CN106903394B - Additive manufacturing method for aluminum-magnesium alloy structural part - Google Patents
Additive manufacturing method for aluminum-magnesium alloy structural part Download PDFInfo
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- CN106903394B CN106903394B CN201710129920.7A CN201710129920A CN106903394B CN 106903394 B CN106903394 B CN 106903394B CN 201710129920 A CN201710129920 A CN 201710129920A CN 106903394 B CN106903394 B CN 106903394B
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- 229910000861 Mg alloy Inorganic materials 0.000 title claims abstract description 78
- SNAAJJQQZSMGQD-UHFFFAOYSA-N aluminum magnesium Chemical compound [Mg].[Al] SNAAJJQQZSMGQD-UHFFFAOYSA-N 0.000 title claims abstract description 77
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 36
- 239000000654 additive Substances 0.000 title claims abstract description 25
- 230000000996 additive effect Effects 0.000 title claims abstract description 25
- 239000000463 material Substances 0.000 claims abstract description 46
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 35
- 238000000034 method Methods 0.000 claims abstract description 31
- 238000005253 cladding Methods 0.000 claims abstract description 24
- 239000000956 alloy Substances 0.000 claims abstract description 15
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 14
- 239000011261 inert gas Substances 0.000 claims abstract description 12
- 238000010891 electric arc Methods 0.000 claims abstract description 8
- 238000003466 welding Methods 0.000 claims description 32
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 29
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 20
- 238000001035 drying Methods 0.000 claims description 13
- 238000005516 engineering process Methods 0.000 claims description 13
- 239000002253 acid Substances 0.000 claims description 12
- 229910052742 iron Inorganic materials 0.000 claims description 12
- 239000000843 powder Substances 0.000 claims description 12
- 238000005266 casting Methods 0.000 claims description 11
- 238000012545 processing Methods 0.000 claims description 11
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 10
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 claims description 10
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 claims description 10
- 238000004140 cleaning Methods 0.000 claims description 10
- 239000000498 cooling water Substances 0.000 claims description 10
- 238000003723 Smelting Methods 0.000 claims description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 8
- 238000000227 grinding Methods 0.000 claims description 8
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 7
- 239000007789 gas Substances 0.000 claims description 7
- 229910052749 magnesium Inorganic materials 0.000 claims description 7
- 239000011777 magnesium Substances 0.000 claims description 7
- 238000005498 polishing Methods 0.000 claims description 7
- 239000007787 solid Substances 0.000 claims description 6
- 244000137852 Petrea volubilis Species 0.000 claims description 5
- 238000000137 annealing Methods 0.000 claims description 5
- 238000010622 cold drawing Methods 0.000 claims description 5
- 239000003344 environmental pollutant Substances 0.000 claims description 5
- 238000005098 hot rolling Methods 0.000 claims description 5
- 239000012535 impurity Substances 0.000 claims description 5
- 238000010330 laser marking Methods 0.000 claims description 5
- 238000003801 milling Methods 0.000 claims description 5
- 231100000719 pollutant Toxicity 0.000 claims description 5
- 229910021642 ultra pure water Inorganic materials 0.000 claims description 5
- 239000012498 ultrapure water Substances 0.000 claims description 5
- 238000004506 ultrasonic cleaning Methods 0.000 claims description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 5
- 238000004804 winding Methods 0.000 claims description 5
- 238000005242 forging Methods 0.000 claims description 3
- 239000000758 substrate Substances 0.000 claims description 3
- CFQGDIWRTHFZMQ-UHFFFAOYSA-N argon helium Chemical compound [He].[Ar] CFQGDIWRTHFZMQ-UHFFFAOYSA-N 0.000 claims description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 abstract description 10
- 229910052786 argon Inorganic materials 0.000 abstract description 5
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 abstract description 5
- 229910052760 oxygen Inorganic materials 0.000 abstract description 5
- 239000001301 oxygen Substances 0.000 abstract description 5
- 239000011148 porous material Substances 0.000 abstract description 3
- 230000007847 structural defect Effects 0.000 abstract description 3
- 238000007712 rapid solidification Methods 0.000 abstract 1
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 3
- 238000009825 accumulation Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 238000011160 research Methods 0.000 description 2
- 229910018134 Al-Mg Inorganic materials 0.000 description 1
- 229910018467 Al—Mg Inorganic materials 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 241001085205 Prenanthella exigua Species 0.000 description 1
- GANNOFFDYMSBSZ-UHFFFAOYSA-N [AlH3].[Mg] Chemical compound [AlH3].[Mg] GANNOFFDYMSBSZ-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
- B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/235—Preliminary treatment
Landscapes
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Laser Beam Processing (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Cleaning And De-Greasing Of Metallic Materials By Chemical Methods (AREA)
