CN113102862B - Ultrasonic-assisted arc additive manufacturing method - Google Patents
Ultrasonic-assisted arc additive manufacturing method Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K28/00—Welding or cutting not covered by any of the preceding groups, e.g. electrolytic welding
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
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- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
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- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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Abstract
Description
技术领域technical field
本发明涉及增材制造领域,特别涉及超声辅助的电弧增材制造方法。The invention relates to the field of additive manufacturing, in particular to an ultrasonic-assisted arc additive manufacturing method.
背景技术Background technique
近年来,在资源节约及高效制造的背景下,基于“加法”加工模式的增材制造技术在复杂形状薄壁件的制造上呈现出广阔的应用前景。随着航空航天、国防军工、轨道交通等关键技术领域对致密金属零件的性能、精度、制造成本和周期的要求日趋苛刻,亟需开展相关研究以突破并掌握金属零件直接成形技术。电弧增材制造多采用熔化极惰性气体保护焊(MIG)、钨极惰性气体保护焊(TIG)以及等离子体焊接(PA)等电弧为热源,添加丝材,在程序控制下,根据三维数字模型由线-面-体逐渐成形出金属零件,主要特点是沉积效率和丝材利用率高、整体制造周期短(沉积速率可以达到1kg/h)、成本低,还具有原位复合制造以及成形大尺寸零件的能力(可以制造大至lm3的工件)。但是电弧增材制造的堆积层实质上就是焊丝熔化后的凝固组织,与电弧堆焊组织类似,组织往往出现不均匀现象,而且在熔合线附近的凝固组织容易长成粗大柱状晶;此外,还可能出现气孔等缺陷,导致增材制造堆积层性能不佳,难以获得高性能的增材制造材料或零件。In recent years, under the background of resource saving and high-efficiency manufacturing, the additive manufacturing technology based on the "additive" processing mode has shown broad application prospects in the manufacture of thin-walled parts with complex shapes. With the increasingly stringent requirements for the performance, precision, manufacturing cost and cycle time of dense metal parts in key technical fields such as aerospace, national defense and military industry, and rail transportation, it is urgent to carry out relevant research to break through and master the direct forming technology of metal parts. Arc additive manufacturing mostly uses arcs such as melting inert gas welding (MIG), tungsten inert gas welding (TIG) and plasma welding (PA) as heat sources, adding wire, and under program control, according to the three-dimensional digital model Metal parts are gradually formed from line-surface-body. The main features are high deposition efficiency and wire utilization, short overall manufacturing cycle (deposition rate can reach 1kg/h), low cost, and in-situ composite manufacturing and large-scale forming. Capability of dimensional parts (workpieces as large as lm3 can be manufactured). However, the accumulation layer of arc additive manufacturing is essentially the solidified structure after the welding wire is melted. Similar to the arc surfacing structure, the structure often appears uneven, and the solidified structure near the fusion line tends to grow into thick columnar crystals; Defects such as pores may occur, resulting in poor performance of the additive manufacturing build-up layer, making it difficult to obtain high-performance additive manufacturing materials or parts.
针对上述问题,CN106363173A和CN111215843A的两篇专利分别公布了一种超声波辅助激光焊增材制造的装置及使用方法和一种电弧增材制造热碾压的制造方法及装置,虽然在一定程度上减少了气孔缺陷,提高了焊缝质量。但仍然存在一下问题:激光焊设备结构较复杂,工艺流程,操作步骤繁琐,成本较高;热碾压设备采用焊后多次碾压,工序复杂,影响生产效率。In response to the above problems, two patents of CN106363173A and CN111215843A respectively announced a device and method of using ultrasonic-assisted laser welding additive manufacturing and a manufacturing method and device of arc additive manufacturing hot rolling, although to a certain extent, the Pore defects are eliminated, and the quality of the weld seam is improved. However, there are still some problems: the structure of laser welding equipment is relatively complex, the process flow, operation steps are cumbersome, and the cost is high; hot rolling equipment uses multiple rolling after welding, and the process is complicated, which affects production efficiency.
此外,CN102794542A和CN101239415A的两篇专利均公开了一种在焊接过程中利用外界震源使焊丝震动以减少焊接气孔的焊接方法,震动丝对焊接气孔的产生有一定改善,但存在一些问题:1)焊丝的融化位置在熔池上方,对熔池的搅拌作用有限;2)震动的焊丝使得焊接电弧随之震动,易造成焊丝稳弧性差,甚至熄弧,从而影响了焊缝的成型质量。In addition, the two patents of CN102794542A and CN101239415A both disclose a welding method that uses an external source of vibration to vibrate the welding wire to reduce welding pores during the welding process. The vibration wire can improve the generation of welding pores, but there are some problems: 1) The melting position of the welding wire is above the molten pool, and the stirring effect on the molten pool is limited; 2) The vibrating welding wire makes the welding arc vibrate accordingly, which is easy to cause poor arc stability of the welding wire, or even arc extinction, thus affecting the forming quality of the weld.
发明内容Contents of the invention
针对上述现有技术的不足,本发明所要解决的技术问题是:怎样提供一种能够在电弧增材制造过程中更好地引入超声辅助,提高超声作用效果,以改善电弧增材制造材料或零件的组织和力学性能的超声辅助的电弧增材制造方法。Aiming at the deficiencies of the above-mentioned existing technologies, the technical problem to be solved by the present invention is: how to provide a method that can better introduce ultrasonic assistance in the arc additive manufacturing process, improve the ultrasonic effect, and improve the arc additive manufacturing materials or parts. Microstructure and Mechanical Properties of Ultrasound-Assisted Arc Additive Manufacturing.
