WO2020098065A1 - 阵列喷射式大尺寸全等轴晶铝合金锭增材制造装备及方法 - Google Patents

阵列喷射式大尺寸全等轴晶铝合金锭增材制造装备及方法 Download PDF

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WO2020098065A1
WO2020098065A1 PCT/CN2018/122252 CN2018122252W WO2020098065A1 WO 2020098065 A1 WO2020098065 A1 WO 2020098065A1 CN 2018122252 W CN2018122252 W CN 2018122252W WO 2020098065 A1 WO2020098065 A1 WO 2020098065A1
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nozzle
liquid
aluminum
array
condensation
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English (en)
French (fr)
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张佼
孙宝德
东青
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Shanghai Jiao Tong University
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Shanghai Jiao Tong University
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Priority to US17/288,038 priority Critical patent/US11524332B2/en
Priority to RU2021114031A priority patent/RU2768633C1/ru
Priority to JP2021509862A priority patent/JP7014932B2/ja
Priority to EP18940117.7A priority patent/EP3862112B1/en
Publication of WO2020098065A1 publication Critical patent/WO2020098065A1/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D7/00—Casting ingots, e.g. from ferrous metals
    • B22D7/005—Casting ingots, e.g. from ferrous metals from non-ferrous metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/22—Direct deposition of molten metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/115—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by spraying molten metal, i.e. spray sintering, spray casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • B22D23/003—Moulding by spraying metal on a surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/53—Nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/55—Two or more means for feeding material
    • 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
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • 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
    • 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
    • B33Y80/00—Products made by additive manufacturing
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/026—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0408—Light metal alloys
    • C22C1/0416—Aluminium-based alloys
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/123—Spraying molten metal
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment
    • C23C4/185—Separation of the coating from the substrate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/20—Cooling means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/30—Platforms or substrates
    • B22F12/33—Platforms or substrates translatory in the deposition plane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to a technology in the field of metallurgy, in particular to an array injection type large-size equiaxed crystal aluminum alloy ingot additive manufacturing equipment and method.
  • Semi-continuous casting is a manufacturing method of large-sized aluminum alloy ingots conventionally adopted in the industry, which mainly includes two methods: one is hot top casting, and the other is direct chill casting.
  • hot top casting is that the liquid surface is stable during the casting process, but deep liquid cavities are generated in the center of the ingot.
  • the solidified structure contains a large area of columnar crystal area. The internal stress remains, the ingot is easy to crack, and the yield rate is low, which is not suitable for the production of aluminum alloy ingot with high alloy content.
  • the advantage of direct chill casting is that it can greatly reduce the depth of the liquid cavity at the center of the ingot, thereby reducing the macro-segregation and internal stress of the ingot; It is also difficult to avoid. Therefore, it is extremely difficult to prepare large-sized ingots with good homogeneity using conventional processes.
  • Additive manufacturing changes the casting mode of large-volume solidification of aluminum liquid.
  • the continuous melting and superposition of micro-units produce large-sized ingots to avoid the formation of liquid holes.
  • a series of shortcomings of conventional casting methods are mainly spray forming and selective laser remelting. Spray forming can be used to prepare ingots without macro-component segregation, but the aluminum ingots prepared by this method have high porosity, less dense structure and severe oxidation.
  • the selective laser remelting method does not have the above problems, and the solidified structure is ideal, but the preparation efficiency is low, the time required is long, and the cost is high. It is difficult to apply it to large-scale industrial ingot production on a large scale.
  • the present invention proposes an array injection type large-size full-equiaxed aluminum alloy ingot additive manufacturing equipment and method, which generates a stable continuous metal liquid column by spraying a large volume of melt by generating negative pressure
  • the large volume of aluminum liquid is evenly dispersed to form tens or even hundreds of continuous liquid flows, combined with the three-dimensional movement of the rapid condensation stage below, to realize the large-area spreading of the thin layer of aluminum liquid And through continuous solidification to form an ingot.
  • the method has high production efficiency, can prepare super-large size aluminum alloy ingots, the solidified structure is fully equiaxed crystals, and there is no macro-segregation.
  • the invention includes: a liquid aluminum spraying mechanism with an array nozzle arranged in a normal pressure chamber, a movable condensation mechanism arranged in the normal pressure cavity and a control mechanism located under the liquid aluminum spraying mechanism, wherein: the control mechanism is released to The mechanism sends an upward command and sends a three-dimensional movement command to the active condensation mechanism, so that the aluminum liquid in the liquid aluminum injection mechanism is sprayed to the surface of the active condensation mechanism in the form of a continuous array of liquid streams according to a preset path and quickly condenses to form an ingot.