- Arc Welding In General (AREA)
Abstract
The invention belongs to the technical field of electric arc fuse wire additive manufacturing, and particularly relates to an additive manufacturing method of an aluminum magnesium alloy structural part. The method is characterized in that: placing a self-made argon protection device on a workbench, placing an aluminum alloy base material inside the workbench, and pre-filling high-purity inert gas to enable the oxygen content in a cavity to be 50-80 mu L/L; conveying the aluminum-magnesium alloy wire to a molten pool generated by electric arc by using a special wire feeding device to form an electric arc cladding layer combined with the pretreated base material; and then, realizing layer-by-layer cladding through a numerical control machining program of each layer, and finally obtaining the three-dimensional aluminum-magnesium alloy structural member with high performance, full compactness and complex shape and the characteristic of rapid solidification structure. The manufacturing method has the advantages of low manufacturing cost, short manufacturing period, high material utilization rate and stable performance, can quickly manufacture complex parts, greatly improves the structural strength of the aluminum alloy structural member, and reduces the structural defects of pores, cracks and the like in the alloy.
Description
Technical Field
The invention belongs to the technical field of electric arc fuse wire additive manufacturing, and particularly relates to an additive manufacturing method of an aluminum magnesium alloy structural part.
Background
The additive manufacturing technology (AM) is a technology for processing and generating a solid part in a layer-by-layer accumulation manner through CAD design data based on a discrete-accumulation idea. The method has the advantages of high forming efficiency, low cost, compact parts and the like, a great deal of research is carried out by scientific research institutes of all countries in the world, the method can be divided into laser welding (LAW), Plasma Arc Welding (PAW), Gas Metal Arc Welding (GMAW), non-gas metal arc welding (GTAW), Electron Beam Welding (EBW) and the like according to different additive manufacturing and cladding processes, and compared with other additive manufacturing technologies, the arc welding additive manufacturing technology has the advantages of low cost, high efficiency, multiple controllable parameters, good mechanical properties, good applicability of metal materials and the like, but also has some problems to be solved: the forming precision has certain difference with the net forming part, the residual stress is larger, the controllability of a molten pool is poor, a special forming material is lacked, the working environment is poor and the like. In the traditional welding technology, the gas metal arc welding (MIG welding) has the advantages of large welding current, high welding efficiency and the like, but the electric arc is unstable, and a molten pool is easy to overflow and collapse in the forming process; the non-consumable electrode gas shielded welding is stable, but the welding current is small, and the welding efficiency is low.
The aluminum alloy has the characteristics of high specific strength, small thermal expansion coefficient, good wear resistance and corrosion resistance and the like, is an excellent structural and functional material, is widely applied to the fields of automobiles, aerospace, mechanical electronics and the like, and is an aluminum magnesium alloy which is the most widely used at present. For complex aluminum-magnesium alloy structural parts, particularly structural parts containing inner cavities, the complex aluminum-magnesium alloy structural parts are difficult to manufacture or even impossible to manufacture by adopting the traditional processes of casting, forging, machining and the like. And the traditional forming process is adopted from the blank to the final part, a large number of dies and a plurality of processes are needed for completion, so that the production period of the cast aluminum-magnesium alloy is long, the cost is high, and the material utilization rate is low. However, with the development of the laser additive manufacturing technology, the laser additive manufacturing technology brings new opportunities for forming aluminum alloy parts, greatly improves the manufacturing freedom of the aluminum magnesium alloy parts, saves the production and manufacturing time, and expands the application range of the aluminum magnesium alloy parts. However, the main problems of additive manufacturing of aluminium magnesium alloys are: because the surfaces of the base material and the aluminum-magnesium alloy wire are not cleaned completely, the heating and cooling speeds are too high in the welding process, so that H + in a molten pool cannot escape completely, and hydrogen holes are easy to form; in addition, the chemical bonding force of aluminum and oxygen is strong, a thin oxide film (Al2O3) is easily formed on the surface, and due to the high melting point (2050 ℃) of the oxide film, the bonding cannot be normally performed, the good bonding between metals is blocked, and the lack of penetration is easily generated, so that the aluminum magnesium alloy product formed by the laser additive manufacturing technology has the defects of poor forming quality, easy generation of spheroidization, pores, slag inclusion, cracks and the like.
