CN116352092A - Method and system for composite additive manufacturing layered heterogeneous parts - Google Patents

Abstract

The invention provides a method and system for manufacturing layered heterogeneous parts with composite additives, including the following steps: processing step: cold spraying preset powder on a preset base material; or, ultrasonically adding material on a preset base material Consolidation of foil; cold spray step: cold spray pre-set powder on the consolidated foil; ultrasonic step: ultrasonic additive consolidation of foil over pre-set powder; alternate execution step: alternate execution of cold spray step and ultrasonic steps to form layered heterogeneous parts. The invention can realize the additive manufacturing of layered heterogeneous composite materials, and the obtained parts have high strength and good toughness.

Description

Method and system for composite additive manufacturing layered heterogeneous parts

technical field

The invention relates to the technical field of metal forming and manufacturing, in particular to a method and system for manufacturing layered heterogeneous parts with composite additive materials. In particular, it preferably relates to a method for ultrasonic-cold spray composite additive manufacturing of layered heterogeneous parts.

Background technique

Layered heterogeneous compounding is a way to realize the high performance of parts by using the characteristics of different materials, including two main types: single metal layered heterogeneous and multi-metal compounding. Parts with soft-hard layered composites can have strength close to the hard layer and plasticity close to the soft layer, achieving excellent strength-plasticity matching. At the same time, the soft-hard interface can prevent crack propagation and enhance the impact and fatigue properties of the material. These advantages enable layered heterogeneous parts to meet the needs of high-end industrial fields. Both cold spray and ultrasonic additives are means by which layered heterogeneous parts can be manufactured.

Cold spray additive manufacturing technology is a kind of metal 3D printing technology. Its principle is that powder particles impact the substrate under the drive of high-speed gas, and the powder undergoes severe plastic deformation and deposits. Cold spraying is a low-temperature additive, suitable for oxygen and heat-sensitive materials, and will not have a thermal impact on the substrate. The severe plastic deformation during the forming process makes it have higher strength and higher deposition efficiency. However, cold spraying has the problems of poor plasticity, large porosity and residual stress, and it is difficult to effectively combine the powder and the substrate when the strength is high, so it is difficult to be used in the manufacture of high-strength materials.

Ultrasonic additive technology is an advanced low-temperature additive technology. Its principle is to convert high-frequency electrical signals into high-frequency mechanical vibrations through transducers. The metal undergoes plastic deformation under the action of vibration and pressure, and the oxide film between the interfaces is destroyed. Destruction, the close contact between metals diffuses, forming a metallurgical bond. During the ultrasonic additive process, the microstructure of the material can be improved, resulting in higher strength. However, as the number of stacked layers increases, ultrasonic additives also have the problem of loose bonding.

The Chinese invention patent document with the publication number CN114985778A discloses a layered heterogeneous steel and its electric arc additive manufacturing system and method. In order to solve the problems of realizing heterogeneous design and composition and organization control of complex structural parts, the present invention realizes arc additive manufacturing of layered heterogeneous material components under the control of full-layer osmotic heat, because of its high deposition efficiency and high density , simple process, low cost, layered forming and other advantages, it can be used as the preferred preparation process for the construction of layered heterogeneous steel. The layered design of complex components can be realized by using the forming characteristics of arc additive manufacturing; the unique full-layer penetration heat control of arc additive manufacturing can regulate the microstructure-structure of different layers, and improve the strength-tough comprehensive mechanical properties of components.

In view of the related technologies mentioned above, the inventor believes that according to the problems existing in the existing process, it is necessary to design a composite process method to make the advantages of different processes complement each other, which is necessary for the manufacture of high-performance layered heterogeneous parts.

Contents of the invention

In view of the deficiencies in the prior art, the object of the present invention is to provide a method and system for manufacturing layered heterogeneous parts by composite additive materials.

