WO2020078055A1 - 连续送粉感应加热金属增材制造方法及装置 - Google Patents
连续送粉感应加热金属增材制造方法及装置 Download PDFInfo
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- WO2020078055A1 WO2020078055A1 PCT/CN2019/096099 CN2019096099W WO2020078055A1 WO 2020078055 A1 WO2020078055 A1 WO 2020078055A1 CN 2019096099 W CN2019096099 W CN 2019096099W WO 2020078055 A1 WO2020078055 A1 WO 2020078055A1
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- powder
- water
- cable
- additive manufacturing
- hollow copper
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Images
Classifications
-
- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
-
- 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
- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
- B22F2003/1053—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding by induction
-
- 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
Definitions
- the invention relates to the field of additive manufacturing, in particular to a continuous powder feeding induction heating metal additive manufacturing method and device.
- metal additive manufacturing technology essentially adopts the additive thinking of numerical discrete / stack forming, and obtains the three-dimensional CAD solid model through the layer-by-layer preparation method.
- its utilization rate of metal raw materials is higher; at the same time, it has unique advantages in the preparation of metal parts with complex shapes; in addition, it can achieve rapid repair of molds and broken parts, It plays the role of shortening the design cycle of metal parts and reducing production costs, and the overall mechanical properties of the final solidified metal structure can be comparable to traditional forgings.
- metal additive manufacturing technology represents a moldless, low-cost, digital advanced manufacturing technology, with unparalleled application prospects.
- the heat sources used in the current metal additive manufacturing technology mainly include the following three categories: laser, electron beam and arc.
- laser as a heat source is a common method.
- Chinese patent CN201710843050.X proposes a laser additive manufacturing method for porous aluminum alloys.
- the linear scanning trajectory of the upper powder is perpendicular to the linear scanning trajectory of the lower powder to achieve layer by layer Stacking, but considering that the aluminum alloy has a high reflectivity to the laser (usually more than 80%), and the aluminum alloy itself has good thermal conductivity, resulting in insufficient absorption of laser energy in the aluminum alloy additive manufacturing process, which is difficult Meet the needs of cost and efficiency.
- Chinese patent CN201710878157.8 proposes a pre-powder-feeding electron beam additive manufacturing device, which can effectively avoid the reflection of metal powder on the energy of the laser beam and make the forming rate fast;
- the electron beam work itself requires a severe vacuum environment, and has high requirements on equipment and process conditions. It is often restricted when molding certain large structures, resulting in higher raw material costs and time costs.
- the arc additive manufacturing technology is another common method.
- the Chinese patent CN201710129920.7 proposes an additive manufacturing method for aluminum-magnesium alloy structural parts.
- the purpose of the present invention is to provide a continuous powder feeding induction heating metal additive manufacturing method and device, improve the utilization rate of heat source energy in the process of metal solidification molding, efficiently realize the automatic production of metal parts, and at the same time ensure that the molded metal is increased
- the parts made of wood have the advantages of high molding accuracy and excellent comprehensive mechanical properties.
- Continuous powder feeding induction heating metal additive manufacturing device including:
- the substrate is used to provide a base for forming the metal layer for additive manufacturing
- a motion control device and a motion unit provided on one side of the substrate the motion unit is provided with a manipulator, and the motion unit is configured to move under the control of the motion control device to drive the manipulator to move in a three-dimensional space, the The movement unit is controlled to move at least in the XY plane and the XZ plane;
- Powder storage tank used to store the transported metal powder
- the low-power induction preheating device is constructed as a sealed container and communicates with the powder storage tank under the first tube;
- the first hollow copper coil is spirally wound outside the low-power induction preheating device, and is used to preheat the passing metal powder;
- the high-power induction heating device includes a thin tube connected to the low-power induction preheating device;
- the second hollow copper coil is spirally wound outside the thin tube, and is used to heat and melt the metal powder passing through the thin tube to form a droplet;
- a water cooling system including a water cooling box and water cooling circulation channels formed in the first hollow copper coil and the second hollow copper coil through a water cooling cable;
- the robot grips the powder storage tank, the powder storage tank, the low-power induction preheating device, the high-power induction heating device, and the corresponding first hollow copper coil and second hollow copper coil are all disposed vertically above the substrate Position, and keep synchronous movement with the manipulator, under the drive of the motion unit, the droplet formed by the heating and melting of the second hollow copper coil by its own gravity and the advance of the droplet above, fall onto the substrate for deposition molding.
- a control valve is provided below the connection position of the powder storage tank and the first tube and below the connection position of the low-power induction preheating device and the thin tube, to facilitate reasonable control of the pre The speed of hot powder and molten powder.
- the water cooling system includes a first water cooling cable and a second water cooling cable, both of which are provided with a water inlet channel and a water outlet channel, the first water cooling cable is connected with the first hollow copper coil to form a first circulation channel, and the second water cooling cable is The second hollow copper coils are connected to form a second circulation channel to facilitate the movement of the pipes of the water cooling system when the robot moves the droplets in the three-dimensional space, which facilitates the accumulation of the metal layer.
