WO2019011132A1 - 微区半固态增材制造方法 - Google Patents

微区半固态增材制造方法 Download PDF

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WO2019011132A1
WO2019011132A1 PCT/CN2018/093506 CN2018093506W WO2019011132A1 WO 2019011132 A1 WO2019011132 A1 WO 2019011132A1 CN 2018093506 W CN2018093506 W CN 2018093506W WO 2019011132 A1 WO2019011132 A1 WO 2019011132A1
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semi
solid
consumables
consumable
manufacturing
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English (en)
French (fr)
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杨武雄
邹江林
徐洁洁
吴世凯
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Beijing University of Technology
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Beijing University of Technology
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Priority to EP18831523.8A priority Critical patent/EP3639964A4/en
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Priority to US16/740,780 priority patent/US11364570B2/en
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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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/1215—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-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
    • B23K10/00—Welding or cutting by means of a plasma
    • B23K10/02—Plasma welding
    • B23K10/027—Welding for purposes other than joining, e.g. build-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
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/0013—Resistance welding; Severing by resistance heating welding for purposes other than joining, e.g. build-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
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B23K15/0086—Welding welding for purposes other than joining, e.g. build-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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/082—Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/14—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
    • B23K26/1462—Nozzles; Features related to nozzles
    • B23K26/1464—Supply to, or discharge from, nozzles of media, e.g. gas, powder, wire
    • 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 groups B23K5/00 - B23K26/00
    • 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
    • B23K3/00—Tools, devices or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/06—Solder feeding devices; Solder melting pans
    • B23K3/0607—Solder feeding devices
    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • 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
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing

Definitions

  • the invention relates to the technical field of metal additive manufacturing, and in particular to a metal additive manufacturing method with metal semi-solid processing properties.
  • the defects such as pores need to be post-densification: usually hot isostatic pressing; the microstructure is controlled by heat treatment; for residual stress and workpiece deformation, preheating, heat treatment, optimization process route, Compound external field (such as shot peening, electromagnetic field, ultrasound) and other methods to solve.
  • these methods can alleviate the above problems to a certain extent, they require special equipment, require additional processes, are inconvenient to operate, and affect processing efficiency, and are even unable to be processed or expensive for some large-sized components.
  • these methods alleviate the extent of these defects to a certain extent, but they do not fundamentally solve the problem.
  • the object of the present invention is to provide an additive manufacturing method for externally intervening strongly in the solidification process of a metal, which mainly refers to a strong mechanical force acting on a semi-solid metal coexisting in solid-liquid two phases during solidification to make it a conventional branch.
  • the crystal growth mode is transformed into an equiaxed crystal fine grain growth mode, and the mechanical force can eliminate the shrinkage and pores of the fused layer to increase the density, and improve the stress distribution state of the formed body to reduce the deformation and cracking tendency of the workpiece.
  • the raw material (consumable material) manufactured by the additive is made by using a straight rod and strip metal, and is applied to the front end region of the consumable material by a high energy beam, an electric arc, a resistance heat or the like, and is placed in a semi-solid state.
  • the rotating torsion and axial thrust exerted on the strip consumables strongly shear, agitate and squeeze the semi-solid metal.
  • the process is essentially a moldless semi-solid flow forming process, instead of the mold acting
  • the semi-solid material contacts the underlying material and the consumable material body, except that the consumables transition through the semi-solid forming process to the underlying material to form a buildup layer.
  • the stacking process is stacked in a set path and layer to form an entity of a particular size and shape.
  • a method for manufacturing a semi-solid additive in a micro-zone characterized in that a bar and a strip-shaped material are used as a consumable material for additive production, hereinafter referred to as a consumable material, and the jaw-driven consumables are rotated at a speed of 200 rpm to 10000 rpm and applied to the consumables during operation.
  • the axial thrust of 10N ⁇ 2000N the front end of the heat source irradiating the consumables is locally heated to a liquid or semi-solid state.
  • the hot metal at the end of these consumables is in axial thrust, rotational torsion and base.
  • the mold Under the action of the reaction force of the material or the accumulation layer, the mold is subjected to agitation and extrusion to form a moldless semi-solid rheologically processed structure; the consumables are uniformly pushed forward at a consumption speed of 0.1 mm/min to 2 m/min and the consumables are generated by discrete sections.