According to a method for composite additively manufacturing layered heterogeneous parts provided by the present invention, it includes the following steps:

Processing steps: cold spray preset powder on preset substrate; or, ultrasonically add material and consolidate foil on preset substrate;

Cold spraying step: cold spray preset powder on the consolidated foil;

Ultrasonic step: use ultrasonic additive to consolidate the foil on the preset powder;

Alternate steps: Alternate cold spray steps and ultrasonic steps to form layered heterogeneous parts.

Preferably, in the processing step, the preset base material includes an aluminum alloy base material; the preset powder includes titanium powder; sandblasting the aluminum alloy base material to roughen the surface of the aluminum alloy base material;

In the ultrasonic step, the foil material includes aluminum alloy foil.

Preferably, the method further includes a machining step: machining the layered heterogeneous parts to make the dimensions of the layered heterogeneous parts meet requirements.

Preferably, in said processing step,

The preset base material includes anti-collision beams; the foil material includes 2219-O aluminum alloy foil; the plate is stamped into the required anti-collision beams; the anti-collision beams are solid-dissolved at 535°C for 40 minutes, quenched to room temperature, Aging at 175°C for 10 hours;

The 2219-O aluminum alloy foil is consolidated on the surface of the anti-collision beam by ultrasonic addition, the consolidation amplitude is 20μm, the consolidation pressure is 0.25MPa, and the ultrasonic frequency is 20kHz;

In the cold spraying step, the preset powder includes 2219-T6 powder; the 2219-T6 powder is cold sprayed on the surface of the aluminum alloy foil, the carrier gas temperature is 350°C, the carrier gas pressure is 2.8MPa, and the nozzle distance is 30mm.

Preferably, in said processing step,

Cold spray titanium powder on the surface of the aluminum alloy according to the cross section of the rib, the carrier gas temperature is 700°C, the carrier gas pressure is 5MPa, and the nozzle distance is 30mm;

In the ultrasonic step, the foil material includes 2219-T6 aluminum foil; the 2219-T6 aluminum foil is consolidated on the titanium powder coating according to the cross-section of the reinforcing rib by ultrasonic additive, the consolidation amplitude is 30 μm, and the consolidation pressure is 0.3MPa, ultrasonic frequency is 20kHz.

According to the present invention, a system for composite and additive manufacturing of layered heterogeneous parts includes the following modules:

Processing module: cold spray preset powder on preset substrate; or, ultrasonically add material and consolidate foil on preset substrate;

Cold spray module: cold spray pre-set powders on consolidated foils;

Ultrasonic module: use ultrasonic additive to consolidate foil on preset powder;

Alternately execute modules: Alternately execute cold spray modules and ultrasonic modules to form layered heterogeneous parts.

Preferably, in the processing module, the preset base material includes an aluminum alloy base material; the preset powder includes titanium powder; sandblasting the aluminum alloy base material to roughen the surface of the aluminum alloy base material;

In the ultrasonic module, the foil material includes aluminum alloy foil.

Preferably, the system further includes a machining module: machining the layered heterogeneous parts so that the dimensions of the layered heterogeneous parts meet requirements.

Preferably, in the processing module,

The preset base material includes anti-collision beams; the foil material includes 2219-O aluminum alloy foil; the plate is stamped into the required anti-collision beams; the anti-collision beams are solid-dissolved at 535°C for 40 minutes, quenched to room temperature, Aging at 175°C for 10 hours;

The 2219-O aluminum alloy foil is consolidated on the surface of the anti-collision beam by ultrasonic addition, the consolidation amplitude is 20μm, the consolidation pressure is 0.25MPa, and the ultrasonic frequency is 20kHz;

In the cold spraying module, the preset powder includes 2219-T6 powder; the 2219-T6 powder is cold sprayed on the surface of the aluminum alloy foil, the carrier gas temperature is 350°C, the carrier gas pressure is 2.8MPa, and the nozzle distance is 30mm.