- the water inlet channel is located at the center of the cable, and has a circular section along the length of the cable
- the water outlet channel is located outside the cable inlet channel, and has a circular section along the length of the cable.
- the use of such a water cooling channel design is beneficial to It is connected to the hollow copper tube (induction heating coil) and the circulating water flow inside and outside.
- the water cooling system includes a first inlet pipe, a second inlet pipe, a first outlet pipe and a second outlet pipe connected to the water cooling box, the first inlet pipe communicates with one end of the water inlet channel of the first water cooling cable, the first An outlet pipe is connected to one end of the outlet channel of the first water-cooled cable, a second inlet pipe is connected to one end of the inlet channel of the second water-cooled cable, and the second outlet pipe is connected to one end of the outlet channel of the second water-cooled cable.
- both ends of the first hollow copper coil wound outside the low-power induction preheating device are respectively connected to the other end of the first water-cooled cable, one end of which is connected to the water inlet channel, and the other end is connected to the water outlet channel.
- two ends of the second hollow copper coil wound outside the high-power induction preheating device are respectively connected to the other end of the second water-cooled cable, one end of which is connected to the water inlet channel, and the other end is connected to the water outlet channel.
- first water-cooled cable and the second water-cooled cable are designed with the same wire structure and different sizes, and the cross-sectional direction includes an outer insulating rubber layer, a water outlet channel, an outer insulating layer, a copper cable Insulation and water inlet channels.
- an additive manufacturing method using the above device including the following steps:
- the powder feeder Turn on the powder feeder and feed the metal powder to the powder storage tank through the powder feed tube.
- the powder capacity in the powder storage tank reaches the set value, it is controlled to be sent to the low-power induction preheating device, which is induced by the first hollow copper coil Heat and preheat the powder;
- the preheated powder capacity in the sealed container After the preheated powder capacity in the sealed container reaches the set value, it is controlled to be delivered to the high-power induction heating device and inductively heated by the second hollow copper coil, and the molten powder forms droplets, wherein the heating power of the second hollow copper coil is greater than the first
- the heating power of the hollow copper coil is controlled to control the temperature of the droplet at 700 °C -900 °C;
- the temperature of the substrate is controlled by preheating at 250 °C -350 °C, and: during the accumulation of the metal layer, through the movement
- the three-dimensional movement of the unit causes the droplets to move in the three-dimensional space above the substrate, causing the metal layer to melt and form on the substrate until printing is completed.
- the present invention uses induction heating as a heat source for melting metal powder.
- the powder has a high utilization rate of energy absorption of the heat source, which plays a role in reducing energy consumption and improving the production efficiency of metal parts. Compared with wire, it can significantly improve the molded parts. Surface accuracy
- the present invention can achieve precise control of the temperature of the molten metal droplets, which not only ensures the superheat requirement of the continuous and stable flow of the metal fluid, but also prevents excessive burning of the element caused by excessive temperature, resulting in the lack of chemical composition of the metal preparation;
- the present invention can work under an inert gas atmosphere such as nitrogen and argon, reducing the restriction on the vacuum environment.
- the three-dimensional coordinated movement of metal powder droplets can realize the preparation of metal parts with complex shapes, and at the same time can ensure the precise control of the size and roughness of parts;
- the metal parts prepared by the invention have the advantages of stable alloy chemical composition and excellent comprehensive mechanical properties.
- FIG. 1 is a schematic diagram of a continuous powder feeding induction heating metal additive manufacturing apparatus provided by an embodiment of the present invention.
- FIG. 2 is a schematic diagram of a powder heating device provided by an embodiment of the present invention.
- FIG. 3 is a schematic diagram of the connection of the water cooling structure provided by the embodiment of the present invention.
- FIG. 4 is a schematic diagram of a hollow induction coil provided by an embodiment of the present invention.
- FIG. 5 is a schematic diagram of a cross section of a water-cooled cable provided by an embodiment of the present invention.
- 23 outer insulation layer; 24-—high-density copper wire; 25—inner insulation layer; 26—water inlet channel;
- the metal powder is continuously conveyed through the powder feeder, and the preheating and melting of the induction coil cause the melted droplets to pass their own gravity and above Under the action of the droplet advancement, the metal layer is deposited and formed on the substrate, and in the process of metal layer accumulation, the position of the droplet is controlled by the movement of the three-dimensional space of the manipulator, so that the metal layer is continuously deposited on the substrate. Until printing is complete.
- the device is evacuated and reaches a certain vacuum degree, it is filled with a high-purity inert gas (such as argon) for protection, and then the metal powder that is delivered passes through low power Induction preheating (hollow induction coil) for preheating. After preheating, the powder at a certain temperature is melted after high power induction heating (hollow induction coil) below. The molten alloy droplets are under their own gravity and above the droplets. Under the action of propulsion, it falls continuously and evenly onto the substrate.