为了解决上述技术问题,本发明采用了如下的技术方案:In order to solve the problems of the technologies described above, the present invention adopts the following technical solutions:
一种超声辅助的电弧增材制造方法,其特征在于,在进行电弧增材制造时,将具有往复超声振动特征的搅拌针插入到增材制造熔池中,并随熔池同步移动,对熔池金属的凝固过程实施超声振动和搅拌,改善其凝固组织和力学性能。An ultrasonic-assisted arc additive manufacturing method is characterized in that, when performing arc additive manufacturing, a stirring needle with reciprocating ultrasonic vibration characteristics is inserted into the additive manufacturing molten pool, and moves synchronously with the molten pool to The solidification process of the pool metal implements ultrasonic vibration and stirring to improve its solidification structure and mechanical properties.
这样,本方法中在电弧增材制造时,直接对熔池插入振动状态的搅拌针,通过搅拌针对熔池引入超声振动,能够更好地利用超声振动的空化效应和振动效应,减少焊接气孔,细化晶粒,提高焊接区域熔池边缘和非焊接区域在结晶过程中的结合强度,改善熔池金属凝固组织和力学性能。相较于其他超声振动方式,如加载于基底母材或通过电弧加载等,本发明的超声振动加载方式对熔池的超声振动更加直接,而且还有很好的机械搅拌作用,对熔池金属凝固组织和力学性能的改善效果更佳。In this way, during arc additive manufacturing in this method, a stirring needle in a vibrating state is directly inserted into the molten pool, and ultrasonic vibration is introduced into the molten pool through stirring, so that the cavitation effect and vibration effect of ultrasonic vibration can be better utilized, and welding pores can be reduced. , refine the grains, increase the bonding strength between the edge of the molten pool in the welded area and the non-welded area during the crystallization process, and improve the solidification structure and mechanical properties of the molten pool metal. Compared with other ultrasonic vibration methods, such as loading on the base material or through arc loading, the ultrasonic vibration loading method of the present invention is more direct to the ultrasonic vibration of the molten pool, and also has a good mechanical stirring effect, which is beneficial to the molten pool metal The improvement effect of coagulation structure and mechanical properties is better.
作为优化,所述搅拌针采用金属钨或者钨合金。As an optimization, the stirring needle is made of metal tungsten or tungsten alloy.
这样,能够更好地保证搅拌针不会和熔池金属产生反应。In this way, it can be better ensured that the stirring needle will not react with the molten pool metal.
作为优化,搅拌针振动方向为沿自身轴向。As an optimization, the vibration direction of the stirring needle is along its own axis.
这样,搅拌针作用于熔池只会带动熔池中液体金属在一定区域范围内做高频的往复振动,搅拌针是依靠振动对熔池产生出类似搅拌的效果(实际并不是常规意义上的搅拌),以减少焊接气孔,提高分子级别的焊接材料结合致密性,进而改善焊接区域力学性能,提高焊接效果。In this way, the stirring needle acting on the molten pool will only drive the liquid metal in the molten pool to perform high-frequency reciprocating vibrations within a certain area. Stirring) to reduce welding porosity and increase the bonding density of welding materials at the molecular level, thereby improving the mechanical properties of the welding area and improving the welding effect.
作为优化,搅拌针振动频率为20-100KHZ,振幅为0.2-1mm。该范围的振动可以更好地保证振动对金属结晶为良性的影响,避免振动过大反而影响结晶,降低焊接质量。As an optimization, the vibration frequency of the stirring needle is 20-100KHZ, and the amplitude is 0.2-1mm. The vibration in this range can better ensure that the vibration has a benign effect on the metal crystallization, and avoid excessive vibration that will affect the crystallization and reduce the welding quality.
作为一种选择,焊接时电弧增材制造焊枪沿垂直于熔池所在产品平面方向布置,搅拌针从电弧增材制造焊枪行进方向的前方或者后方斜向下插入到熔池中部下方实现超声振动。As an option, the arc additive manufacturing welding torch is arranged along the direction perpendicular to the product plane where the molten pool is located, and the stirring pin is inserted obliquely downward from the front or rear of the arc additive manufacturing welding gun to the middle of the molten pool to achieve ultrasonic vibration.
这样是因为常规电弧增材制造时焊枪是沿垂直于产品平面方向布置,故此种方式在常规电弧增材制造工艺控制过程的基础上直接增加搅拌针引入超声振动即可实施,无需再调整电弧增材制造焊枪的控制程序,方便实施应用。This is because the welding torch is arranged perpendicular to the product plane during conventional arc additive manufacturing, so this method can be implemented by directly adding a stirring needle to introduce ultrasonic vibration on the basis of the conventional arc additive manufacturing process control process, and there is no need to adjust the arc augmentation. The control program of the material manufacturing welding torch is convenient for implementation and application.