Disclosure of Invention
Aiming at the problems, the invention provides the additive manufacturing method for the aluminum-magnesium alloy structural part, which has the advantages of simple process, low cost, no structural defects of the prepared structural part, high precision and good structural strength.
In order to realize the purpose of the invention, the invention adopts the following technical scheme:
an additive manufacturing method of an aluminum magnesium alloy structural part specifically comprises the following steps:
(1) pretreatment of a base material: firstly, grinding and polishing an aluminum alloy base material by using sand paper, then cleaning for 20-30 min by using an acid solution at the temperature of 30-50 ℃, then cleaning by using clear water, then sequentially putting the aluminum alloy base material into acetone, ethanol and ultrapure water for ultrasonic cleaning for 5-10 min so as to remove surface impurities, taking out and drying, and carrying out surface microstructure processing on the aluminum alloy base material by using a laser marking machine to form frustum-shaped microstructures with the spacing of 50-200 mu m for later use;
(2) preparing an aluminum-magnesium alloy wire: adding a certain proportion of pure magnesium ingot, aluminum powder and iron-based alloy powder into a dry smelting furnace, and smelting for 3-5 hours at the temperature of 700-800 ℃ to obtain aluminum-magnesium alloy melt; secondly, casting the aluminum-magnesium alloy solution obtained in the step one into an aluminum-magnesium alloy cast ingot with the thickness of 400-500 mm under the conditions that the temperature is 650-700 ℃, the casting speed is 3-3.5 mm/min, the cooling water strength is 0.1-0.15 MPa and the cooling water temperature is 10-20 ℃; milling oxide skin on the surface of the aluminum-magnesium alloy cast ingot obtained in the step II, and then performing a series of normal processes of hot forging cogging, hot rolling coiling, polishing, cold drawing and vacuum annealing to obtain aluminum-magnesium alloy wire coils with the diameter of 1-2 mm; fourthly, removing oxide skins and pollutants on the surfaces of the finished wires by using acid and acetone under a stress-free state, drying, and then winding the dried finished wires on a rotary table of an automatic wire feeder for later use;
(3) under the drive of the aluminum magnesium alloy structural member CAD three-dimensional solid model slicing data, utilizing a slicing technology to disperse a continuous three-dimensional CAD digital analog into layered slices with a certain layer thickness and sequence, wherein the slice thickness is 500-600 mu m, converting the three-dimensional data information of the aluminum magnesium alloy structural member into a series of two-dimensional plane data, extracting the profile generated by each layer of slices, designing reasonable process parameters such as a path, a laser scanning speed and a lap joint rate according to the slice profile, generating a numerical control processing program of each layer along a scanning track determined by the two-dimensional plane data, and transmitting the numerical control processing program to a numerical control workbench;
(4) placing a self-made inert gas protection device on a workbench, placing a dried aluminum alloy base material inside, and pre-filling a certain flow of high-purity inert gas;
(5) starting a welding robot, calling out a processing program, clicking an operation button, enabling the robot arm to operate according to a preset processing track, and meanwhile, conveying an aluminum-magnesium alloy wire to a generated molten pool by a wire feeding device to form a cladding layer metallurgically bonded with a base material; and after one layer is cladded, the welding gun rises to a certain height, the height corresponds to the thickness of the thin layer, the welding gun follows a certain running track, and the three-dimensional aluminum-magnesium alloy structural member with a certain geometric shape is accumulated layer by layer in a circulating reciprocating manner.
Further, the acid solution in the step (1) is composed of a hydrofluoric acid solution with the concentration of 3% and a sulfuric acid solution with the concentration of 8% according to the mass ratio of 1: 3.