  • the moving path moves at a speed of 0.1 mm/min to 4 m/min to form a continuous buildup layer, and the stacking process is repeated to form a shaped body;
  • the heat source includes a laser beam, an electron beam, a plasma beam, an electric arc, a resistance heat, an induction heating or a flame.
  • the arc is TIG, MIG or CMT.
  • the consumable form is a rod or strip material
  • the cross-sectional shape is a solid circle, a hollow circle, a rectangle, a polygon
  • the consumables are arranged one by one or more
  • the length of the consumable material is 5 cm to 600 cm, and one is used up continuously.
  • the laser spot shape is a circular spot, an elliptical spot, a rectangular spot or a multi-spot.
  • the inclination angle of the consumables is the angle between the centerline of the consumable and the accumulation layer is 45° to 90°, and the inclination direction is opposite to the direction in which the consumables move; the self-movement mode of the consumables is rotation or plane reciprocation; the laser acts before the direction of movement of the consumables.
  • the inclination angle is 5° to 60°.
  • the upper and lower vibrations are added to the consumables to enhance the forging effect, and the vibration frequency is 1 Hz to 1 kHz, and the amplitude is 0.1 mm to 1 mm.
  • the laser and electron beam high energy beam heat source adopts a scanning heating method, and the scanning frequency is 1 Hz to 5 kHz.
  • a reinforced composite material or a functionally graded material is prepared by simultaneously injecting an alloy powder, reinforcing particles, whiskers or short fibers having a size of 20 nm to 500 ⁇ m into the V port between the consumable and the accumulation layer.
  • the combination of additive manufacturing technology and semi-solid technology is introduced into the additive manufacturing process by transforming the semi-solid flow into a shape.
  • a uniform spherical fine-grained structure can be obtained without macrosegregation; the metal solidifies under the action of extrusion and stirring. It can eliminate defects such as pores, voids, shrinkage and slag inclusion inside the accumulation layer, and the workpiece can be fully dense, and the stress distribution state of the formed body can be reduced to reduce the deformation and cracking tendency of the workpiece.
  • the solid-solid forming shrinkage of the semi-solid forming metal is small, the forming dimensional accuracy can be improved, and the near-net forming is easy to be realized; the slurry in the process of the semi-solid metal forming process is always in a controlled stable state, so that the flow and splashing of the metal solution hardly occur. It reduces the oxidation and entrapment of the alloy, and enhances the purity of the material while achieving multi-directional growth without the need to provide a special support structure.
  • rods and strips have obvious advantages such as abundant material types, high material utilization rate, good economy, and low pollution.
  • the semi-solid forming has a low forming temperature, strong controllability in structure and properties, and has a small forming resistance, a strong controllability, and a mechanical property that can reach or exceed the forging level.
  • Semi-solid additive manufacturing with high energy beam as heat source can achieve or exceed forgings in both static mechanical properties and fatigue properties.
  • the semi-solid material has high viscosity
  • the composite material or the gradient functional material can be prepared by synchronous injection or surface pre-formed alloy powder or reinforcing fiber or ceramic particles during the processing, which can completely solve the macrosegregation and uneven distribution of the reinforcing phase. problem.
  • the invention opens up a new method for additive manufacturing and provides a new idea for the development and popularization of semi-solid forming technology.
  • Fig. 1 is a schematic diagram showing the principle of manufacturing a micro-region semi-solid additive by using a laser as a heat source and vibrating up and down the consumables
  • FIG. 2 is a partially enlarged schematic view showing the principle of a micro-region semi-solid additive manufacturing method using a laser as a heat source.
  • FIG. 3 is a schematic diagram showing the principle of manufacturing a micro-region semi-solid additive by using TIG as a heat source.
  • Figure 4 is a schematic diagram showing the principle of manufacturing a micro-region semi-solid additive using a MIG laser as a heat source.
  • Figure 5 is a schematic diagram of the fabrication principle of micro-region semi-solid laser additive for particle reinforced composite preparation and current field.
  • Fig. 6 is a schematic view showing the principle of manufacturing the laser micro-region additive for the lateral reciprocating motion of rectangular consumables
  • Figure 7 is a comparison of the microstructure characteristics of semi-solid laser additive manufacturing, a) stainless steel original tissue b) stainless steel semi-solid laser additive organization
  • the consumable material of this embodiment is a 304 stainless steel round bar with a diameter.