作为另一种选择,焊接时电弧增材制造焊枪布置为上端沿电弧增材制造焊枪行进方向的前方倾斜布置,搅拌针布置在电弧增材制造焊枪后方并垂直向下插入到增材制造熔池中部实现超声振动。As another option, the arc additive manufacturing welding torch is arranged so that the upper end of the arc additive manufacturing welding torch is arranged obliquely in front of the traveling direction of the arc additive manufacturing welding torch, and the stirring pin is arranged behind the arc additive manufacturing welding torch and inserted vertically downward into the additive manufacturing molten pool Ultrasonic vibration is achieved in the middle.
这样,电弧增材制造焊枪上端沿行进方向倾斜,可以更好地为熔池前方的待加工区域预热,同时可以为搅拌针让出沿熔池正中间位置垂直布置的空间,搅拌针垂直布置于熔池中部位置后,其超声振动可以非常均匀地传递作用到整个熔池,避免超声振动在熔池中传递不均匀导致对金属结晶融合效果的影响,极大地提高了产品成形质量。In this way, the upper end of the arc additive manufacturing welding torch is inclined along the direction of travel, which can better preheat the area to be processed in front of the molten pool, and at the same time make room for the vertical arrangement of the stirring needle along the middle of the molten pool, and the vertical arrangement of the stirring needle After being located in the middle of the molten pool, the ultrasonic vibration can be transmitted to the entire molten pool very uniformly, avoiding the influence of the uneven transmission of ultrasonic vibration in the molten pool on the fusion effect of metal crystals, and greatly improving the forming quality of the product.
进一步地,本方法依靠以下的电弧增材制造设备实现,所述电弧增材制造设备,包括一个电弧增材制造焊枪,电弧增材制造焊枪安装在一个整体沿水平设置的保持架上且焊接头一端向下,保持架上还安装有一个振动搅拌装置,振动搅拌装置包括一个超声振动器,超声振动器下端向下设置有一根搅拌针,超声振动器能够为搅拌针提供沿轴向的振动。Further, the method is realized by means of the following arc additive manufacturing equipment, the arc additive manufacturing equipment includes an arc additive manufacturing welding torch, the arc additive manufacturing welding torch is installed on a horizontally arranged cage as a whole and the welding head One end is downward, and a vibrating stirring device is installed on the cage. The vibrating stirring device includes an ultrasonic vibrator. A stirring needle is arranged downward at the lower end of the ultrasonic vibrator. The ultrasonic vibrator can provide axial vibration for the stirring needle.
这样,焊枪和振动搅拌装置安装在同一个保持架上,能够更好地保证搅拌针跟随焊枪同步实现振动搅拌。In this way, the welding gun and the vibration stirring device are installed on the same cage, which can better ensure that the stirring needle follows the welding gun synchronously to realize vibration stirring.
进一步地,电弧增材制造焊枪安装在一个焊枪安装套上,焊枪安装套通过一个焊枪安装套转动调节手柄可竖向转动地安装在保持架上。Further, the arc additive manufacturing welding torch is installed on a welding torch mounting sleeve, and the welding torch mounting sleeve is vertically rotatably mounted on the holder through a welding torch mounting sleeve rotation adjustment handle.
这样拧松焊枪安装套转动调节手柄可以转动调节焊枪安装套在竖直方向的倾斜角度,进而可以根据需要实现对焊枪角度的调节,调节到位后拧紧焊枪安装套转动调节手柄可实现固定。方案中涉及调节手柄具体实现调节紧固的结构属于成熟现有技术,可以在调节手柄上设置一个螺栓穿过焊枪安装套并和保持架上对应的螺孔配合即可实现,具体结构不在此详述。Unscrew the welding torch mounting sleeve and turn the adjusting handle so that the angle of inclination of the welding torch mounting sleeve in the vertical direction can be rotated, and then the angle of the welding torch can be adjusted as required. The structure involving the adjustment handle in the scheme to realize the adjustment and fastening is a mature existing technology. It can be realized by setting a bolt on the adjustment handle through the welding torch mounting sleeve and cooperating with the corresponding screw hole on the cage. The specific structure will not be detailed here. stated.
进一步地,电弧增材制造焊枪可沿轴向滑动地安装在所述焊枪安装套上,焊枪安装套上还贯穿地旋接设置有焊枪紧固用螺栓实现对电弧增材制造焊枪的固定。Further, the arc additive manufacturing welding torch can be slidably installed on the welding gun mounting sleeve in the axial direction, and the welding gun mounting sleeve is also screwed with a welding gun fastening bolt to fix the arc additive manufacturing welding gun.
这样,可以方便调节焊枪在倾斜调整后,再调整高低位置,使其能够保持足够的熔池深度以及调节出和搅拌针相配合的相对位置。In this way, it is convenient to adjust the height position of the welding torch after the inclination adjustment, so that it can maintain sufficient molten pool depth and adjust the relative position matched with the stirring needle.
进一步地,所述超声振动器竖向安装在一个振动器安装套上,振动器安装套通过一个振动器安装套振动调节手柄可竖向转动地安装在一个滑动套上,滑动套可水平滑动地安装在保持架上。Further, the ultrasonic vibrator is installed vertically on a vibrator mounting sleeve, and the vibrator mounting sleeve is vertically rotatably mounted on a sliding sleeve through a vibration adjustment handle of the vibrator mounting sleeve, and the sliding sleeve can slide horizontally Installed on the cage.