Further, the components in the step (2) in percentage by mass are as follows: 5-10% of pure magnesium ingot, 60-80% of aluminum powder and 15-30% of iron-based alloy powder.
Further, the iron-based alloy powder comprises the following components in percentage by mass: cr: 35.5, Mn: 10. si: 5.2, B: 4.5, Ni: 4.0, Zn: 2.7, C: 3.8, Fe: and (4) the balance.
Further, the inert gas in the step (4) is argon-helium mixed gas.
Further, the purity of the inert gas in the step (4) is more than or equal to 99.99%, and the flow rate is 25-40 L.min-1。
Further, the arc cladding process parameters in the step (5) are as follows: the output power is 2-20 kW, and the wire feeding speed is 650-1-22 mm/min.
Further, the thickness of the single cladding layer in the step (5) is 1-2.5 mm.
Further, the welding gun head moving track in the step (5) is horizontal scanning of the nth layer, the (n + 1) th layer is perpendicular to the nth layer, the (n + 2) th layer is perpendicular to the (n + 1) th layer and opposite to the scanning direction of the nth layer, the (n + 3) th layer is perpendicular to the (n + 2) th layer and opposite to the scanning direction of the (n + 1) th layer, and n is an integer starting from 1.
The invention has the following beneficial effects:
(1) according to the additive manufacturing method for the aluminum-magnesium alloy structural member, disclosed by the invention, the surface microstructure of the base material is processed to form the frustum pyramid type microstructure, so that the adhesion force between the aluminum-magnesium alloy pipe and the base material is favorably improved, and the bonding strength of an interface is enhanced.
(2) According to the additive manufacturing method for the aluminum-magnesium alloy structural member, the operation track of the welding gun head is perpendicular to adjacent layers, so that the problem that the arc starting and arc closing positions are uneven before and after single-direction stacking can be solved, the stable proceeding of the multilayer stacking process is ensured, and the average tensile strength of the structural member is greatly improved.
(3) The additive manufacturing method for the aluminum-magnesium alloy structural part has the advantages of simple process, capability of greatly saving magnesium-aluminum alloy materials, low manufacturing cost, no structural defect of the prepared aluminum-magnesium alloy structural part, high precision and good structural strength.
Drawings
FIG. 1 is a schematic diagram of additive manufacturing of an Al-Mg alloy structural member according to the present invention;
fig. 2 is a schematic diagram of a laser head operation track in the additive manufacturing of the aluminum magnesium alloy structural part.
Detailed Description
The present invention will now be described in further detail with reference to examples.
Example 1
An additive manufacturing method of an aluminum magnesium alloy structural part specifically comprises the following steps:
(1) pretreatment of a base material: firstly, grinding and polishing an aluminum alloy base material by using sand paper, then, at the temperature of 40 ℃, cleaning for 20-30 min by using an acid solution which is composed of a hydrofluoric acid solution with the concentration of 3% and a sulfuric acid solution with the concentration of 8% according to the mass ratio of 1:3, then cleaning by using clear water, then sequentially putting the aluminum alloy base material into acetone, ethanol and ultrapure water for ultrasonic cleaning for 5-10 min so as to remove surface impurities, taking out the aluminum alloy base material and drying the aluminum alloy base material by drying, and processing a surface microstructure of the aluminum alloy base material by using a laser marking machine to form a prismoid type microstructure with the spacing of 50 mu m for later use;
(2) preparing an aluminum-magnesium alloy wire: adding 8 mass percent of pure magnesium ingot, 70 mass percent of aluminum powder and 22 mass percent of iron-based alloy powder into a dry smelting furnace, wherein the mass percent of the iron-based alloy powder is as follows: cr: 35.5, Mn: 10. si: 5.2, B: 4.5, Ni: 4.0, Zn: 2.7, C: 3.8, Fe: the balance; smelting for 3-5 h at the temperature of 700-800 ℃ to obtain aluminum magnesium alloy melt; secondly, casting the aluminum-magnesium alloy solution obtained in the step one into an aluminum-magnesium alloy cast ingot with the thickness of 400-500 mm under the conditions that the temperature is 650-700 ℃, the casting speed is 3-3.5 mm/min, the cooling water strength is 0.1-0.15 MPa and the cooling water temperature is 10-20 ℃; milling oxide skin on the surface of the aluminum-magnesium alloy cast ingot obtained in the step II, and then performing a series of normal processes of hot section opening, hot rolling disc rounding, grinding, cold drawing and vacuum annealing to process the aluminum-magnesium alloy cast ingot into aluminum-magnesium alloy disc wires with the diameter of 1 mm; fourthly, removing oxide skins and pollutants on the surfaces of the finished wires by using acid and acetone under a stress-free state, and winding the finished wires on a turntable of an automatic wire feeder after drying for later use;
