110) is provided with a magnetic induction coil;
s3: establishing a three-dimensional solid geometric model of the sample, obtaining a machining procedure of laser additive manufacturing, and introducing the machining procedure into laser additive manufacturing equipment;
s4: the dried powder (3) is arranged on a top cover (9), the magnetic induction intensity of an in-situ magnetic field generator (5) is set, and an in-situ magnetic field regulating and controlling system (6) is started to enable a laser scanning path to be in a magnetic field range in the process that the powder (3) is formed into a sample according to a processing procedure, and the magnetic induction intensities of different forming positions of laser scanning are the same;
s5: and (5) carrying out post-treatment on the sample.
6. The method for controlling the formability of laser additive manufacturing according to claim 5, wherein the powder in step S1 is an aluminum alloy mixture powder containing aluminum, zinc, magnesium, copper, and chromium, wherein the content of zinc is 5.6wt.%, the content of magnesium is 2.5wt.%, the content of copper is 1.6wt.%, and the content of chromium is 0.30wt.%; the particle size of the aluminum alloy mixture powder is in the range of 20-63 μm.
7. The method for adjusting and controlling formability of laser additive manufacturing according to claim 5, wherein in the step of planning a laser scanning path in step S3, laser process parameters are set as follows: the laser power is 375-425W, the scanning speed is 800-1200 mm/s, the scanning interval is 60 mu m, the powder layer thickness is 30 mu m, the island-shaped scanning strategy is adopted, the island side length is 4.8mm, and the laser filling direction rotation between adjacent layers is 37 degrees.
8. The method for controlling the formability of laser additive manufacturing according to claim 5, further comprising the step of exposing the in-situ magnetic field generator (5) to an inert gas atmosphere having an oxygen content of less than 50ppm before the sample is formed in step S4; the current of the nonlinear magnetic field generating unit (110) is 0-5A, and the magnetic induction intensity B of the nonlinear magnetic field generating unit (110) is set to be 0-1T.
9. The method for controlling the formability of laser additive manufacturing according to claim 5, wherein after the sample is formed and the top cover (9) is cooled in step S4, the top cover (9) is disassembled, and the sample is separated from the top cover by using a wire cutting technique to obtain the sample; post-treatment of the sample includes grinding, polishing and corroding the sample.
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