这样,可以方便根据需要调节搅拌针的倾斜角度,使其形成垂直于熔池方向布置,或者倾斜布置,也可以方便调节搅拌针相对于焊枪的前后距离,使其下端能够更好地位于熔池中部位置。振动器安装套振动调节手柄的调节结构可以和焊枪安装套转动调节手柄一致,不在此详述。In this way, it is convenient to adjust the inclination angle of the stirring needle according to the needs, so that it is arranged perpendicular to the direction of the molten pool, or arranged obliquely, and it is also convenient to adjust the front and rear distance of the stirring needle relative to the welding torch, so that the lower end can be better located in the molten pool middle position. The adjustment structure of the vibration adjustment handle of the vibrator installation sleeve can be consistent with the rotation adjustment handle of the welding torch installation sleeve, and will not be described in detail here.
进一步地,保持架呈上下宽度一致的长条形,滑动套可水平滑动地套接安装在保持架上,滑动套上还贯穿地旋接设置有滑动套紧固用螺栓实现对滑动套的固定。Further, the cage is in the shape of a long strip with the same width from top to bottom, and the sliding sleeve can be horizontally slidably sleeved and installed on the cage, and the sliding sleeve is also threaded through and provided with fastening bolts for the sliding sleeve to fix the sliding sleeve. .
这样,更加方便调节并固定搅拌针的前后位置。In this way, it is more convenient to adjust and fix the front and rear positions of the stirring needle.
进一步地,超声振动器通过消振弹簧安装在振动器安装套上。Further, the ultrasonic vibrator is mounted on the vibrator mounting sleeve through a vibration damping spring.
这样,消振弹簧作用于超声振动器和振动器安装套之间,能够避免超声振动通过振动器安装套传递到保持架上,进而造成焊枪的振动。能够更好地保持焊枪的工作稳定。In this way, the vibration-absorbing spring acts between the ultrasonic vibrator and the vibrator mounting sleeve, which can prevent the ultrasonic vibration from being transmitted to the holder through the vibrator mounting sleeve, thereby causing vibration of the welding torch. It can better keep the working stability of the welding torch.
进一步地,超声振动器为气动超声振动器。Further, the ultrasonic vibrator is a pneumatic ultrasonic vibrator.
这样具有效果稳定,利于控制,方便实施且超声振动对保持架反作用影响效果小的优点。而且气动式超声振动源,对热和高温的容忍程度高得多,更适合电弧增材制造这样的高温工况。This has the advantages of stable effect, favorable control, convenient implementation and little effect of ultrasonic vibration on the reaction effect of the cage. Moreover, the pneumatic ultrasonic vibration source has a much higher tolerance to heat and high temperature, and is more suitable for high-temperature conditions such as arc additive manufacturing.
进一步地,保持架固定安装在电弧增材制造专用机器人的机械臂上。Further, the cage is fixedly installed on the mechanical arm of the special robot for arc additive manufacturing.
这样方便通过机器人计算机控制实现对产品的自动电弧增材制造。In this way, it is convenient to realize automatic arc additive manufacturing of products through robot computer control.
进一步地,搅拌针下端具有一圈水平外凸的凸起。Further, the lower end of the stirring needle has a circle of horizontally convex protrusions.
这样,在搅拌针沿轴向上下振动时,该凸起能够对熔池起到极大的振动增幅作用,提高超声振动效果。具体实施时,该凸起外凸距离不宜过大,一般可以控制在搅拌针三倍直径以内,具体大小可根据试验验证获得。In this way, when the stirring needle vibrates up and down along the axial direction, the protrusion can greatly amplify the vibration of the molten pool and improve the effect of ultrasonic vibration. During specific implementation, the protrusion distance should not be too large, and generally can be controlled within three times the diameter of the stirring needle, and the specific size can be obtained according to experimental verification.
进一步地,所述凸起为周向均匀布置的多个,每个凸起的上表面和下表面分别设置为反向对称的倾斜面或者螺旋叶面。Furthermore, a plurality of protrusions are evenly arranged in the circumferential direction, and the upper surface and the lower surface of each protrusion are respectively set as reverse symmetrical inclined surfaces or helical blade surfaces.
这样,随着搅拌针沿轴向的往复振动,凸起的上下表面在往复运动时会形成在周向上往复回旋地向外推动金属液的作用效果,进而对金属液产生沿轴向方向的振动的同时产生一个沿圆周方向的往复振动,其中轴向方向的振动可以更好地作用于熔池底部,沿圆周方向的振动可以更好地作用于熔池周壁,双重振动对金属液熔池形成一个复合的高频振动效果,极大地提高了熔池对周壁金属的结合性,可以更好地细化金属结晶组织,提高振动对金属结晶融合效果的影响,提高了产品的成形质量。In this way, with the reciprocating vibration of the stirring needle in the axial direction, the upper and lower surfaces of the protrusion will form the effect of pushing the molten metal outward in a reciprocating manner in the circumferential direction during the reciprocating motion, and then vibrate the molten metal in the axial direction At the same time, a reciprocating vibration along the circumferential direction is generated, wherein the vibration in the axial direction can better act on the bottom of the molten pool, and the vibration in the circumferential direction can better act on the surrounding wall of the molten pool. A composite high-frequency vibration effect greatly improves the bonding of the molten pool to the surrounding wall metal, which can better refine the metal crystal structure, improve the influence of vibration on the metal crystal fusion effect, and improve the forming quality of the product.