(3) under the drive of the aluminum magnesium alloy structural member CAD three-dimensional solid model slicing data, utilizing a slicing technology to disperse a continuous three-dimensional CAD digital model into layered slices with a certain layer thickness and sequence, wherein the slice thickness is 500 mu m, converting the three-dimensional data information of the aluminum magnesium alloy structural member into a series of two-dimensional plane data, extracting the profile generated by each layer of slices, designing reasonable process parameters such as a path, laser scanning speed and lap joint rate according to the slice profile, generating a numerical control processing program of each layer along the scanning track determined by the two-dimensional plane data, and transmitting the numerical control processing program to a numerical control workbench;
(4) placing a self-made nitrogen protection device on a workbench (as shown in figure 1), placing the dried aluminum alloy base material inside, and pre-charging high-purity nitrogen with the purity of not less than 99.99% and the flow of 25 L.min-1Making the oxygen content in the cavity be 50 mu L/L;
(5) starting the welding robot, calling out a machining program, outputting 20kW of power, clicking an operation button, and operating the arc according to a preset machining track; meanwhile, the wire feeder conveys the aluminum-magnesium alloy wire to a molten pool generated by a molten arc at the speed of 22mm/min to form a cladding layer which is metallurgically bonded with the base material and has the thickness of 500 mu m; the method comprises the steps of realizing layer-by-layer cladding through a numerical control machining program of each layer to obtain a cladding section, after one layer of cladding is finished, raising a welding gun head by a certain height, wherein the height generally corresponds to the thickness of a thin layer, the welding gun head follows the horizontal scanning of the nth layer, the (n + 1) th layer is vertical to the nth layer, the (n + 2) th layer is vertical to the (n + 1) th layer and is opposite to the scanning direction of the nth layer, the (n + 3) th layer is vertical to the (n + 2) th layer and is opposite to the scanning direction of the (n + 1) th layer, n is a certain operation track (shown in figure 2 in the attached drawing description) of an integer from 1, and the operation track is repeated in a circulating mode.
Example 2
An additive manufacturing method of an aluminum magnesium alloy structural part specifically comprises the following steps:
(1) pretreatment of a base material: firstly, grinding and polishing an aluminum alloy base material by using sand paper, then cleaning for 20-30 min by using an acid solution consisting of a hydrofluoric acid solution with the concentration of 3% and a sulfuric acid solution with the concentration of 8% at the temperature of 30 ℃ according to the mass ratio of 1:3, then cleaning by using clear water, then sequentially putting the aluminum alloy base material into acetone, ethanol and ultrapure water for ultrasonic cleaning for 5-10 min so as to remove surface impurities, taking out the aluminum alloy base material and drying the aluminum alloy base material by drying, and processing a surface microstructure of the aluminum alloy base material by using a laser marking machine to form a prismoid type microstructure with the spacing of 100 mu m for later use;
(2) preparing an aluminum-magnesium alloy wire: adding 5% of pure magnesium ingot, 65% of aluminum powder and 30% of iron-based alloy powder into a dry smelting furnace, wherein the iron-based alloy powder comprises the following components in percentage by mass: cr: 35.5, Mn: 10. si: 5.2, B: 4.5, Ni: 4.0, Zn: 2.7, C: 3.8, Fe: the balance; smelting for 3-5 h at the temperature of 700-800 ℃ to obtain aluminum magnesium alloy melt; secondly, casting the aluminum-magnesium alloy solution obtained in the step one into an aluminum-magnesium alloy cast ingot with the thickness of 400-500 mm under the conditions that the temperature is 650-700 ℃, the casting speed is 3-3.5 mm/min, the cooling water strength is 0.1-0.15 MPa and the cooling water temperature is 10-20 ℃; milling oxide skin on the surface of the aluminum-magnesium alloy cast ingot obtained in the step II, and then performing a series of normal processes of hot section opening, hot rolling coiling, grinding, cold drawing and vacuum annealing to process the aluminum-magnesium alloy cast ingot into aluminum-magnesium alloy wire coils with the diameter of 1.5 mm; fourthly, removing oxide skins and pollutants on the surfaces of the finished wires by using acid and acetone under a stress-free state, and winding the finished wires on a turntable of an automatic wire feeder after drying for later use;