Preferably, in the processing module,

Cold spray titanium powder on the surface of the aluminum alloy according to the cross section of the rib, the carrier gas temperature is 700°C, the carrier gas pressure is 5MPa, and the nozzle distance is 30mm;

In the ultrasonic module, the foil material includes 2219-T6 aluminum foil; the 2219-T6 aluminum foil is consolidated on the titanium powder coating according to the cross-section of the reinforcement by using ultrasonic additives, the consolidation amplitude is 30 μm, and the consolidation pressure is 0.3MPa, ultrasonic frequency is 20kHz.

Compared with the prior art, the present invention has the following beneficial effects:

1. The invention can realize the additive manufacturing of layered heterogeneous composite materials, and the obtained parts have high strength and good toughness;

2. The present invention takes cold spraying technology as the main body, and the efficiency of material addition is high, and the material is strengthened during the spraying process to obtain higher strength;

3. The present invention introduces ultrasonic material addition technology as an auxiliary, which solves the problems of difficult adhesion of cold spray coating, large porosity, and large residual stress.

Description of drawings

Other characteristics, objects and advantages of the present invention will become more apparent by reading the detailed description of non-limiting embodiments made with reference to the following drawings:

Fig. 1 is a schematic diagram of the technical route of the present invention;

Fig. 2 is the schematic diagram of making W-shaped anti-collision beam sample for the present invention;

Fig. 3 is a schematic diagram of the present invention to manufacture thin-walled parts with ribs.

Detailed ways

The present invention will be described in detail below in conjunction with specific embodiments. The following examples will help those skilled in the art to further understand the present invention, but do not limit the present invention in any form. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all belong to the protection scope of the present invention.

Embodiment 1 of the present invention discloses a method for manufacturing layered heterogeneous composite materials by ultrasonic-cold spraying additively. The described additive manufacturing process comprises the following steps:

Processing steps: cold spray preset powder on preset substrate; or, ultrasonically add material and consolidate foil on preset substrate.

Cold spraying step: Cold spray pre-set powder on the consolidated foil.

Ultrasonic step: Ultrasonic additive consolidation of foils on preset powders.

Alternate steps: Alternate cold spray steps and ultrasonic steps to form layered heterogeneous parts.

Machining step: Machining the additively manufactured part to meet the required dimensions.

That is, the forming process is as follows:

S1. Cold spray a layer of titanium powder on the aluminum alloy substrate.

S2. Use ultrasonic additive technology to consolidate a layer of aluminum alloy foil on the titanium powder.

S3. Repeat the above process to form an aluminum-titanium layered heterogeneous composite material until the shape of the target part is close to that of the target part.

S4. Machining the additively manufactured part to meet the required dimensions.

The powder used in the cold spraying process in S1 includes titanium powder, but the present invention can also use other material powders with higher strength.

The aluminum foil used in the ultrasonic additive process in S2 includes 2219 aluminum alloy, but the present invention can also use other materials that are softer than those used in the cold spray process.

In S3, the cold spraying process and the ultrasonic additive process are alternately used for additive manufacturing until the shape of the desired part is roughly the same.

The present invention realizes near-net-shape manufacturing of parts by simultaneously using ultrasonic waves and cold spraying methods. By adding ultrasonic additive manufacturing processes, it can remove residual stress and increase the density of the cold spray coating in the previous process, and The next cold spraying process is still carried out on a softer substrate, which enhances the interface bonding strength, and the obtained parts are composed of layered heterogeneous composite materials with high strength and high toughness.

The purpose of the present invention is to overcome the limitations of the above-mentioned prior art and application, and provide a method for manufacturing layered heterogeneous parts by ultrasonic-cold spray composite additive. In the forming process, firstly, titanium powder is cold-sprayed on the aluminum alloy substrate, and then the aluminum foil is consolidated on the titanium coating by means of ultrasonic addition, and the above process is repeated until the shape of the part is roughly the same, and a titanium-aluminum alloy is formed. Layered heterogeneous composite materials, which are machined to obtain the desired parts. Cold spraying has high deposition efficiency, fast manufacturing speed, and severe plastic deformation in the process to obtain higher strength materials. The ultrasonic additive process has the effect of removing internal stress and densifying the existing titanium coating. The softer aluminum foil acts as the substrate for the subsequent cold spraying process, and the interface is tightly bonded. The layered heterogeneous composite of soft-hard materials has Features of high strength and high toughness.