故本发明的方案在电弧增材制造中引入了超声振动搅拌,一方面能够打碎生长中的柱状晶,使晶粒得到细化和均匀化,另一方面能够促进熔池中气体溢出,降低气孔率,二者综合作用极大地改善了电弧增材制造材料或零件的力学性能。Therefore, the scheme of the present invention introduces ultrasonic vibration stirring in the arc additive manufacturing, on the one hand, it can break the growing columnar crystals, so that the grains can be refined and homogenized, and on the other hand, it can promote the gas overflow in the molten pool and reduce the Porosity, the combined effect of the two greatly improves the mechanical properties of arc additive manufacturing materials or parts.
综上所述,本发明具有能够在电弧增材制造过程中更好地引入超声辅助,提高超声作用效果,以改善电弧增材制造材料或零件的组织和力学性能的优点。To sum up, the present invention has the advantages of being able to better introduce ultrasonic assistance in the arc additive manufacturing process, improve the effect of ultrasonic action, and improve the structure and mechanical properties of arc additive manufacturing materials or parts.
附图说明Description of drawings
图1为本发明实施时采用的电弧增材制造设备的结构示意图。Fig. 1 is a structural schematic diagram of arc additive manufacturing equipment used in the implementation of the present invention.
图2为图1中焊枪和搅拌针调节方向后的示意图。Fig. 2 is a schematic diagram of the direction of the welding torch and the stirring needle in Fig. 1 adjusted.
图3为图1中单独搅拌针下端凸起的结构示意图。Fig. 3 is a schematic structural view of the protrusion at the lower end of the individual stirring needle in Fig. 1 .
具体实施方式Detailed ways
下面结合具体实施方式对本发明作进一步的详细说明。The present invention will be further described in detail below in combination with specific embodiments.
具体实施时:一种超声辅助的电弧增材制造方法,其改进点在于,在进行电弧增材制造时,将具有往复超声振动特征的搅拌针插入到增材制造熔池中,并随熔池同步移动,对熔池金属的凝固过程实施超声振动和搅拌,改善其凝固组织和力学性能。In the specific implementation: an ultrasonic-assisted arc additive manufacturing method, the improvement point is that when performing arc additive manufacturing, a stirring needle with reciprocating ultrasonic vibration characteristics is inserted into the additive manufacturing molten pool, and along with the molten pool Synchronous movement, ultrasonic vibration and stirring are performed on the solidification process of molten pool metal to improve its solidification structure and mechanical properties.
这样,本方法中在电弧增材制造时,直接对熔池插入振动状态的搅拌针,通过搅拌针对熔池引入超声振动,能够更好地利用超声振动的空化效应和振动效应,减少焊接气孔,细化晶粒,提高焊接区域熔池边缘和非焊接区域在结晶过程中的结合强度,改善熔池金属凝固组织和力学性能。相较于其他超声振动方式,如加载于基底母材或通过电弧加载等,本发明的超声振动加载方式对熔池的超声振动更加直接,而且还有很好的机械搅拌作用,对熔池金属凝固组织和力学性能的改善效果更佳。In this way, during arc additive manufacturing in this method, a stirring needle in a vibrating state is directly inserted into the molten pool, and ultrasonic vibration is introduced into the molten pool through stirring, so that the cavitation effect and vibration effect of ultrasonic vibration can be better utilized, and welding pores can be reduced. , refine the grains, increase the bonding strength between the edge of the molten pool in the welded area and the non-welded area during the crystallization process, and improve the solidification structure and mechanical properties of the molten pool metal. Compared with other ultrasonic vibration methods, such as loading on the base material or through arc loading, the ultrasonic vibration loading method of the present invention is more direct to the ultrasonic vibration of the molten pool, and also has a good mechanical stirring effect, which is beneficial to the molten pool metal The improvement effect of coagulation structure and mechanical properties is better.
实施时,所述搅拌针采用金属钨或者钨合金。其尺寸参数可以为直径1.0-2.0mm,长度80-150mm。During implementation, the stirring needle is made of metal tungsten or tungsten alloy. Its size parameters can be 1.0-2.0mm in diameter and 80-150mm in length.
这样,能够更好地保证搅拌针不会和熔池金属产生反应。In this way, it can be better ensured that the stirring needle will not react with the molten pool metal.
实施时,搅拌针振动方向为沿自身轴向。During implementation, the vibration direction of the stirring needle is along its own axis.
这样,搅拌针作用于熔池只会带动熔池中液体金属在一定区域范围内做高频的往复振动,搅拌针是依靠振动对熔池产生出类似搅拌的效果(实际并不是常规意义上的搅拌),以减少焊接气孔,提高分子级别的焊接材料结合致密性,进而改善焊接区域力学性能,提高焊接效果。In this way, the stirring needle acting on the molten pool will only drive the liquid metal in the molten pool to perform high-frequency reciprocating vibrations within a certain area. Stirring) to reduce welding porosity and increase the bonding density of welding materials at the molecular level, thereby improving the mechanical properties of the welding area and improving the welding effect.
实施时,搅拌针振动频率为20-100KHZ,振幅为0.2-1mm。该范围的振动可以更好地保证振动对金属结晶为良性的影响,避免振动过大反而影响结晶,降低焊接质量。During implementation, the vibration frequency of the stirring needle is 20-100KHZ, and the amplitude is 0.2-1mm. The vibration in this range can better ensure that the vibration has a benign effect on the metal crystallization, and avoid excessive vibration that will affect the crystallization and reduce the welding quality.