(3) under the drive of the aluminum magnesium alloy structural member CAD three-dimensional solid model slicing data, utilizing a slicing technology to disperse a continuous three-dimensional CAD digital model into layered slices with a certain layer thickness and sequence, wherein the slice thickness is 550 mu m, converting the three-dimensional data information of the aluminum magnesium alloy structural member into a series of two-dimensional plane data, extracting the profile generated by each layer of slices, designing reasonable process parameters such as a path, laser scanning speed and lap joint rate according to the slice profile, generating a numerical control processing program of each layer along the scanning track determined by the two-dimensional plane data, and transmitting the numerical control processing program to a numerical control workbench;
(4) placing a self-made argon protection device on a workbench (as shown in figure 1), placing the dried aluminum alloy substrate inside, and pre-charging high-purity argon with the purity of more than or equal to 99.99% and the flow of 30 L.min-1Making the oxygen content in the cavity 65 mu L/L;
(5) starting the welding robot, calling out a processing program, outputting 2kW of power, clicking an operation button, and operating a laser beam according to a preset processing track; meanwhile, the wire feeder conveys the aluminum-magnesium alloy wire into a molten pool generated by electric arc at the speed of 1mm/min to form a cladding layer which is metallurgically bonded with the base material and has the thickness of 550 mu m; the method comprises the steps of realizing layer-by-layer cladding through a numerical control machining program of each layer to obtain a cladding section, after one layer of cladding is finished, raising a welding gun head by a certain height, wherein the height generally corresponds to the thickness of a thin layer, the welding gun head follows the horizontal scanning of the nth layer, the (n + 1) th layer is vertical to the nth layer, the (n + 2) th layer is vertical to the (n + 1) th layer and is opposite to the scanning direction of the nth layer, the (n + 3) th layer is vertical to the (n + 2) th layer and is opposite to the scanning direction of the (n + 1) th layer, n is a certain operation track (shown in figure 2 in the attached drawing description) of an integer from 1, and the operation track is repeated in a circulating mode.
Example 3
An additive manufacturing method of an aluminum magnesium alloy structural part specifically comprises the following steps:
(1) pretreatment of a base material: firstly, grinding and polishing an aluminum alloy base material by using sand paper, then, at the temperature of 50 ℃, cleaning for 20-30 min by using an acid solution which is composed of a hydrofluoric acid solution with the concentration of 3% and a sulfuric acid solution with the concentration of 8% according to the mass ratio of 1:3, then cleaning by using clear water, then sequentially putting the aluminum alloy base material into acetone, ethanol and ultrapure water for ultrasonic cleaning for 5-10 min so as to remove surface impurities, taking out the aluminum alloy base material and drying the aluminum alloy base material by drying, and processing a surface microstructure of the aluminum alloy base material by using a laser marking machine to form a frustum type microstructure with the spacing of 200 mu m for later use;
(2) preparing an aluminum-magnesium alloy wire: adding 10% of pure magnesium ingot, 75% of aluminum powder and 15% of iron-based alloy powder into a dry smelting furnace, wherein the iron-based alloy powder comprises the following components in percentage by mass: cr: 35.5, Mn: 10. si: 5.2, B: 4.5, Ni: 4.0, Zn: 2.7, C: 3.8, Fe: the balance; smelting for 3-5 h at the temperature of 700-800 ℃ to obtain aluminum magnesium alloy melt; secondly, casting the aluminum-magnesium alloy solution obtained in the step one into an aluminum-magnesium alloy cast ingot with the thickness of 400-500 mm under the conditions that the temperature is 650-700 ℃, the casting speed is 3-3.5 mm/min, the cooling water strength is 0.1-0.15 MPa and the cooling water temperature is 10-20 ℃; milling oxide skin on the surface of the aluminum-magnesium alloy cast ingot obtained in the step II, and then performing a series of normal processes of hot section opening, hot rolling disc rounding, grinding, cold drawing and vacuum annealing to process the aluminum-magnesium alloy cast ingot into aluminum-magnesium alloy disc wires with the diameter of 2 mm; fourthly, removing oxide skins and pollutants on the surfaces of the finished wires by using acid and acetone under a stress-free state, and winding the finished wires on a turntable of an automatic wire feeder after drying for later use;