  • the substrate is Q235 low carbon steel, the angle between the consumption rod and the accumulation layer is 75°, the angle between the laser beam and the accumulation layer is 15°, the laser power is 4KW, the laser focusing spot is rectangular, and the size is 6mm ⁇ 1mm.
  • the specific forming process includes the following steps:
  • the moving mechanism When the laser is turned on, the moving mechanism is opened, and the moving mechanism moves at a running speed of 0.6 m/min according to the planned processing path, and the additive manufacturing process is implemented;
  • step 7 Repeat the stacking process of step 7 to finally obtain the deposited body, and perform the remaining processing and detection on the deposited body.
  • FIG. 7 is a comparison view of the original structure of the 304 stainless steel forming structure and the consumable rod of the embodiment, and FIG. 7(a) is the original structure of the 304 stainless steel rod consumable, which is mainly composed of a large piece of primary austenite, and the grain boundary morphology is
  • Figure 7(b) shows the micro-area semi-solid laser forming structure.
  • the primary austenite grains form a specific spherical or pellet shape under intense stirring and friction, and the grain size is finer.
  • the bright part between the spherulites is not a grain boundary in the conventional sense, but an extremely fine liquid-hardened structure, so that it is almost impossible to distinguish its morphology under an optical microscope.
  • Embodiment 2 This embodiment differs from the specific embodiment in that: the consumables are two diameters arranged side by side.
  • the metal bars, other steps and parameters are the same as in the first embodiment.
  • Embodiment 3 As shown in FIG. 3 , the difference between the embodiment and the specific embodiment is that the heat source is Tig, the angle between the welding gun and the accumulation layer is 55°, and the diameter of the consumption rod is The angle between the consumable bar and the accumulated layer is 60°, the current is 200 A, the processing speed is 0.3 m/min, and the axial thrust of the consumable is 100 N.
  • the heat source is Tig
  • the angle between the welding gun and the accumulation layer is 55°
  • the diameter of the consumption rod is The angle between the consumable bar and the accumulated layer is 60°
  • the current is 200 A
  • the processing speed is 0.3 m/min
  • the axial thrust of the consumable is 100 N.
  • the other steps and parameters are the same as in the first embodiment.
  • the present embodiment differs from the specific embodiment in that the heat source is Mig, the angle between the welding gun and the accumulation layer is 55°, the angle between the consumption rod and the accumulation layer is 60°, the current is 300 A, and the processing speed is 0.4m/min, the axial thrust of the consumable is 100N, and other steps and parameters are the same as in the first embodiment.
  • the present embodiment differs from the specific embodiment in that the consumable material is a rectangular strip having a cross-sectional dimension of 10 mm ⁇ 3 mm, and the self-moving mode of the consumable is a transverse mechanical reciprocating motion, and the reciprocating frequency is 100 Hz, amplitude 0.8 mm, laser power 6KW, processing speed 0.4m/min.
  • Embodiment 6 As shown in FIG. 5 , the difference between the embodiment and the specific embodiment is that the consumption rod and the substrate are both 6061 aluminum alloy, the laser power is 6 KW, the moving speed of the consumable is 0.4 m/min, and the axial pressure of the consumable is 50 N.
  • a particle-reinforced aluminum-based composite material was prepared by simultaneously injecting 320 mesh SiC reinforcing particles into the angle between the consumable and the accumulation layer during the forming process, and the volume fraction was 25%. The other steps and parameters are the same as in the first embodiment.
  • the SiC reinforced aluminum matrix composite prepared by the micro-region semi-solid laser additive manufacturing method has complete density, good bonding between the particle and the matrix interface, the elastic modulus strength is increased by 27%, and the strength is increased by 18%.