- a high-purity inert gas such as argon
- the forming process of the melt-formed metal layer can be observed and monitored by a camera device (such as a CCD) in real time.
- a camera device such as a CCD
- FIG. 1 shows an alternative implementation of an exemplary continuous powder feeding autonomous induction heating additive manufacturing device.
- the continuous powder-feeding induction heating metal additive manufacturing apparatus includes a substrate 6 for providing a base for forming the additive manufacturing metal layer.
- a motion control device and a motion unit provided on the side of the substrate 6 provide three-dimensional driving of the drop position of the melt droplet, and control the drop position of the melt droplet by the movement in the three-dimensional space of the manipulator 5.
- the motion control device includes a control box 1, the motion unit includes a first motion unit 2, a second motion unit 3, and a third motion unit 4, the first motion unit 2, the second motion unit 3, and the third motion
- the units 4 each include a corresponding motor and gear transmission mechanism for driving rotary motion.
- the first motion unit 2 is configured as a circular motion platform unit, which can horizontally rotate around the center axis of the circle to realize X-Y plane motion.
- the second motion unit 3 and the third motion unit 4 are fixed, and are fixed to the circular motion platform unit through the connection seat and the rod, and can keep synchronously following the rotation with the rotation of the circular motion platform unit.
- Both the second movement unit 3 and the third movement unit 4 can realize the X-Z plane rotation movement around their rotation axes.
- the control box 1 can be equipped with supporting motion control software for program design according to the objectives of additive manufacturing printing, and control the three motion units (2, 3, 4) to move according to the set direction and position.
- the motion unit (ie, the third motion unit 4) is provided with a manipulator 5, and the motion of the three motion units (2, 3, 4) causes the manipulator to move in a three-dimensional space to drive the powder storage held by the manipulator The movement of the slot 17.
- the powder storage tank 17 is used to store the transported metal powder.
- a powder feeder 20 continuously conveys metal powder into the powder storage tank 17 through a powder feed pipe 18.
- the powder storage tank 17, the first tube 36, the low-power induction preheating device 13, the second tube 37, and the high-power induction heating device 9 adopt a fixed design.
- the low-power induction preheating device 13 is configured as a sealed container, and communicates with the lower part of the powder storage tank 17 through the first tube 36.
- the first tube 36 is also provided with a first control valve 12 for controlling the metal powder in the powder storage tank to fall into the low-power induction preheating device 13.
- the first hollow copper coil 14, as a low-power heating induction coil, is spirally wound outside the low-power induction preheating device 13 for preheating the passing metal powder to heat the powder to a predetermined temperature, avoiding direct high During power heating, powders are prone to large temperature gradients due to heat transfer and heat radiation.
- the high-power induction heating device 9 includes a thin tube connected to the low-power induction preheating device through the second tube 37. When the preheated powder falls, it flows into the thin tube.
- a second control valve 16 is further provided between the low-power induction preheating device 13 and the thin tube to control the transportation of the preheated metal powder to the thin tube.
- the setting of two control valves (12, 16) is conducive to reasonably controlling the speed of preheating powder and melting powder according to the rate of powder feeding.
- the second hollow copper coil 10 as a high-power heating induction coil, is spirally wound outside the thin tube, and is used to heat and melt the metal powder passing through the thin tube to form a droplet.
- the water cooling system includes a water cooling box 19 and water cooling circulation channels formed in the first hollow copper coil 14 and the second hollow copper coil 10 by water cooling cables (11, 15), respectively.
- the manipulator 5 clamps the powder storage tank 17, the powder storage tank 17, the low power induction preheating device 13, the high power induction heating device 9, and the corresponding first hollow copper coil 14, second hollow
- the copper coils 10 are all set vertically above the substrate, and keep moving synchronously with the manipulator 5. Under the drive of the motion unit (2, 3, 4), the second hollow copper coil 10 is heated and melted to form droplets through its own gravity and With the advancement of the upper droplet, it falls onto the substrate 6 and is deposited and formed.
- the water cooling system includes a first water-cooling cable 11 and a second water-cooling cable 15, both of which are provided with a water inlet channel and a water outlet channel.
- the first water cooling cable 11 is connected to the first hollow copper coil 14 to form a first circulation channel
- the second water-cooled cable 15 is connected to the second hollow copper coil 10 to form a second circulation channel to facilitate the movement of the pipes of the water-cooled system when the robot moves the droplets in the three-dimensional space, which facilitates the accumulation of the metal layer .
- the water inlet channel is located in the center of the cable and is circular along the length of the cable, and the water outlet channel is located outside the cable inlet channel and is circular along the length of the cable. It is beneficial to the connection when the hollow copper tube (induction heating coil) is docked and the circulating water flow inside and outside.