  • the normal pressure chamber is provided with a vacuum pump connected to the control mechanism, and the internal air pressure is further adjusted by the vacuum pump.
  • the normal pressure chamber is connected with an inert gas source to provide inert gas protection inside.
  • the liquid aluminum spraying mechanism includes a release mechanism, an aluminum liquid chamber and an array nozzle.
  • the array nozzle is arranged at the bottom of the aluminum liquid chamber.
  • the release mechanism is connected to the control mechanism to control the opening and closing of the aluminum liquid spraying process.
  • the release mechanism includes a pull-up device and a plug rod, wherein: the plug rod is matched with the array nozzle, and the pull-up device is respectively connected to the plug rod and the control mechanism to receive a release command and control the plug rod to lift to release the array type nozzle.
  • the aluminum liquid chamber is further provided with an in-cavity heater connected to the control mechanism.
  • a liquid level gauge is provided in the aluminum liquid chamber.
  • One side of the aluminum liquid chamber is provided with a liquid inlet tank with a gate to input aluminum liquid.
  • the exterior of the aluminum liquid chamber is provided with a thermal insulation structure.
  • a nozzle heater is further provided on the outside of the array nozzle.
  • the movable condensing mechanism includes: a condensing platform arranged directly opposite to the array nozzle, a two-dimensional movable mechanism vertically arranged under the condensing platform, and a lowering device, wherein the two-dimensional movable mechanism and the lowering device are respectively connected with the control mechanism Connect and receive two-dimensional movement instructions and vertical movement instructions to achieve three-dimensional movement.
  • the vertical movable setting is realized by the downward guiding device arranged under the two-dimensional movable mechanism.
  • a cooling liquid flow channel is provided inside the condensation table.
  • the control mechanism includes: a motion control unit and a general control unit, wherein: the motion control unit is connected to the general control unit and transmits the motion information of the active condensation mechanism, and the general control unit is respectively connected to the release mechanism and the vacuum pump and transmits the release mechanism motion and The information about the opening and closing of the vacuum pump is connected to the two-dimensional movable mechanism and transmits the motion information of the two-dimensional movable mechanism, and is connected to the downdraft device and transmits the motion information of the downdraft device.
  • the invention relates to an array injection type large-size full-equiaxed aluminum alloy ingot additive manufacturing method based on the above device, which includes the following steps:
  • Step 1 Place the stopper rod at the lowest position, so that the nozzle is closed; turn on the heater in the cavity to preheat, continue to keep warm after preheating to the temperature of the aluminum liquid, open the inlet gate, and let the aluminum liquid flow into the aluminum liquid chamber, through the liquid
  • the inlet gate is closed, the nozzle heater is turned on to preheat the nozzle, the closed condensation chamber is closed, and the vacuum pump is turned on to evacuate the closed condensation chamber; after the vacuum degree reaches the requirement, the vacuum pump is turned off and the inert gas is passed.
  • the source is filled with inert gas to the preset pressure;
  • Step 2 Turn on the cooling water, control the lower lead device through the motion control unit, so that the distance between the nozzle and the condensation table reaches the preset distance, turn on the two-dimensional motion device, and make the nozzle periodically and repeatedly move relative to the condensation table; open the upper lead device to lift
  • the plug rod allows the aluminum liquid to enter the nozzle; the vacuum pump is turned on and the pressure of the closed condensation chamber is pumped to less than 1 atm.
  • the aluminum liquid is ejected through the nozzle to form a stable liquid column under the negative pressure formed by the upper and closed condensation chambers and sprayed to the condensation
  • the ingot is formed on the table; after the ingot preparation starts, the lowering device is controlled to move down the condensation table.
  • the ingot preparation process as the aluminum liquid is continuously consumed, when the liquid level of the aluminum liquid chamber drops to the warning level, the inlet is opened
  • the gate is supplemented with aluminum liquid, and the inlet gate is closed after reaching a stable level;
  • Step 3 After the ingot preparation is completed, the plug rod is closed to block the aluminum liquid from flowing out of the nozzle, the two-dimensional motion device and the down-draw device are closed, the heating power is turned off, the cooling water is turned off after the ingot is cooled, and the preparation process is ended.