参见图1,作为一种实施选择,焊接时电弧增材制造焊枪1沿垂直于熔池所在产品平面方向布置,搅拌针2从电弧增材制造焊枪行进方向的前方或者后方斜向下插入到熔池中部下方实现超声振动。Referring to Fig. 1, as an implementation option, the arc
这样是因为常规电弧增材制造时焊枪是沿垂直于产品平面方向布置,故此种方式在常规电弧增材制造工艺控制过程的基础上直接增加搅拌针引入超声振动即可实施,无需再调整电弧增材制造焊枪的控制程序,方便实施应用。This is because the welding torch is arranged perpendicular to the product plane during conventional arc additive manufacturing, so this method can be implemented by directly adding a stirring needle to introduce ultrasonic vibration on the basis of the conventional arc additive manufacturing process control process, and there is no need to adjust the arc augmentation. The control program of the material manufacturing welding torch is convenient for implementation and application.
参见图2,作为另一种实施选择,焊接时电弧增材制造焊枪1布置为上端沿电弧增材制造焊枪行进方向的前方倾斜布置,搅拌针2布置在电弧增材制造焊枪后方并垂直向下插入到增材制造熔池中部实现超声振动。Referring to Fig. 2, as another implementation option, during welding, the arc additive
这样,电弧增材制造焊枪上端沿行进方向倾斜,可以更好地为熔池前方的待加工区域预热,同时可以为搅拌针让出沿熔池正中间位置垂直布置的空间,搅拌针垂直布置于熔池中部位置后,其超声振动可以非常均匀地传递作用到整个熔池,避免超声振动在熔池中传递不均匀导致对金属结晶融合效果的影响,极大地提高了产品成形质量。In this way, the upper end of the arc additive manufacturing welding torch is inclined along the direction of travel, which can better preheat the area to be processed in front of the molten pool, and at the same time make room for the vertical arrangement of the stirring needle along the middle of the molten pool, and the vertical arrangement of the stirring needle After being located in the middle of the molten pool, the ultrasonic vibration can be transmitted to the entire molten pool very uniformly, avoiding the influence of the uneven transmission of ultrasonic vibration in the molten pool on the fusion effect of metal crystals, and greatly improving the forming quality of the product.
具体地说,本方法实施时,依靠图1-3所示的电弧增材制造设备实现,所述电弧增材制造设备,包括一个电弧增材制造焊枪1,电弧增材制造焊枪安装在一个整体沿水平设置的保持架4上且焊接头一端向下,保持架4上还安装有一个振动搅拌装置,振动搅拌装置包括一个超声振动器3,超声振动器3下端向下设置有一根搅拌针2,超声振动器3能够为搅拌针2提供沿轴向的振动。Specifically, when this method is implemented, it is realized by relying on the arc additive manufacturing equipment shown in Figures 1-3. The arc additive manufacturing equipment includes an arc additive
这样,焊枪和振动搅拌装置安装在同一个保持架上,能够更好地保证搅拌针跟随焊枪同步实现振动搅拌。In this way, the welding gun and the vibration stirring device are installed on the same cage, which can better ensure that the stirring needle follows the welding gun synchronously to realize vibration stirring.
其中,电弧增材制造焊枪安装在一个焊枪安装套5上,焊枪安装套5通过一个焊枪安装套转动调节手柄6可竖向转动地安装在保持架4上。Wherein, the arc additive manufacturing welding torch is installed on a welding torch mounting sleeve 5 , and the welding torch mounting sleeve 5 is vertically rotatably mounted on the
这样拧松焊枪安装套转动调节手柄可以转动调节焊枪安装套在竖直方向的倾斜角度,进而可以根据需要实现对焊枪角度的调节,调节到位后拧紧焊枪安装套转动调节手柄可实现固定。方案中涉及调节手柄具体实现调节紧固的结构属于成熟现有技术,可以在调节手柄上设置一个螺栓穿过焊枪安装套并和保持架上对应的螺孔配合即可实现,具体结构不在此详述。Unscrew the welding torch mounting sleeve and turn the adjusting handle so that the angle of inclination of the welding torch mounting sleeve in the vertical direction can be rotated, and then the angle of the welding torch can be adjusted as required. The structure involving the adjustment handle in the scheme to realize the adjustment and fastening is a mature existing technology. It can be realized by setting a bolt on the adjustment handle through the welding torch mounting sleeve and cooperating with the corresponding screw hole on the cage. The specific structure will not be detailed here. stated.
其中,电弧增材制造焊枪可沿轴向滑动地安装在所述焊枪安装套5上,焊枪安装套上还贯穿地旋接设置有焊枪紧固用螺栓10实现对电弧增材制造焊枪的固定。Wherein, the arc additive manufacturing welding torch can be slidably installed on the welding gun mounting sleeve 5 in the axial direction, and a welding
这样,可以方便调节焊枪在倾斜调整后,再调整高低位置,使其能够保持足够的熔池深度以及调节出和搅拌针相配合的相对位置。In this way, it is convenient to adjust the height position of the welding torch after the inclination adjustment, so that it can maintain sufficient molten pool depth and adjust the relative position matched with the stirring needle.