- the water cooling system includes a first inlet pipe 31, a second inlet pipe 32, a first outlet pipe 33, and a second outlet pipe 34 connected to the water cooling tank.
- the first inlet pipe 31 communicates with one end of the water inlet channel of the first water cooling cable 11
- the first outlet pipe 33 is connected to one end of the outlet channel of the first water-cooled cable 11
- the second inlet pipe 33 is connected to one end of the inlet channel of the second water-cooled cable
- the second outlet pipe 34 is connected to the outlet channel of the second water-cooled cable One end.
- the two ends of the first hollow copper coil 14 wound outside the low-power induction preheating device are respectively connected to the other end of the first water-cooled cable 11, where one end is connected to the water inlet channel and the other end is connected to the water outlet channel .
- Two ends of the second hollow copper coil 10 wound outside the high-power induction preheating device are respectively connected to the other end of the second water-cooled cable 15, one end of which is connected to the water inlet channel, and the other end is connected to the water outlet channel.
- the first water-cooled cable and the second water-cooled cable have the same wire structure and different sizes, and the cross-sectional direction includes an outer insulating rubber layer 21, a water outlet channel 22, an outer insulating layer 23, and a cable in order from the outside to the inside Copper wire 24, inner insulating layer 25 and water inlet channel 26.
- the cable copper wire 24 is preferably a high-density cable copper wire.
- the first hollow copper coil and the second hollow copper coil are designs with the same wire structure and different sizes.
- the process of additive manufacturing includes the following steps:
- the powder feeder 20 Turn on the powder feeder 20 and feed the metal powder to the powder storage tank 17 through the powder feed pipe 18.
- the powder capacity in the powder storage tank reaches the set value, the powder is controlled and transferred to the low-power induction preheating device, through the first hollow copper Induction heating of the coil to preheat the powder;
- the preheated powder capacity in the sealed container After the preheated powder capacity in the sealed container reaches the set value, it is controlled to be delivered to the high-power induction heating device and inductively heated by the second hollow copper coil, and the molten powder forms droplets, wherein the heating power of the second hollow copper coil is greater than the first
- the heating power of the hollow copper coil is controlled to control the temperature of the droplet at 700 °C -900 °C;
- the temperature of the substrate is controlled by preheating at 250 °C -350 °C, and: during the accumulation of the metal layer, through the movement
- the three-dimensional movement of the unit causes the droplets to move in the three-dimensional space above the substrate, causing the metal layer to melt and form on the substrate until printing is completed.
- the set capacity of the aforementioned powder in the powder storage tank and the sealed container can be selected as 50% to facilitate continuous transportation and production, and it is not too full to affect the transportation.
- CCD camera devices 8 may also be provided on the two edges of the substrate 6, which are the first camera device and the second camera device, respectively, with the imaging lenses facing the formed metal layer. To observe the forming process of the melt-formed metal layer in real time.
- the operation process of the continuous powder feeding induction heating metal induction heating additive manufacturing device proposed in the foregoing embodiment, that is, the steps of using it for additive manufacturing include:
- the powder feeder Turn on the powder feeder and feed the metal powder to the powder storage tank through the powder feed tube.
- the powder capacity in the powder storage tank reaches the set value, it is controlled to be sent to the low-power induction preheating device, which is induced by the first hollow copper coil. Heat and preheat the powder;
- the preheated powder capacity in the sealed container After the preheated powder capacity in the sealed container reaches the set value, it is controlled to be delivered to the high-power induction heating device and inductively heated by the second hollow copper coil, and the molten powder forms droplets, wherein the heating power of the second hollow copper coil is greater than the first
- the heating power of the hollow copper coil is controlled to control the temperature of the droplet at 700 °C -900 °C;
- the temperature of the substrate is controlled by preheating at 250 °C -350 °C, and: during the accumulation of the metal layer, through the movement
- the three-dimensional movement of the unit causes the droplets to move in the three-dimensional space above the substrate, causing the metal layer to melt and form on the substrate until printing is completed.
- the four metal powders of 6061 aluminum alloy, 4047 aluminum alloy, 2319 aluminum alloy and pure copper will be taken as examples to realize the additive manufacturing printing process of the technical solution in the embodiment of the present invention. .
- the metal additive manufacturing equipment and the entire environment are evacuated and filled with an inert protective gas.
- the vacuum gauge indicates that the system pressure is less than 200Pa
- turn on the Roots pump to continue vacuum extraction until the pressure value in the device is less than 5Pa.
- turn off the mechanical pre-pumping pump and Roots pump in turn, then turn on the diffusion pump to perform high vacuum extraction on the device until the vacuum degree of the device is less than 10 -2 Pa, then turn off the diffusion pump, complete the whole pumping of the device, and the vacuuming time is about 11min.
- the equipment is filled with 99.999% high purity inert gas argon for protection.