  • the present invention generates a stable continuous metal liquid column by spraying a large volume of melt by generating a negative pressure, and by arranging a plurality of nozzles in an array arrangement design, the large volume of aluminum liquid is uniformly dispersed to form tens Even hundreds of continuous liquid flows, combined with the three-dimensional movement of the rapid condensation stage below, realize the large-area spreading of the thin layer of aluminum liquid and the formation of ingots through continuous solidification.
  • Figure 1 is a schematic diagram of the structure of the present invention
  • Figure 2 is a schematic diagram of the nozzle structure
  • Figure 3 is a schematic diagram of the moving path of the nozzle liquid column
  • Example 4 and 5 are metallographic photos of Example 1;
  • Example 2 6 and 7 are metallographic photos of Example 2.
  • inlet gate 1 diversion tank 2, aluminum liquid 3, insulation layer 4, intake pipe 5, inert gas 6, nozzle heater 7, baffle 8, condensation table 9, two-dimensional motion device 10, guide rail 11, Support table 12, upper lead device 13, plug rod 14, in-cavity heater 15, aluminum liquid chamber 16, nozzle 17, liquid level gauge 18, ingot 19, cooling water pipe 20, closed condensation chamber 21, motion control unit 22, Downward drawing device 23, vacuum pump 24, general control unit 25.
  • FIG. 1 it is an array injection type large-size full-equiaxed aluminum alloy ingot additive manufacturing device according to this embodiment, including: an inlet gate 1, a diversion groove 2, an aluminum liquid 3, an insulation layer 4, an air inlet pipe 5.
  • the aluminum liquid chamber maintains 1 atmosphere pressure, the closed condensation chamber is completely sealed, and the pressure P can be adjusted by the vacuum pump 24 and the air inlet pipe. During the preparation of the ingot, the pressure P is less than 1 atmosphere pressure.
  • the nozzles 17 are arranged in an array, the row spacing of the nozzles is W (W ⁇ 300mm), the column spacing is L (L ⁇ 300mm), and the nozzle aperture is D (0.2mm ⁇ D ⁇ 30mm ).
  • the two-dimensional motion device 10 carries the translation of the condensing platform in the horizontal X and Y directions, the moving speed is v (v ⁇ 1000mm / s), and the maximum travel in the two directions is X (X ⁇ 1m) and Y respectively (Y ⁇ 1m), through the movement, the movement path of the nozzle liquid column relative to the condensing table similar to that shown in FIG. 3 can be realized, but it is not limited to this movement path, and the distance between adjacent passes is d (d ⁇ 30mm).
  • the single-pass movement length of a single nozzle is equal to the nozzle row pitch L
  • the total movement width of the single nozzle is equal to the nozzle row pitch W.
  • the down-drawing device 13 realizes the movement of the condensing platform in the vertical direction, the moving speed is v 1 (v 1 ⁇ 50 mm / s), and the total stroke Z (Z ⁇ 5 m).
  • This embodiment relates to an array injection type large-size full-equiaxed aluminum alloy ingot additive manufacturing method, including the following steps:
  • Step 2 Turn on the cooling water, control the lowering device through the motion control unit so that the distance between the nozzle and the condensation table is H (H ⁇ 50cm), turn on the two-dimensional movement device, and make the nozzle periodically repeat relative to the condensation table in the manner of FIG. 2 motion.
  • Turn on the lead device lift the plug rod, and let the aluminum liquid enter the nozzle.
  • Turn on the vacuum pump and pump the pressure of the closed condensing chamber to P 2 (P 2 ⁇ 1 atm) the aluminum liquid is ejected through the nozzle to form a stable liquid column under the negative pressure formed by the upper and the closed condensing chamber, and sprayed to the condensing table to form Ingot.
  • the down-drawing device is controlled to move the condensing table downward at a speed v 1 (v 1 ⁇ 50 mm / s) so that the height from the nozzle to the surface of the ingot is always maintained at the height H.
  • v 1 v 1 ⁇ 50 mm / s
  • Step 3 After the ingot preparation is completed, the plug rod is closed to block the aluminum liquid from flowing out of the nozzle, the two-dimensional motion device and the down-draw device are closed, the heating power is turned off, the cooling water is turned off after the ingot is cooled, and the preparation process is ended.
  • the 7050 aluminum alloy ingot was prepared by the above method, the molten aluminum temperature was set to 680 ° C, the nozzle diameter was 8 mm, the horizontal movement speed of the condensing table was 300 mm / s, the array nozzle spray area was 2 m * 5 m, and the ingot thickness was 0.5 m After 40 minutes, a large ingot of 2m * 5m * 0.5m was prepared.