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Abstract

一种微区半固态增材制造方法，以棒条状材料作为耗材，采用高能束、电弧、电阻热等加热方式作用于耗材前端并使其处于固液两相共存的半固态，同时，在耗材上施加的旋转扭力和轴向推力对半固态金属进行强烈地剪切、搅拌和挤压等作用，也即进行无模半固态流变成形。耗材以这种方式连续向底层金属过渡并与之形成冶金结合，按离散化切片处理后的规划路径重复该堆积过程即可形成特定形状的实体件或堆积层。本方法操作工艺简单，制件性能优良，解决成形件的组织均匀性、性能可靠性、应力与变形、气孔和裂纹等问题，可以应用于大型构件的成形、受损零件修复和复合材料制备。

Description

微区半固态增材制造方法 技术领域
本发明涉及金属增材制造技术领域，特别提供了一种具有金属半固态加工性质的金属增材制造方法。
背景技术
现有金属增材制造技术中，由于多重非平衡热物理过程和冶金过程导致构件组织、性能均匀性和稳定性差，变形与开裂倾向严重，易产生气孔、缩孔与未熔合等缺陷，这些存在的问题严重影响增材制件的服役性能，同时也给增材制造技术的发展和推广带来了很大的困难。
通常解决气孔等缺陷需进行后致密化处理：通常为热等静压处理；调控显微组织形貌则通过热处理的方法解决；针对残余应力和工件变形则采用预热、热处理、优化工艺路线、复合外场(如喷丸、电磁场、超声)等方法解决。这些方法虽能在一定程度上缓解上述存在问题，但需要专门的设备，需额外的工序，操作不便，影响加工效率，对于某些大尺寸的构件甚至无法处理或耗费极大。总之，这些方法都在一定程度上减轻了这些缺陷的程度，但并没有根本性地解决问题。
发明内容
本发明目的在于提供一种对金属凝固过程进行外部强烈干预的增材制造方法，主要是指在凝固过程中对处于固液两相共存的半固态金属进行强烈机械力作用使其由传统的枝晶生长模式转变为等轴晶细晶生长模式，同时机械力可消除熔凝层的缩松、孔洞从而提高致密度，改善成形体的应力分布状态减小工件变形和开裂倾向。
本发明的具体技术方案是：
增材制造的原材料(消耗材料)是采用经过校直的棒、条金属，以高能束、电弧、电阻热等加热方式作用于消耗材料的前端区域并使其处于半固态状态，同时，在棒条状耗材上施加的旋转扭力和轴向推力对处于半固态的金属进行强烈剪切、搅拌和挤压作用，该过程实质上是无模半固态流变成形过程，代替模具作用的是与半固态材料接触的底层材料和消耗材料本体，不同的是耗材经半固态成形过程过渡到底层材料形成堆积层。将该堆积过 程按设定路径和分层进行堆积即可形成特定尺寸和形状的实体。
1.微区半固态增材制造方法，其特征在于：以棒、条状材料作为增材制造的消耗材料，以下简称耗材，工作时卡爪带动耗材以200rpm～10000rpm的速度旋转并给耗材施加10N～2000N的轴向推力，热源辐照耗材前端面使其局部加热至液态或半固态，在紧跟的冷却凝固过程中，这些耗材端部的热态金属在轴向推力、旋转扭力以及基材或堆积层反作用力的作用下经历了搅拌、挤压作用形成无模半固态流变加工组织；耗材以0.1mm/min～2m/min的消耗速度向前均匀推送以及耗材按离散切片生成的运动路径以0.1mm/min～4m/min的速度移动形成连续堆积层，重复该堆积过程形成成形体；热源包括激光束、电子束、等离子束，电弧、电阻热、感应加热或火焰。
2.进一步，电弧为TIG、MIG或CMT。
3.进一步，耗材形式是棒、条状材料，截面形状是实心圆、空心圆、矩形、多边形；耗材为一根或多根并排排列；耗材单根长度5cm～600cm,一根用完续接另一根；激光光斑形状是圆光斑、椭圆光斑、矩形光斑或多光斑。
4.进一步，耗材倾角即耗材中心线与堆积层的夹角为45°～90°，倾斜方向与耗材移动方向相反；耗材的自运动方式是旋转或平面往复运动；激光作用在耗材移动方向前侧，与耗材相对，倾角为5°～60°。
5.进一步，在耗材上附加上下振动增强锻造效果，振动频率为1Hz～1kHz，振幅为0.1mm～1mm。
6.进一步，激光、电子束高能束热源采用扫描加热方式，扫描频率为1Hz～5kHz。