- the oxygen content in the internal cavity of the equipment is measured by an oxygen analyzer in real time to ensure that the oxygen content is controlled below 100ppm.
- the particle size of this 6061 aluminum alloy powder is 45 ⁇ 105 ⁇ m, and the chemical composition is: 0.34% copper, 0.95% magnesium, 0.73% silicon , 0.71% iron, the rest is aluminum and a small amount of other alloying elements.
- the powder feeding speed of 6061 aluminum alloy powder is 50mg / s.
- the first control valve is controlled to open, so that the 6061 aluminum alloy powder enters the low-power induction preheating device for preheating.
- the flow rate of powder flowing into the preheating device is controlled to 50mg / s; the working power of the preheating device is 330W, to ensure that the temperature of the powder is stable at about 300 °C, and the temperature sensing system and control system on the inner wall of the device measure the temperature in the preheating device in real time And at any time by adjusting the induction preheating power to ensure that the powder temperature meets the requirements.
- the 6061 aluminum alloy material has a large thermal conductivity and a small particle size value, which results in a large temperature gradient between the powder due to heat transfer and heat radiation, which may eventually lead to uneven structure and internal structure of the molded part. Cracks and other defects affect the overall performance of the molded part. Therefore, the method of preheating alloy powder is used to adjust the temperature distribution heterogeneity between the powders, and the possibility of defects is minimized; in addition, preheating alloy powder can also increase the absorption rate of the heat source energy, and make full use of high power for subsequent use The energy of the induction heating device provides the necessary conditions.
- the second control valve is controlled to open, and the pre-heated 6061 aluminum alloy powder enters the high-power induction heating device for melting.
- the flow rate of powder into the heating device is controlled at 50mg / s; the working power of the heating device is 620W, and a temperature sensing system and a control system are also installed on the inner wall of the heating device to ensure that the temperature of the alloy droplets is controlled at about 850 ° C.
- the induction heating method does not require the use of the alloy's own resistance to generate heat, it is particularly suitable for low-resistivity metal wires; at the same time, the aluminum alloy does not have a reflective effect on the energy of induction heating, and the absorption and utilization rate of the heat source energy is high.
- the preheating process of alloy powder undoubtedly provides a guarantee for the stability of the droplet temperature. At this temperature, it satisfies the best requirements for superheat of the metal flow of 100-250 ° C, and achieves continuous and stable flow of metal droplets; at the same time, reasonable superheat conditions also reduce the burning loss of low-melting aluminum and other elements , So that the chemical composition of the final alloy molded part is more uniform and stable.
- the 6061 aluminum alloy droplets in the continuous molten state fall on the substrate by the gravity of themselves and the aluminum alloy droplets on the top to form a deposit.
- the temperature of the substrate is controlled at about 300 ° C through preheating to prevent the occurrence of large temperature gradients on the edges and inside of the molded part, which increases the internal stress of the part, thereby reducing the possibility of micro-cracks.
- the alloy powder completes the three-dimensional coordinated movement, thereby realizing the horizontal and vertical precision molding of the complex 6061 aluminum alloy parts, and using the CCD camera devices on both sides of the substrate to monitor the deposition molding in real time process.
- the alloy composition of the 6061 aluminum alloy parts formed is 0.35% copper, 0.93% magnesium, 0.75% silicon, 0.74% iron, and the rest is aluminum and a small amount of other alloying elements, which meet the chemical composition requirements of the target aluminum alloy.
- the surface roughness, tensile strength, yield strength and elongation at break of the three samples were tested and compared. The results are shown in Table 1.
- the metal additive manufacturing equipment and the environment as a whole are evacuated and filled with an inert protective gas.
- the vacuum gauge indicates that the system pressure is less than 200Pa
- turn on the Roots pump to continue vacuuming the device until the pressure value in the device is less than 5Pa.
- turn off the mechanical pre-pumping pump and Roots pump in turn, and then turn on the diffusion pump for high vacuum extraction.
- the vacuum degree of the equipment is less than 10 -2 Pa
- turn off the diffusion pump which completes the overall vacuuming of the equipment, and the vacuuming time is 10min (Requires control within 15min).
- the equipment is filled with 99.999% high-purity inert gas nitrogen for protection.
- the oxygen content in the internal cavity of the equipment is measured in real time by an oxygen analyzer to ensure that the oxygen content is controlled within 100ppm.
- the particle size of this 4047 aluminum alloy powder is 53-150 ⁇ m, and the chemical composition is: 12.4% silicon, 0.47% iron, 0.26% copper , The rest is aluminum and a small amount of other alloying elements.
- the feeding speed of 4047 aluminum alloy powder is 75mg / s.
- the first control valve is automatically opened, so that the 4047 aluminum alloy powder enters the low-power induction preheating device for preheating.
- the flow rate of powder into the preheating device is controlled to 75mg / s; the working power of the preheating device is 450W, which ensures that the temperature of the powder is stable at about 300 °C, and the temperature sensing system and control system on the inner wall of the device measure the temperature in the preheating device in real time And at any time by adjusting the induction preheating power to ensure that the powder temperature meets the requirements.