  • the solidified structure of the ingot is dense, without macro-segregation, and it is an equiaxed crystal with an average grain size of 60-80 ⁇ m, as shown in Figure 4.
  • Figure 5 shows the grain structure of the ingot obtained by semi-continuous casting. By comparison, the grain structure of the ingot prepared by this method is significantly refined.
  • the Al-4.5Cu aluminum alloy ingot was prepared by the same method as in Example 1.
  • the molten aluminum temperature was set at 700 ° C
  • the nozzle diameter was 6 mm
  • the horizontal moving speed of the condenser table was 260 mm / s
  • the spray area of the array nozzle It is 2m * 5m
  • the thickness of the ingot is 0.8m
  • a large ingot of 2m * 5m * 0.8m is prepared after 60 minutes.
  • the structure of the ingot is dense, without macrosegregation, and it is an equiaxed crystal.
  • the average grain size is 60-90 ⁇ m.
  • the metallographic photos along the center line of the ingot cross section at 1/4 and 1/2 are shown in Figures 6 and 7 respectively. As shown.

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  • Manufacture And Refinement Of Metals (AREA)
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Abstract

一种阵列喷射式大尺寸全等轴晶铝合金锭增材制造装备，其包括：设置于常压腔内的带有阵列式喷嘴（17）的液态喷铝机构和位于液态喷铝机构下方的设置于常压腔内的活动冷凝机构以及控制机构，其中：控制机构分别向释放机构发出上引指令，向活动冷凝机构发出三维移动指令，从而实现液态喷铝机构中的铝液根据预设路径以连续阵列液流的形式喷射至活动冷凝机构的表面并快速冷凝形成铸锭。以及一种基于该装置的增材制造方法。利用该装置制备铸锭生产效率高，可以制备超大尺寸铝合金铸锭，凝固组织为全等轴晶，且无宏观偏析。

Description

阵列喷射式大尺寸全等轴晶铝合金锭增材制造装备及方法 技术领域
本发明涉及的是一种冶金领域的技术，具体是一种阵列喷射式大尺寸全等轴晶铝合金锭增材制造装备及方法。
背景技术
半连续铸造是工业上常规采用的大尺寸铝合金锭的制造方法，主要包括两种方式：一种是热顶铸造，另一种是直接激冷铸造。热顶铸造的优点是浇铸过程液面平稳，但在铸锭中心产生较深的液穴，凝固组织中含有大面积柱状晶区，从铸锭中心到边部宏观偏析严重，且有较高的内应力残留，铸锭易开裂，成材率低，不适用于高合金含量铝合金铸锭的生产。直接激冷铸造的优点是可很大程度上减少铸锭中心处液穴的深度，进而减轻铸锭的宏观偏析和内应力；但是在浇铸过程中液面不平稳，容易卷渣，柱状晶区也难以避免。因此，应用常规工艺制备均质性好的大尺寸铸锭极为困难。