(3) under the drive of the aluminum magnesium alloy structural member CAD three-dimensional solid model slicing data, utilizing a slicing technology to disperse a continuous three-dimensional CAD digital model into layered slices with a certain layer thickness and sequence, wherein the slice thickness is 600 mu m, converting the three-dimensional data information of the aluminum magnesium alloy structural member into a series of two-dimensional plane data, extracting the profile generated by each layer of slices, designing reasonable process parameters such as a path, laser scanning speed and lap joint rate according to the slice profile, generating a numerical control processing program of each layer along the scanning track determined by the two-dimensional plane data, and transmitting the numerical control processing program to a numerical control workbench;
(4) placing a self-made argon protection device on a workbench (as shown in the figure)1) placing the dried aluminum alloy substrate inside, and pre-filling a certain flow of high-purity argon gas, wherein the purity is more than or equal to 99.99 percent, and the flow is 40 L.min-1Making the oxygen content in the cavity be 80 muL/L;
(5) starting a welding robot, calling out a processing program, outputting the power of 12kW, clicking an operation button, and operating a laser beam according to a preset processing track at a scanning speed of 10 mm/min; meanwhile, the wire feeder conveys the aluminum-magnesium alloy wire into a molten pool generated by an electric arc beam at the speed of 1000mm/min to form a cladding layer which is metallurgically bonded with the base material and has the thickness of 600 mu m; the method comprises the steps of realizing layer-by-layer cladding through a numerical control machining program of each layer to obtain a cladding section, after one layer of cladding is finished, raising a welding gun head by a certain height, wherein the height generally corresponds to the thickness of a thin layer, the welding gun head follows the horizontal scanning of the nth layer, the (n + 1) th layer is vertical to the nth layer, the (n + 2) th layer is vertical to the (n + 1) th layer and is opposite to the scanning direction of the nth layer, the (n + 3) th layer is vertical to the (n + 2) th layer and is opposite to the scanning direction of the (n + 1) th layer, n is a certain operation track (shown in figure 2 in the attached drawing description) of an integer from 1, and the operation track is repeated in a circulating mode.
Comparative example 1 is substantially the same as example 1 except that: the microstructure processing is not carried out on the surface of the base material in the step (1).
Comparative example 2 is substantially the same as example 1 except that: and (4) protecting without introducing inert gas.
Product detection: the external surfaces of the al-mg alloy shaped parts obtained in examples 1 to 3 were clear, bright white in color, regular in shape and free from macrocracks. The metallographic structure of the formed part is analyzed by making the formed part into a cross section, and the scanning electron microscope SEM shows that the aluminum alloy formed part has no air holes and cracks in the structure, uniform structure and metallurgical bonding between layers. The hardness measured by a Vickers hardness tester is 808HV0.5、815HV0.5、817HV0.5. Compared with the example 1, the formed piece has poor adhesion with the base material, low strength and easy breakage; comparative example 2 compared with example 1, the aluminum alloy formed article had pores and cracks in the structure and the structure distribution was not uniform.
In light of the foregoing description of the preferred embodiment of the present invention, many modifications and variations will be apparent to those skilled in the art without departing from the spirit and scope of the invention. The technical scope of the present invention is not limited to the content of the specification, and must be determined according to the scope of the claims.