7.进一步，在耗材上同时施加电流、磁场、超声一种或几种组合外场增强调控组织和性能。
8.进一步，在增材制造过程中同时向耗材与堆积层之间的V口中喷入大小为20nm～500μm的合金粉末、增强颗粒、晶须或短纤维制备增强复合材料或功能梯度材料。
与其它金属沉积工艺相比，本发明的优势和有益效果是：
将增材制造技术和半固态技术相结合，通过将半固态流变成形过程引入增材制造，金属凝固后可获得均匀球状细晶组织，无宏观偏析；金属在挤压与搅拌作用下凝固，可消除 堆积层内部的气孔、空洞、缩松和夹渣等缺陷，工件可达到全致密、改善成形体的应力分布状态减小工件变形和开裂倾向。
半固态成形金属凝固收缩率小，可提高成形尺寸精度，易于实现近净成形；半固态金属成形过程加工过程浆料始终处于受控稳定状态，所以几乎不会发生金属溶液的流淌、喷溅、减轻了合金的氧化和裹气现象，在增强材料的纯净度的同时可实现多方向生长而不用设置专门的支撑结构。相比于粉末状消耗材料，棒、条材具有材料种类丰富、材料利用率高、经济性好、不易被污染等明显优势。
对热源种类无特殊限制，无需复杂的设备，由于应力、变形以及组织得到了很好的控制，大多数情况下可省略后续处理过程，缩短工艺流程。与铸件比，半固态成形的成形温度低，组织、性能可控性强，与锻件比，成形阻力小，控形能力强，力学性能可达到或超过锻件水平。以高能束作为热源的半固态增材制造在静态力学性能和疲劳性均能达到或超过锻件。
半固态材料粘度高，在加工过程中利用坡口同步喷入或表面预制合金粉末或增强纤维、陶瓷颗粒等可制备复合材料或梯度功能材料，可彻底解决增强相的宏观偏析和分布不均的问题。
本发明为增材制造开辟出一条新方法的同时为半固态成形技术的发展和推广应用提供了一条新思路。
附图说明
图1为以激光为热源并附带耗材上下振动的微区半固态增材制造方法原理示意图
图2为以激光为热源的微区半固态增材制造方法原理局部放大示意图
图3为以TIG为热源的微区半固态增材制造方法原理示意图
图4为以MIG激光为热源的微区半固态增材制造方法原理示意图
图5为颗粒增强复合材料制备和电流场的微区半固态激光增材制造原理示意图
图6为矩形耗材横向往复运动激光微区增材制造原理示意图
图7为半固态激光增材制造组织特征比较,a)不锈钢原始组织b)不锈钢半固态激光增材组织
具体实施方式
具体实施方式一：本实施例耗材材质为304不锈钢圆棒，直径
Figure PCTCN2018093506-appb-000001
基材为Q235低碳钢，消耗棒与堆积层夹角为75°，激光束与堆积层夹角为15°，激光功率：4KW，激光聚焦光斑为矩形，尺寸为6mm×1mm。
具体成形过程包括以下步骤：
1、建立金属零件3D模型，通过软件完成切片处理并生成机器加工路径；
2、去除基材和耗材表面去氧化膜、污物；
3、按设定布置耗材、基材和激光的相对位置，固定基材，用带水冷的三爪卡住耗材；
4、打开电源使三爪携带棒状耗材旋转，旋转速度为800n/min，检查耗材旋转的同轴度、圆跳度；
5、打开惰性气体保护，氩气气体流量为30L/min，喷管直径
Figure PCTCN2018093506-appb-000002
6、耗材棒旋转的同时向下移动并挤压基材，三爪在旋转的同时给耗材施加辅助上下振动和轴向推力，推力大小为200N；
7、开启激光的同时开启运动机构，运动机构以0.6m/min的运行速度按规划加工路径移动，实施增材制造过程；
8、重复步骤7的堆积过程最终得到堆积体，对堆积体进行余量加工及检测。
图7是该实施例的304不锈钢成形组织与耗材棒原始组织的对比图,图7(a)为304不锈钢棒状耗材原始组织，主要由大块的初生奥氏体组成，晶界形貌以
平直特征为主，图7(b)为微区半固态激光成形组织，初生奥氏体晶粒在强烈搅拌、摩擦作用下形成特定球状或球团状，且晶粒尺寸更为细小。球晶之间发亮的部分并非传统意义上的晶界，而是极为细小的液相淬火组织，以至于在光学显微镜下几乎无法分辨其形貌。
具体实施方式二：本实施方式与具体实施方式一不同的是：耗材为两根并排布置的直径为
Figure PCTCN2018093506-appb-000003