增材制造改变了铝液大体积凝固的铸造模式，通过微元区域的连续熔融和叠加制备大尺寸铸锭，避免了液穴形成，同时冷却速度的提升有利于形成全等轴晶组织，克服了常规铸造方法的一系列缺点。当前代表性的方法主要是喷射成形和选择性激光重熔。喷射成形可以用于制备无宏观成分偏析的铸锭，但该方法制备的铝锭气孔率高、组织不致密且氧化严重。选择性激光重熔方法不存在上述问题，凝固组织较理想，但是制备效率低，所需时间长，成本高企，难以大规模应用于工业大型铸锭生产。现有技术中有采用磁场控制带电金属液滴直接沉积成型的金属微滴增材制造方法，但金属液滴成型效率低下，不可能用于大型铸锭的生产。当前也尚没有通过产生负压使大体积熔体经喷射形成稳定连续金属液柱并快速冷凝形成大型、异形且具有无偏析全等轴晶组织铸锭的方法。
发明内容
本发明针对现有技术存在的上述不足，提出一种阵列喷射式大尺寸全等轴晶铝合金锭增材制造装备及方法，通过产生负压使大体积熔体经喷射形成稳定连续金属液柱，通过对多个喷嘴进行阵列式的排布设计，使大体积铝液均匀分散形成数十乃至数百股连续液流，结合下方快速冷凝台的三维运动，实现薄层铝液的大面积铺展并通过连续凝固形成铸锭。该方法生产效率高，可以制备超大尺寸铝合金铸锭，凝固组织为全等轴晶，且无宏观偏析。
本发明是通过以下技术方案实现的：
本发明包括：设置于常压腔内的带有阵列式喷嘴的液态喷铝机构和位于液态喷铝机构下 方的设置于常压腔内的活动冷凝机构以及控制机构，其中：控制机构分别向释放机构发出上引指令，向活动冷凝机构发出三维移动指令，从而实现液态喷铝机构中的铝液根据预设路径以连续阵列液流的形式喷射至活动冷凝机构的表面并快速冷凝形成铸锭。
所述的常压腔上设有与控制机构相连的真空泵，通过真空泵以进一步调节内部气压。
所述的常压腔与惰性气源相连，以向其内部提供惰性气体保护。
所述的液态喷铝机构包括：释放机构、铝液腔以及阵列式喷嘴，其中：阵列式喷嘴设置于铝液腔的底部，释放机构与控制机构相连以控制铝液的喷射过程的开闭。
所述的释放机构包括上引装置和塞杆，其中：塞杆与阵列式喷嘴相匹配设置，上引装置分别与塞杆和控制机构相连以接收释放指令并控制塞杆上提以释放阵列式喷嘴。
所述的铝液腔内进一步设有与控制机构相连的腔内加热器。
所述的铝液腔内设有液位仪。
所述的铝液腔的一侧设有带有闸门的进液槽以输入铝液。
所述的铝液腔的外部设有保温结构。
所述的阵列式喷嘴的外部进一步设有喷嘴加热器。
所述的活动冷凝机构包括：正对阵列式喷嘴设置的冷凝台、竖直活动设置于冷凝台下的二维活动机构以及下引装置，其中：二维活动机构和下引装置分别与控制机构相连并接收二维移动指令和竖直移动指令从而实现三维移动。
竖直活动设置，通过设置于二维活动机构下的下引装置实现。
所述的冷凝台内部设有冷却液流道。
所述的控制机构包括：运动控制单元和总控制单元，其中：运动控制单元与总控制单元相连并传输活动冷凝机构的运动信息，总控制单元分别与释放机构和真空泵相连并传输释放机构运动和真空泵开闭的信息，与二维活动机构相连并传输二维活动机构的运动信息，与下引装置相连并传输下引装置的运动信息。
本发明涉及一种基于上述装置的阵列喷射式大尺寸全等轴晶铝合金锭增材制造方法，包括以下步骤：
步骤1、将塞杆放置在最低位，使喷嘴处于关闭状态；开启腔内加热器进行预热，预热到铝液温度后持续保温，打开进口闸门，使铝液流入铝液腔，通过液位仪控制铝液达到预设高度后关闭进口闸门，开启喷嘴加热器对喷嘴进行预热，将密闭冷凝腔密闭，开启真空泵将密闭冷凝腔抽真空；真空度达到要求后关闭真空泵，通过惰性气源充入惰性气体至预设压力；
步骤2、开启冷却水，通过运动控制单元控制下引装置，使喷嘴到冷凝台的距离达到预设距离后，开启二维运动装置，使喷嘴相对冷凝台周期性重复运动；开启上引装置提起塞杆， 使铝液进入喷嘴；开启真空泵，将密闭冷凝腔压力抽至小于1个大气压，铝液在上、密闭冷凝腔形成的负压作用下经喷嘴形成稳定液柱喷出，喷射到冷凝台上形成铸锭；铸锭制备开始后，控制下引装置向下移动冷凝台，铸锭制备过程中，随着铝液不断消耗，待铝液腔液位降低至警戒液位时，打开进口闸门补充铝液，至稳定水平后再关闭进口闸门；
步骤3、铸锭制备完毕后，关闭塞杆阻断铝液从喷嘴流出，关闭二维运动装置和下引装置，关闭加热电源，待铸锭冷却后关闭冷却水，结束制备过程。