The invention realizes the manufacture of layered heterogeneous parts through ultrasonic-cold spraying composite method, and the obtained parts have the advantages of high density, high strength, strong toughness, etc., and can be used for strengthening and additive manufacturing of thin plate parts.

As shown in Figure 1, it is the process route designed for parts with crossed high ribs according to the present invention, and the process route is illustrated by taking aluminum alloy 2219 and titanium powder as examples.

First, 2219 aluminum alloy is used as the base material, and it is sandblasted to roughen the surface.

A layer of titanium powder is cold sprayed on the aluminum alloy surface.

A layer of 2219 aluminum foil is consolidated on the titanium powder coating by ultrasonic additive.

The process of cold spraying aluminum alloy-ultrasonic consolidation titanium was repeated to obtain a material with soft-hard layered heterogeneity.

The resulting parts are machined.

Embodiment 2 of the present invention discloses a method for manufacturing a layered heterogeneous composite material by ultrasonic-cold spraying additively, as shown in FIG. 2 , which is a part obtained by strengthening the W-shaped anti-collision beam of the present invention.

Stamp the 2219-O plate into the required W-shaped anti-collision beam.

The anti-collision beam was solid-dissolved at 535°C for 40 minutes, quenched to room temperature, and aged at 175°C for 10 hours to reach the T6 state. T6 is the peak aging state of aluminum alloys, and only some grades of aluminum alloys have this state (such as 2219, 2024).

A layer of 2219-O aluminum alloy foil with a thickness of 200 μm was consolidated on the surface of the anti-collision beam parts by ultrasonic addition. The consolidation amplitude was 20 μm, the consolidation pressure was 0.25 MPa, and the ultrasonic frequency was 20 kHz.

A layer of 2219-T6 powder with a particle size of 75 μm was cold sprayed on the surface of the O-state aluminum alloy, the carrier gas temperature was 350 °C, the carrier gas pressure was 2.8 MPa, and the nozzle distance was 30 mm.

The ultrasonic additive consolidation and cold spray processes were repeated until the layered heterogeneous material reached the desired thickness.

Parts are machined.

Embodiment 3 of the present invention also discloses a method for manufacturing layered heterogeneous composite materials by ultrasonic-cold spraying additively. As shown in FIG. 3 , it is a ribbed thin-walled part obtained by additively manufacturing according to the present invention.

First, 2219-T6 aluminum alloy is used as the base material, and it is sandblasted to roughen the surface.

A layer of Ti-01 powder with a particle size of 60 μm was cold-sprayed on the surface of the aluminum alloy according to the cross-section of the rib, the carrier gas temperature was 700 °C, the carrier gas pressure was 5 MPa, and the nozzle distance was 30 mm.

Ultrasonic additives are used to consolidate a layer of 2219-T6 aluminum foil with a thickness of 200 μm on the titanium powder coating according to the cross-section of the rib, with a consolidation amplitude of 30 μm, a consolidation pressure of 0.3 MPa, and an ultrasonic frequency of 20 kHz.

The process of cold-sprayed aluminum alloy-ultrasonic consolidation of titanium was repeated to obtain a material with soft-hard layered heterogeneity up to the geometry of the desired part.

The resulting part is machined to remove excess material to obtain the final part.

The present invention also provides a system for manufacturing layered heterogeneous parts with composite additives, the system for manufacturing layered heterogeneous parts with composite additives can execute the process steps of the method for manufacturing layered heterogeneous parts with composite additives To achieve this, those skilled in the art can understand the method for composite additive manufacturing of layered heterogeneous parts as a preferred embodiment of the system for composite additive manufacturing of layered heterogeneous parts.

The system includes the following modules:

Processing module: Cold spray preset powder on preset substrate; or, ultrasonically add material to consolidate foil on preset substrate.

Cold Spray Module: Cold spray preset powders on consolidated foils.