- the second control valve is automatically opened, and the preheated 4047 aluminum alloy powder enters the high-power induction heating device for melting.
- the flow rate of powder into the heating device is controlled at 75mg / s; the working power of the heating device is 850W, and the temperature sensor system and control system are also installed on the inner wall of the heating device to ensure that the temperature of the alloy droplets is controlled at about 800 °C. At this temperature, it not only meets the superheat requirement of continuous and stable flow of metal liquid; but also reduces the burning loss of low melting point aluminum and other elements, making the chemical composition of the final alloy molded part more uniform and stable.
- the 4047 aluminum alloy droplets in the continuous molten state fall on the substrate to be deposited and shaped by their own gravity and the propulsion of the aluminum alloy droplets above.
- the temperature of the substrate is controlled at about 300 ° C through preheating to prevent the occurrence of large temperature gradients on the edges and inside of the molded part, which increases the internal stress of the part, thereby reducing the possibility of micro-cracks.
- the motion unit to drive the spatial movement of the robot 5 to complete the three-dimensional coordinated movement of the alloy powder, thereby achieving precise horizontal and vertical precision molding of the complex 4047 aluminum alloy parts, and at the same time using the CCD camera devices on both sides of the substrate to monitor the deposition molding process.
- the alloy components of the formed 4047 aluminum alloy parts are 12.3% silicon, 0.49% iron, 0.26% copper, and the rest are aluminum and a small amount of other alloying elements, which meet the chemical composition requirements of the target aluminum alloy.
- the surface roughness, tensile strength, yield strength, and elongation at break of the three samples were tested and compared. The results are shown in Table 2.
- the metal additive manufacturing equipment and the environment as a whole are evacuated and filled with an inert protective gas.
- the vacuum gauge indicates that the system pressure is less than 200Pa
- turn on the Roots pump to continue vacuuming the device until the pressure value in the device is less than 5Pa.
- turn off the mechanical pre-pumping pump and Roots pump in turn, and then turn on the diffusion pump for high vacuum extraction.
- the vacuum degree of the equipment is less than 10 -2 Pa
- turn off the diffusion pump to complete the overall vacuuming of the equipment.
- the vacuuming time is 13 min ( (Requires control within 15min).
- the device is filled with 99.999% high-purity inert gas argon for protection.
- the oxygen content in the inner cavity of the device is measured by an oxygen analyzer in real time to ensure that the oxygen content is controlled within 100 ppm.
- the particle size of the 2319 aluminum alloy powder is 45-150 ⁇ m, and the chemical composition is: 6.0% copper, 0.32% manganese, 0.26% zinc , 0.25% iron, the rest is aluminum and a small amount of other alloying elements.
- the powder feeding speed of 2319 aluminum alloy powder is 100 mg / s.
- the first control valve is automatically opened to allow the 2319 aluminum alloy powder to enter the low-power induction preheating device for preheating.
- the flow rate of powder flowing into the preheating device is controlled to 100 mg / s; the working power of the preheating device is 600 W to ensure that the temperature of the powder is stable at about 300 ° C.
- the temperature sensing system and control system on the inner wall of the device measure the temperature in the preheating device in real time And at any time by adjusting the induction preheating power to ensure that the powder temperature meets the requirements.
- the second control valve is automatically opened, and the preheated 2319 aluminum alloy powder enters the high-power induction heating device for melting.
- the flow rate of powder into the heating device is controlled at 100mg / s; the working power of the heating device is 1150W, and the temperature sensor system and control system are also installed on the inner wall of the heating device to ensure that the temperature of the alloy droplets is controlled at about 800 °C. At this temperature, it not only meets the superheat requirement of continuous and stable flow of metal liquid; but also reduces the burning loss of low melting point aluminum and other elements, making the chemical composition of the final alloy molded part more uniform and stable.
- the continuous molten 2319 aluminum alloy droplets fall on the substrate by their own gravity and propelled by the upper aluminum alloy droplets to be deposited and formed.
- the temperature of the substrate is controlled at about 300 ° C through preheating to prevent the occurrence of large temperature gradients on the edges and inside of the molded part, which increases the internal stress of the part, thereby reducing the possibility of micro-cracks.
- the alloy powder completes the three-dimensional coordinated movement, thereby achieving precise horizontal and vertical precision molding of the complex 2319 aluminum alloy parts, and at the same time using the CCD camera devices on both sides of the substrate to monitor the deposition molding in real time process.
- the alloy components of the formed 2319 aluminum alloy parts are 6.3% copper, 0.31% manganese, 0.27% zinc, 0.26% iron, and the rest are aluminum and a small amount of other alloying elements, which meet the chemical composition requirements of the target aluminum alloy.