其中,所述超声振动器3竖向安装在一个振动器安装套7上,振动器安装套7通过一个振动器安装套振动调节手柄9可竖向转动地安装在一个滑动套8上,滑动套可水平滑动地安装在保持架上。Wherein, the
这样,可以方便根据需要调节搅拌针的倾斜角度,使其形成垂直于熔池方向布置,或者倾斜布置,也可以方便调节搅拌针相对于焊枪的前后距离,使其下端能够更好地位于熔池中部位置。振动器安装套振动调节手柄的调节结构可以和焊枪安装套转动调节手柄一致,不在此详述。In this way, it is convenient to adjust the inclination angle of the stirring needle according to the needs, so that it is arranged perpendicular to the direction of the molten pool, or arranged obliquely, and it is also convenient to adjust the front and rear distance of the stirring needle relative to the welding torch, so that the lower end can be better located in the molten pool middle position. The adjustment structure of the vibration adjustment handle of the vibrator installation sleeve can be consistent with the rotation adjustment handle of the welding torch installation sleeve, and will not be described in detail here.
其中,保持架4呈上下宽度一致的长条形,滑动套8可水平滑动地套接安装在保持架上,滑动套上还贯穿地旋接设置有滑动套紧固用螺栓11实现对滑动套8的固定。Among them, the
这样,更加方便调节并固定搅拌针的前后位置。In this way, it is more convenient to adjust and fix the front and rear positions of the stirring needle.
其中,超声振动器3通过消振弹簧安装在振动器安装套上。Wherein, the
这样,消振弹簧作用于超声振动器和振动器安装套之间,能够避免超声振动通过振动器安装套传递到保持架上,进而造成焊枪的振动。能够更好地保持焊枪的工作稳定。In this way, the vibration-absorbing spring acts between the ultrasonic vibrator and the vibrator mounting sleeve, which can prevent the ultrasonic vibration from being transmitted to the holder through the vibrator mounting sleeve, thereby causing vibration of the welding torch. It can better keep the working stability of the welding torch.
其中,超声振动器3为气动超声振动器。Wherein, the
这样具有效果稳定,利于控制,方便实施且超声振动对保持架反作用影响效果小的优点。而且气动式超声振动源,对热和高温的容忍程度高得多,更适合电弧增材制造这样的高温工况。This has the advantages of stable effect, favorable control, convenient implementation and little effect of ultrasonic vibration on the reaction effect of the cage. Moreover, the pneumatic ultrasonic vibration source has a much higher tolerance to heat and high temperature, and is more suitable for high-temperature conditions such as arc additive manufacturing.
其中,保持架4固定安装在电弧增材制造专用机器人的机械臂上(电弧增材制造专用机器人为成熟现有产品,可以计算机编程控制焊枪的行走路径,实现增材焊接制造,故图中未显示)。Among them, the
这样方便通过机器人计算机控制实现对产品的自动电弧增材制造。In this way, it is convenient to realize automatic arc additive manufacturing of products through robot computer control.
其中,搅拌针2下端具有一圈水平外凸的凸起12。Wherein, the lower end of the stirring
这样,在搅拌针沿轴向上下振动时,该凸起能够对熔池起到极大的振动增幅作用,提高超声振动效果。具体实施时,该凸起外凸距离不宜过大,一般可以控制在搅拌针三倍直径以内,具体大小可根据试验验证获得。In this way, when the stirring needle vibrates up and down along the axial direction, the protrusion can greatly amplify the vibration of the molten pool and improve the effect of ultrasonic vibration. During specific implementation, the protrusion distance should not be too large, and generally can be controlled within three times the diameter of the stirring needle, and the specific size can be obtained according to experimental verification.
其中,所述凸起为周向均匀布置的多个,每个凸起的上表面和下表面分别设置为反向对称的倾斜面或者螺旋叶面。Wherein, the plurality of protrusions are evenly arranged in the circumferential direction, and the upper surface and the lower surface of each protrusion are respectively set as reverse symmetrical inclined surfaces or helical blade surfaces.
这样,随着搅拌针沿轴向的往复振动,凸起的上下表面在往复运动时会形成在周向上往复回旋地向外推动金属液的作用效果,进而对金属液产生沿轴向方向的振动的同时产生一个沿圆周方向的往复振动,其中轴向方向的振动可以更好地作用于熔池底部,沿圆周方向的振动可以更好地作用于熔池周壁,双重振动对金属液熔池形成一个复合的高频振动效果,极大地提高了熔池对周壁金属的结合性,可以更好地细化金属结晶组织,提高振动对金属结晶融合效果的影响,提高了产品的成形质量。In this way, with the reciprocating vibration of the stirring needle in the axial direction, the upper and lower surfaces of the protrusion will form the effect of pushing the molten metal outward in a reciprocating manner in the circumferential direction during the reciprocating motion, and then vibrate the molten metal in the axial direction At the same time, a reciprocating vibration along the circumferential direction is generated, wherein the vibration in the axial direction can better act on the bottom of the molten pool, and the vibration in the circumferential direction can better act on the surrounding wall of the molten pool. A composite high-frequency vibration effect greatly improves the bonding of the molten pool to the surrounding wall metal, which can better refine the metal crystal structure, improve the influence of vibration on the metal crystal fusion effect, and improve the forming quality of the product.