Ultrasonic module: Consolidation of foils using ultrasonic additives on pre-set powders.

Alternately execute modules: Alternately execute cold spray modules and ultrasonic modules to form layered heterogeneous parts.

Machining module: Machining the layered heterogeneous parts to make the size of the layered heterogeneous parts meet the requirements.

In one embodiment, in the processing module, the preset base material includes an aluminum alloy base material; the preset powder includes titanium powder; sandblasting is performed on the aluminum alloy base material to make the surface of the aluminum alloy base material roughen.

In the ultrasonic module, the foil material includes aluminum alloy foil.

In one embodiment, in the processing module, the preset base material includes an anti-collision beam; the foil includes a 2219-O aluminum alloy foil; the plate is stamped into a required anti-collision beam; the anti-collision beam is Solid solution at 535°C for 40 minutes, quenched to room temperature, and aged at 175°C for 10 hours, so that the anti-collision beam can reach the T6 state.

The 2219-O aluminum alloy foil was consolidated on the surface of the anti-collision beam by ultrasonic addition, with a consolidation amplitude of 20 μm, a consolidation pressure of 0.25 MPa, and an ultrasonic frequency of 20 kHz.

In the cold spraying module, the preset powder includes 2219-T6 powder, and the 2219-T6 powder is cold sprayed on the surface of the aluminum alloy foil, the carrier gas temperature is 350°C, the carrier gas pressure is 2.8MPa, and the nozzle distance is 30mm.

In one embodiment, in the processing module, the preset base material includes an aluminum alloy base material; the preset powder includes titanium powder.

Sandblasting is performed on the aluminum alloy substrate to roughen the surface of the aluminum alloy substrate.

Titanium powder was cold-sprayed on the surface of the aluminum alloy according to the cross-section of the rib, the temperature of the carrier gas was 700°C, the pressure of the carrier gas was 5MPa, and the nozzle distance was 30mm.

In the ultrasonic module, the foil material includes T6 aluminum foil; the T6 aluminum foil is consolidated on the titanium powder coating according to the cross section of the rib by using ultrasonic additives, the consolidation amplitude is 30 μm, and the consolidation pressure is 0.3 MPa. The frequency is 20kHz.

Those skilled in the art know that, in addition to realizing the system provided by the present invention and its various devices, modules, and units in a purely computer-readable program code mode, the system provided by the present invention and its various devices can be completely programmed by logically programming the method steps. , modules, and units implement the same functions in the form of logic gates, switches, ASICs, programmable logic controllers, and embedded microcontrollers. Therefore, the system and its various devices, modules, and units provided by the present invention can be regarded as a hardware component, and the devices, modules, and units included in it for realizing various functions can also be regarded as hardware components. The structure; the devices, modules, and units for realizing various functions can also be regarded as not only the software modules for realizing the method, but also the structures in the hardware components.

Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art may make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. In the case of no conflict, the embodiments of the present application and the features in the embodiments can be combined with each other arbitrarily.

Claims (10)