- the surface roughness, tensile strength, yield strength, and elongation at break of the three samples were tested and compared. The results are shown in Table 3.
- the metal additive manufacturing equipment and the environment as a whole are evacuated and filled with an inert protective gas.
- the vacuum gauge indicates that the system pressure is less than 200Pa
- turn on the Roots pump to continue vacuuming the device until the pressure value in the device is less than 5Pa.
- turn off the mechanical pre-pumping pump and Roots pump in turn, and then turn on the diffusion pump for high vacuum extraction.
- the vacuum degree of the equipment is less than 10 -2 Pa
- turn off the diffusion pump to complete the overall vacuuming of the equipment.
- the vacuuming time is 12 minutes ( (Requires control within 15min).
- the equipment is filled with 99.999% high-purity inert gas nitrogen for protection.
- the oxygen content in the internal cavity of the equipment is measured in real time by an oxygen analyzer to ensure that the oxygen content is controlled within 100ppm.
- the particle size of the pure copper powder is 53-105 ⁇ m, the chemical composition is: 99.96% copper, and the rest are a small amount of other alloying elements.
- the feeding speed of pure copper powder is 25mg / s.
- the first control valve is automatically opened to allow the pure copper powder to enter the low-power induction preheating device for preheating.
- the flow rate of powder into the preheating device is controlled to 25mg / s; the working power of the preheating device is 300W, which ensures that the temperature of the powder is stable at about 500 ° C, and the temperature sensing system and control system on the inner wall of the device measure the temperature in the preheating device in real time And at any time by adjusting the induction preheating power to ensure that the powder temperature meets the requirements.
- the second control valve is automatically opened, and the pure copper powder after preheating enters the high-power induction heating device for melting.
- the flow rate of powder into the heating device is controlled at 25mg / s; the working power of the heating device is 600W, and the temperature sensor system and control system are also installed on the inner wall of the heating device to ensure that the temperature of the alloy droplets is controlled at about 1250 °C. At this temperature, it not only satisfies the superheat requirement of continuous and stable flow of metal liquid; but also reduces the burning loss of low melting point elements, making the chemical composition of the final alloy molded part more uniform and stable.
- the continuous molten pure copper droplets fall on the substrate by their own gravity and propelled by the pure copper molten droplets.
- the temperature of the substrate is controlled at about 500 ° C by preheating to prevent a large temperature gradient from occurring at the edges and inside of the molded part to increase the internal stress of the part, thereby reducing the possibility of micro-cracks.
- the spatial movement of the manipulator 5 is driven by controlling the motion unit to complete the three-dimensional coordinated movement of the alloy powder, thereby realizing the precise molding of complex pure copper parts in the horizontal and vertical directions, and using the CCD camera devices on both sides of the substrate to monitor the deposition molding process in real time .
- the composition of the formed pure copper parts is 99.95% copper, and the rest are a small amount of other alloying elements, which meet the target pure copper chemical composition requirements.
- the surface roughness, tensile strength, yield strength and elongation at break of the three samples were tested and compared. The results are shown in Table 4.
- the surface roughness values in the data tables 1-4 of the examples are used to evaluate the dimensional accuracy of the metal samples.
- the tensile strength value, yield strength value and elongation at break value are used to evaluate the comprehensive mechanical properties of metal samples. The larger the tensile strength value, the yield strength value and the elongation at break value, the better the comprehensive mechanical properties.
- the induction heating preheating process reduces the temperature gradient inside the powder under the premise of ensuring a higher energy utilization rate of the metal powder, and provides the necessary conditions for obtaining a metal sample with excellent comprehensive mechanical properties.
- the three-dimensional coordinated movement of the metal powder droplets provides a guarantee for the high precision of metal parts.