Claims (1)
1. The additive manufacturing method of the aluminum-magnesium alloy structural part is characterized by comprising the following steps:
(1) pretreatment of a base material: firstly, grinding and polishing an aluminum alloy base material by using sand paper, then cleaning for 20-30 min by using an acid solution at the temperature of 30-50 ℃, wherein the acid solution consists of a hydrofluoric acid solution with the concentration of 3% and a sulfuric acid solution with the concentration of 8% according to the mass ratio of 1:3, then cleaning by using clear water, then sequentially putting the aluminum alloy base material into acetone, ethanol and ultrapure water for ultrasonic cleaning for 5-10 min so as to remove surface impurities, taking out the aluminum alloy base material and drying the aluminum alloy base material, and processing a surface microstructure of the aluminum alloy base material by using a laser marking machine to form frustum-shaped microstructures with the spacing of 50-200 mu m for later use;
(2) preparing an aluminum-magnesium alloy wire: adding a certain proportion of pure magnesium ingot, aluminum powder and iron-based alloy powder into a dry smelting furnace, wherein the mass percentages of the components are as follows: 5-10% of pure magnesium ingot, 60-80% of aluminum powder and 15-30% of iron-based alloy powder, wherein the iron-based alloy powder comprises the following components in percentage by mass: cr: 35.5, Mn: 10. si: 5.2, B: 4.5, Ni: 4.0, Zn: 2.7, C: 3.8, Fe: the balance is smelted for 3-5 hours at the temperature of 700-800 ℃ to obtain aluminum-magnesium alloy melt; secondly, casting the aluminum-magnesium alloy solution obtained in the step one into an aluminum-magnesium alloy cast ingot with the thickness of 400-500 mm under the conditions that the temperature is 650-700 ℃, the casting speed is 3-3.5 mm/min, the cooling water strength is 0.1-0.15 MPa and the cooling water temperature is 10-20 ℃; milling oxide skin on the surface of the aluminum-magnesium alloy cast ingot obtained in the step II, and then performing a series of normal processes of hot forging cogging, hot rolling coiling, polishing, cold drawing and vacuum annealing to obtain aluminum-magnesium alloy wire coils with the diameter of 1-2 mm; fourthly, removing oxide skins and pollutants on the surfaces of the finished wires by using acid and acetone under a stress-free state, drying, and then winding the dried finished wires on a rotary table of an automatic wire feeder for later use;
(3) under the drive of the aluminum magnesium alloy structural member CAD three-dimensional solid model slicing data, utilizing a slicing technology to disperse a continuous three-dimensional CAD digital analog into layered slices with a certain layer thickness and sequence, wherein the slice thickness is 500-600 mu m, converting the three-dimensional data information of the aluminum magnesium alloy structural member into a series of two-dimensional plane data, extracting the profile generated by each layer of slices, designing reasonable process parameters such as a path, a laser scanning speed and a lap joint rate according to the slice profile, generating a numerical control processing program of each layer along a scanning track determined by the two-dimensional plane data, and transmitting the numerical control processing program to a numerical control workbench;
(4) placing a self-made inert gas protection device on a workbench, placing a dried aluminum alloy substrate inside the self-made inert gas protection device, and pre-filling a certain flow of high-purity inert gas, wherein the inert gas is argon-helium mixed gas, the purity of the inert gas is more than or equal to 99.99%, and the flow of the inert gas is 25-40 L.min-1；
(5) Starting a welding robot, calling out a processing program, clicking an operation button, enabling the robot arm to operate according to a preset processing track, and meanwhile, conveying an aluminum-magnesium alloy wire to a generated molten pool by a wire feeding device to form a cladding layer metallurgically bonded with a base material; carrying out layer-by-layer cladding through a numerical control machining program of each layer to obtain a cladding section, after one layer of cladding, raising a welding gun by a certain height, wherein the height corresponds to the thickness of a thin layer, the thickness of the single cladding layer is 1-2.5mm, the welding gun follows a certain running track, the process is repeated in a circulating mode, a three-dimensional aluminum-magnesium alloy structural member with a certain geometric shape is piled up layer by layer, and the process parameters of electric arc cladding are as follows: the output power is 2-20 kW, and the wire feeding speed is 1-22 mm/min;
the welding gun head moving track in the step (5) is that the nth layer is horizontally scanned, the (n + 1) th layer is perpendicular to the nth layer, the (n + 2) th layer is perpendicular to the (n + 1) th layer and opposite to the scanning direction of the nth layer, the (n + 3) th layer is perpendicular to the (n + 2) th layer and opposite to the scanning direction of the (n + 1) th layer, and n is an integer starting from 1.
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