1. A method for composite additive manufacturing layered heterogeneous parts, is characterized in that, comprises the steps: Processing steps: cold spray preset powder on preset substrate; or, ultrasonically add material and consolidate foil on preset substrate; Cold spraying step: cold spray preset powder on the consolidated foil; Ultrasonic step: use ultrasonic additive to consolidate the foil on the preset powder; Alternate steps: Alternate cold spray steps and ultrasonic steps to form layered heterogeneous parts. 2. The method for composite additive manufacturing of layered heterogeneous parts according to claim 1, characterized in that, in the processing step, the preset base material includes an aluminum alloy base material; the preset powder includes Titanium powder; sandblasting the aluminum alloy substrate to roughen the surface of the aluminum alloy substrate; In the ultrasonic step, the foil material includes aluminum alloy foil. 3. The method for composite additively manufacturing layered heterogeneous parts according to claim 1, characterized in that the method further comprises a machining step: machining the layered heterogeneous parts to make the layered heterogeneous parts size meet the requirements. 4. The method for composite and additive manufacturing of layered heterogeneous parts according to claim 1, characterized in that, in the processing step, the preset base material includes an anti-collision beam; the foil material includes 2219- O aluminum alloy foil; punch the plate into the required anti-collision beam; solid-solution the anti-collision beam at 535°C for 40 minutes, quench to room temperature, and age at 175°C for 10 hours; The 2219-O aluminum alloy foil is consolidated on the surface of the anti-collision beam by ultrasonic addition, the consolidation amplitude is 20μm, the consolidation pressure is 0.25MPa, and the ultrasonic frequency is 20kHz; In the cold spraying step, the preset powder includes 2219-T6 powder; the 2219-T6 powder is cold sprayed on the surface of the aluminum alloy foil, the carrier gas temperature is 350°C, the carrier gas pressure is 2.8MPa, and the nozzle distance is 30mm. 5. The method for composite and additive manufacturing of layered heterogeneous parts according to claim 2, characterized in that, in the processing step, Cold spray titanium powder on the surface of the aluminum alloy according to the cross section of the rib, the carrier gas temperature is 700°C, the carrier gas pressure is 5MPa, and the nozzle distance is 30mm; In the ultrasonic step, the foil material includes 2219-T6 aluminum foil; the 2219-T6 aluminum foil is consolidated on the titanium powder coating according to the cross-section of the reinforcing rib by ultrasonic additive, the consolidation amplitude is 30 μm, and the consolidation pressure is 0.3MPa, ultrasonic frequency is 20kHz. 6. A system for composite and additive manufacturing of layered heterogeneous parts, characterized in that it includes the following modules: Processing module: cold spray preset powder on preset substrate; or, ultrasonically add material and consolidate foil on preset substrate; Cold spray module: cold spray pre-set powders on consolidated foils; Ultrasonic module: use ultrasonic additive to consolidate foil on preset powder; Alternately execute modules: Alternately execute cold spray modules and ultrasonic modules to form layered heterogeneous parts. 7. The system for composite additive manufacturing of layered heterogeneous parts according to claim 6, characterized in that, in the processing module, the preset base material includes an aluminum alloy base material; the preset powder includes Titanium powder; sandblasting the aluminum alloy substrate to roughen the surface of the aluminum alloy substrate; In the ultrasonic module, the foil material includes aluminum alloy foil. 8. The system for composite additively manufacturing layered heterogeneous parts according to claim 6, characterized in that the system also includes a machining module: machining the layered heterogeneous parts to make the layered heterogeneous parts meet the requirements. 9. The system for composite additive manufacturing of layered heterogeneous parts according to claim 6, characterized in that, in the processing module, the preset base material includes an anti-collision beam; the foil material includes 2219- O aluminum alloy foil; punch the plate into the required anti-collision beam; solid-solution the anti-collision beam at 535°C for 40 minutes, quench to room temperature, and age at 175°C for 10 hours; The 2219-O aluminum alloy foil is consolidated on the surface of the anti-collision beam by ultrasonic addition, the consolidation amplitude is 20μm, the consolidation pressure is 0.25MPa, and the ultrasonic frequency is 20kHz; In the cold spraying module, the preset powder includes 2219-T6 powder; the 2219-T6 powder is cold sprayed on the surface of the aluminum alloy foil, the carrier gas temperature is 350°C, the carrier gas pressure is 2.8MPa, and the nozzle distance is 30mm. 10. The system for composite and additive manufacturing of layered heterogeneous parts according to claim 7, characterized in that, in the processing module, Cold spray titanium powder on the surface of the aluminum alloy according to the cross section of the rib, the carrier gas temperature is 700°C, the carrier gas pressure is 5MPa, and the nozzle distance is 30mm; In the ultrasonic module, the foil material includes 2219-T6 aluminum foil; the 2219-T6 aluminum foil is consolidated on the titanium powder coating according to the cross-section of the rib by using ultrasonic additives, the consolidation amplitude is 30 μm, and the consolidation pressure is 0.3MPa, ultrasonic frequency is 20kHz.

Images