的金属棒条，其它步骤和参数与具体实施方式一相同。
具体实施方式三：如图3，本实施方式与具体实施方式一不同的是：热源为Tig，焊枪与堆积层夹角55°，消耗棒直径为
Figure PCTCN2018093506-appb-000004
消耗棒与堆积层夹角为60°，电流200A，加工速度0.3m/min，耗材轴向推力大小为100N，其它步骤和参数与具体实施方式一相同。
具体实施方式四：如图4，本实施方式与具体实施方式一不同的是：热源为Mig，焊枪与堆积层夹角55°，消耗棒与堆积层夹角为60°，电流300A，加工速度0.4m/min，耗材轴向推力大小为100N，其它步骤和参数与具体实施方式一相同。
具体实施方式五：如图6，本实施方式与具体实施方式一不同的是：消耗材料为矩形条材，截面尺寸为10mm×3mm，耗材的自运动方式为横向机械往复运动，往复运动频率为100Hz，振幅0.8mm，激光功率为6KW，加工速度0.4m/min。
具体实施方式六：如图5，本实施方式与具体实施方式一不同的是：消耗棒和基材均为6061铝合金，激光功率6KW，耗材移动速度0.4m/min，耗材轴向压力50N，在成形过程中同步向耗材与堆积层之间夹角中喷入320目SiC增强颗粒制备颗粒增强铝基复合材料，体积分数为25％加入量。其它步骤和参数与具体实施方式一相同。
采用微区半固态激光增材制造方法制备的SiC增强铝基复合材料具有完全致密度，颗粒和基体界面结合良好，弹性模量强度提高27％，强度提高18％。
以上实施方式仅是对本发明所作的进一步详细说明，不能认定本发明的具体实施方式只限于这些说明，在不脱离本发明构思的前提下，简单推衍派生出来的系列方法，都应视为属于本发明的权利保护范围。

Claims (8)

  1. 微区半固态增材制造方法，其特征在于：以棒、条状材料作为增材制造的消耗材料，以下简称耗材，工作时卡爪带动耗材以200rpm～10000rpm的速度旋转并给耗材施加10N～2000N的轴向推力，热源辐照耗材前端面使其局部加热至液态或半固态，在紧跟的冷却凝固过程中，这些耗材端部的热态金属在轴向推力、旋转扭力以及基材或堆积层反作用力的作用下经历了搅拌、挤压作用形成无模半固态流变加工组织；耗材以0.1mm/min～2m/min的消耗速度向前均匀推送以及耗材按离散切片生成的运动路径以0.1mm/min～4m/min的速度移动形成连续堆积层，重复该堆积过程形成成形体；热源包括激光束、电子束、等离子束，电弧、电阻热、感应加热或火焰。
  2. 根据权利要求1所述的半固态增材制造方法，其特征在于：电弧为TIG、MIG或CMT。
  3. 根据权利要求1所述的半固态增材制造方法，其特征在于：耗材形式是棒、条状材料，截面形状是实心圆、空心圆、矩形、多边形；耗材为一根或多根并排排列；耗材单根长度5cm～600cm,一根用完续接另一根；激光光斑形状是圆光斑、椭圆光斑、矩形光斑或多光斑。
  4. 根据权利要求1所述的半固态增材制造方法，其特征在于：耗材倾角即耗材中心线与堆积层的夹角为45°～90°，倾斜方向与耗材移动方向相反；耗材的自运动方式是旋转或平面往复运动；激光作用在耗材移动方向前侧，与耗材相对，倾角为5°～60°。
  5. 根据权利要求1所述的半固态增材制造方法，其特征在于：在耗材上附加上下振动增强锻造效果，振动频率为1Hz～1kHz，振幅为0.1mm～1mm。
  6. 根据权利要求1所述的半固态增材制造方法，其特征在于：激光、电子束高能束热源采用扫描加热方式，扫描频率为1Hz～5kHz。
  7. 根据权利要求1所述的半固态增材制造方法，其特征在于：在耗材上同时施加电流、磁场、超声一种或几种组合外场增强调控组织和性能。
  8. 根据权利要求1所述的半固态增材制造方法，其特征在于：在增材制造过程中同时向耗材与堆积层之间的V口中喷入大小为20nm～500μm的合金粉末、增强颗粒、晶须或短纤维制备增强复合材料或功能梯度材料。
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