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Abstract
Description
项目 | 表面粗糙度(mm) | 抗拉强度(MPa) | 屈服强度(MPa) | 断后伸长率(%) |
实施例1 | 0.12 | 298 | 253 | 24.2 |
普通成型件 | 0.21 | 272 | 215 | 17.1 |
项目 | 表面粗糙度(mm) | 抗拉强度(MPa) | 屈服强度(MPa) | 断后伸长率(%) |
实施例2 | 0.13 | 191 | 88 | 20.8 |
普通成型件 | 0.23 | 151 | 78 | 17.8 |
项目 | 表面粗糙度(mm) | 抗拉强度(MPa) | 屈服强度(MPa) | 断后伸长率(%) |
实施例3 | 0.15 | 268 | 131 | 12.2 |
普通成型件 | 0.26 | 197 | 101 | 8.9 |
项目 | 表面粗糙度(mm) | 抗拉强度(MPa) | 屈服强度(MPa) | 断后伸长率(%) |
实施例4 | 0.12 | 407 | 349 | 8.1 |
普通成型件 | 0.25 | 370 | 317 | 6.3 |
Claims (10)
- 连续送粉感应加热金属增材制造装置,其特征在于,包括:基板,用于提供增材制造金属层的形成基底;设置在基板一侧的运动控制装置以及运动单元,所述运动单元上设置有机械手,运动单元被设置用于在所述运动控制装置的控制下移动以驱使机械手在三维空间内运动;储粉槽,用以储存运送的金属粉末;低功率感应预热装置,构造为一密封容器,经由第一管连通到所述储粉槽下方;第一中空铜线圈,螺旋缠绕在所述低功率感应预热装置的外部,用于对经过的金属粉末进行预热;高功率感应加热装置,包括一连通到低功率感应预热装置的细管;第二中空铜线圈,螺旋缠绕在所述细管的外部,用于对经过细管的金属粉末加热熔融形成熔滴;水冷***,包括水冷箱以及通过水冷电缆在所述第一中空铜线圈、第二中空铜线圈中各自形成的水冷循环通道;其中,所述机械手夹持所述储粉槽,储粉槽、低功率感应预热装置、高功率感应加热装置以及对应的第一中空铜线圈、第二中空铜线圈均设置在基板的垂直上方位置,并且与机械手保持同步移动,在所述运动单元的驱动下,第二中空铜线圈加热熔融形成的熔滴通过自身重力以及上方熔滴的推进下,落入基板上沉积成型。
- 根据权利要求1所述的连续送粉感应加热金属增材制造装置,其特征在于,所述的运动单元被控制至少在X-Y平面和X-Z平面内运动。
- 根据权利要求1所述的连续送粉感应加热金属增材制造装置,其特征在于,所述储粉槽与所述第一管的连接位置下方以及低功率感应预热装置与所述细管的连接位置下方分别设置有控制阀。
- 根据权利要求1所述的连续送粉感应加热金属增材制造装置,其特征在于,所述水冷***包括第一水冷电缆以及第二水冷电缆,均设置有入水通道和出水通道,第一水冷电缆与第一中空铜线圈连接,形成第一循环通道,第二水冷电缆与第二中空铜线圈连接,形成第二循环通道。
- 根据权利要求4所述的连续送粉感应加热金属增材制造装置,其特征在于,所述入水通道位于电缆中心,沿着电缆长度方向并截面呈圆形,出水通道位于电缆入水通道外侧,沿着电缆长度方向并截面呈圆环形。
- 根据权利要求4所述的连续送粉感应加热金属增材制造装置,其特征在于,所述水冷***包括连接到水冷箱的第一入口管、第二入口管、第一出口管和第二出口管,第一入口管 连通到第一水冷电缆的入水通道的一端,第一出口管连通到第一水冷电缆的出水通道的一端,第二入口管连通到第二水冷电缆的入水通道的一端,第二出口管连通到第二水冷电缆的出水通道的一端。
- 根据权利要求6所述的连续送粉感应加热金属增材制造装置,其特征在于,所述缠绕到低功率感应预热装置外部的第一中空铜线圈的两端分别接入到第一水冷电缆的另一端,其中一端连通入水通道,另一端连通出水通道。
- 根据权利要求6所述的连续送粉感应加热金属增材制造装置,其特征在于,所述缠绕到高功率感应预热装置外部的第二中空铜线圈的两端分别接入到第二水冷电缆的另一端,其中一端连通入水通道,另一端连通出水通道。
- 根据权利要求4-8中任意一项所述的连续送粉感应加热金属增材制造装置,其特征在于,所述第一水冷电缆以及第二水冷电缆为线材结构相同、尺寸不同的设计,其截面方向从外到内依次包括外部绝缘橡胶层、出水通道、外绝缘层、电缆铜线、内绝缘层以及入水通道。
- 一种使用权利要求1-9中任意一项所述装置的增材制造方法,其特征在于,包括以下步骤:真空环境的抽取与保持,包括对装置及所处的环境进行抽真空,直到真空度低于10 -2Pa,然后冲入惰性气体,并监测氧含量;开启送粉器并通过送粉管向储粉槽送入金属粉末,在储粉槽中的粉末容量达到设定值时控制输送到低功率感应预热装置中,通过第一中空铜线圈进行感应加热,预热粉末;密封容器内预热的粉末容量达到设定值后控制输送到高功率感应加热装置并通过第二中空铜线圈进行感应加热,熔融粉末形成熔滴,其中第二中空铜线圈的加热功率大于第一中空铜线圈的加热功率,控制熔滴的温度控制在700℃-900℃;连续熔融态的熔滴通过自身重力以及上方熔滴推进的作用下,落入基板上成型,其中基板的温度通过预热控制在250℃-350℃,并且:在金属层堆积过程中,通过运动单元的三维运动使得熔滴在基板上方的三维空间范围内运动,使得金属层在基板上熔融堆积成型,直至完成打印。
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CN112276115A (zh) * | 2020-11-26 | 2021-01-29 | 上海航天设备制造总厂有限公司 | 用于3d打印设备基板预热的加热装置 |
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