在上述具体实施方式的基础上,申请人进一步进行了以下试验对比验证。试验时选用以下的材料和参数:电弧增材制造的基底均为铝合金,几何尺寸为100×50×10mm,采用MIG焊机,工艺参数为:焊接电流80A,电压19.8V,焊丝直径为1.6mm,送丝速度为120cm/min,焊接速度为200mm/min,保护气体为99.99%的氩气,气体流量15L/min。电弧增材制造4道堆积层,每个道次间隔两分钟,每个实施例焊3个样,每个样取前中后三个位置进行测试,测试性能后取平均值。On the basis of the above-mentioned specific implementation methods, the applicant further conducted the following tests for comparison and verification. The following materials and parameters were selected during the test: the substrate of arc additive manufacturing is aluminum alloy, the geometric size is 100×50×10mm, and a MIG welding machine is used. The process parameters are: welding current 80A, voltage 19.8V, welding wire diameter 1.6 mm, the wire feeding speed is 120cm/min, the welding speed is 200mm/min, the shielding gas is 99.99% argon, and the gas flow rate is 15L/min.
对照例:Comparative example:
直接采用MIG焊机和ER5356铝合金焊丝进行电弧增材制造,无超声波辅助。Directly use MIG welding machine and ER5356 aluminum alloy welding wire for arc additive manufacturing without ultrasonic assistance.
实验结果:电弧增材制造堆积层的平均抗拉强度为248.7MPa。Experimental results: The average tensile strength of the arc additive manufacturing build-up layer is 248.7MPa.
试验例1:Test example 1:
采用MIG焊机和ER5356焊丝进行电弧增材制造,同时采用本方法图1所示方式,对电弧增材制造熔池金属的凝固过程实施超声振动和搅拌,往复超声振动方向为钨针的轴向,钨针尺寸为直径1.5mm×长度100mm,振动频率为20KHZ,振幅为0.8mm。Use MIG welding machine and ER5356 welding wire to carry out arc additive manufacturing. At the same time, adopt the method shown in Figure 1 of this method to implement ultrasonic vibration and stirring for the solidification process of arc additive manufacturing molten pool metal. The reciprocating ultrasonic vibration direction is the axial direction of the tungsten needle. , The size of the tungsten needle is 1.5mm in diameter x 100mm in length, the vibration frequency is 20KHZ, and the amplitude is 0.8mm.
实验结果:电弧增材制造堆积层的平均抗拉强度为259.2MPa,而且与对照例相比,增材制造堆积层组织晶粒更加细小,无柱状晶和气孔出现。Experimental results: The average tensile strength of the arc additive manufacturing stacked layer is 259.2MPa, and compared with the control example, the grains of the additively manufactured stacked layer are finer, and there are no columnar grains and pores.
实施例2:Example 2:
采用MIG焊机和ER5356铝合金焊丝进行电弧增材制造,同时采用本方法图2所示方式,对电弧增材制造熔池金属的凝固过程实施超声振动和搅拌,往复超声振动方向为钨针的轴向,钨针尺寸为直径1.2mm×长度90mm,振动频率为25KHZ,振幅为0.6mm。Use MIG welding machine and ER5356 aluminum alloy welding wire to carry out arc additive manufacturing. At the same time, adopt the method shown in Figure 2 of this method to implement ultrasonic vibration and stirring for the solidification process of arc additive manufacturing molten pool metal. The reciprocating ultrasonic vibration direction is the direction of the tungsten needle. Axially, the size of the tungsten needle is 1.2mm in diameter x 90mm in length, the vibration frequency is 25KHZ, and the amplitude is 0.6mm.
实验结果:电弧增材制造堆积层的平均抗拉强度为264.5MPa,而且与对照例相比,增材制造堆积层组织晶粒更加细小,无柱状晶和气孔出现。Experimental results: The average tensile strength of the arc additive manufacturing stacked layer is 264.5MPa, and compared with the control example, the grains of the additively manufactured stacked layer are finer, and there are no columnar grains and pores.
实施例3:Example 3:
采用MIG焊机和ER5356铝合金焊丝进行电弧增材制造,同时采用本方法图2所示方式,对电弧增材制造熔池金属的凝固过程实施超声振动和搅拌,往复超声振动方向为钨针的轴向,钨针尺寸为直径1.0mm×长度80mm,振动频率为28KHZ,振幅为0.5mm。Use MIG welding machine and ER5356 aluminum alloy welding wire to carry out arc additive manufacturing. At the same time, adopt the method shown in Figure 2 of this method to implement ultrasonic vibration and stirring for the solidification process of arc additive manufacturing molten pool metal. The reciprocating ultrasonic vibration direction is the direction of the tungsten needle. Axially, the size of the tungsten needle is 1.0mm in diameter x 80mm in length, the vibration frequency is 28KHZ, and the amplitude is 0.5mm.
实验结果:电弧增材制造堆积层的平均抗拉强度为261.7MPa,而且与对照例相比,增材制造堆积层组织晶粒更加细小,无柱状晶和气孔出现。Experimental results: The average tensile strength of the arc additive manufacturing stacked layer is 261.7MPa, and compared with the control example, the grains of the additively manufactured stacked layer are finer, and there are no columnar grains and pores.
综上所述,由实施例结果可以看出,采用本发明的技术方案后,获得的电弧增材制造堆积层组织和力学性能更佳。In summary, it can be seen from the results of the examples that, after adopting the technical solution of the present invention, the structure and mechanical properties of the stacked layer obtained by arc additive manufacturing are better.
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