技术效果
与现有技术相比，本发明通过产生负压使大体积熔体经喷射形成稳定连续金属液柱，通过对多个喷嘴进行阵列式的排布设计，使大体积铝液均匀分散形成数十乃至数百股连续液流，结合下方快速冷凝台的三维运动，实现薄层铝液的大面积铺展并通过连续凝固形成铸锭。
附图说明
图1为本发明结构示意图；
图2为喷嘴结构示意图；
图3为喷嘴液柱移动路径示意图；
图4和图5为实施例1金相照片；
图6和图7为实施例2金相照片；
图中：进口闸门1、导流槽2、铝液3、保温层4、进气管5、惰性气体6、喷嘴加热器7、挡板8、冷凝台9、二维运动装置10、导轨11、支撑台12、上引装置13、塞杆14、腔内加热器15、铝液腔16、喷嘴17、液位仪18、铸锭19、冷却水管20、密闭冷凝腔21、运动控制单元22、下引装置23、真空泵24、总控制单元25。
具体实施方式
实施例1
如图1所示，为本实施例涉及的阵列喷射式大尺寸全等轴晶铝合金锭增材制造装置，包括：进口闸门1、导流槽2、铝液3、保温层4、进气管5、惰性气体6、喷嘴加热器7、挡板8、冷凝台9、二维运动装置10、导轨11、支撑台12、上引装置13、塞杆14、腔内加热器15、铝液腔16、喷嘴17、液位仪18、铸锭19、冷却水管20、密闭冷凝腔21、运动控制单元22、下引装置23、真空泵24、总控制单元25。
所述的铝液腔保持1个大气压，密闭冷凝腔完全密封，压力P可以通过真空泵24和进气管进行调节，铸锭制备过程中，压力P小于1大气压。
如图2所示，所述的喷嘴17为阵列式排布，喷嘴的行间距为W(W<300mm)，列间距为L(L<300mm)，喷嘴孔径为D(0.2mm<D<30mm)。
所述的二维运动装置10承载冷凝台沿水平X、Y两个方向的平移，移动速度为v(v<1000mm/s)，两个方向的最大行程分别为X(X<1m)、Y(Y<1m)，通过移动，可以实现喷嘴液柱相对冷凝台发生类似如图3所示的移动路径，但不限于该移动路径，相邻道次间距为d(d<30mm)。如图2和图3所示，单个喷嘴的单道次运动长度与喷嘴列间距L相等，单个喷嘴的运动总宽度与喷嘴行间距W相等。
所述的下引装置13实现冷凝台沿竖直方向移动，移动速度为v 1(v 1<50mm/s)，总行程Z(Z<5m)。
本实施例涉及阵列喷射式大尺寸全等轴晶铝合金锭增材制造方法，包括以下步骤：
步骤1、将塞杆放置在最低位，使喷嘴处于关闭状态。开启腔内加热器进行预热，预热到铝液温度T 1(T 1>600℃)后持续保温，打开进口闸门，使铝液流入铝液腔，通过液位仪控制铝液达到预设高度后关闭进口闸门，开启喷嘴加热器对喷嘴进行预热，预热温度为T 2(T2>500℃)，将密闭冷凝腔密闭，开启真空泵将密闭冷凝腔抽真空。真空度达到要求后关闭真空泵，通过进气管充入惰性气体至压力P 1(P 1＝1个大气压)。
步骤2、开启冷却水，通过运动控制单元控制下引装置，使喷嘴到冷凝台的距离为H(H<50cm)，开启二维运动装置，使喷嘴相对冷凝台以图2的方式周期性重复运动。开启上引装置，提起塞杆，使铝液进入喷嘴。开启真空泵，将密闭冷凝腔压力抽至P 2(P 2<1个大气压)，铝液在上、密闭冷凝腔形成的负压作用下经喷嘴形成稳定液柱喷出，喷射到冷凝台上形成铸锭。铸锭制备开始后，控制下引装置以速度v 1(v 1<50mm/s)向下移动冷凝台，使喷嘴到铸锭表面的高度始终保持在高度H。铸锭制备过程中，随着铝液不断消耗，待铝液腔液位降低至警戒液位时，打开进口闸门补充铝液，至稳定水平后再关闭进口闸门。
步骤3、铸锭制备完毕后，关闭塞杆阻断铝液从喷嘴流出，关闭二维运动装置和下引装置，关闭加热电源，待铸锭冷却后关闭冷却水，结束制备过程。
通过上述方法制备7050铝合金铸锭，设定铝液温度为680℃，喷嘴直径为8mm，冷凝台水平移动速度为300mm/s，阵列式喷嘴喷射面积为2m*5m，铸锭厚度为0.5m，经过40分钟制备出2m*5m*0.5m的大铸锭。铸锭凝固组织致密，无宏观偏析，为全等轴晶，晶粒平均尺寸60-80μm，如图4所示。图5为半连续铸造得到铸锭的晶粒组织。通过比较，本方法制备的铸锭晶粒组织得到明显细化。
实施例2
本实施例采用与实施例1相同的方法制备Al-4.5Cu铝合金铸锭，设定铝液温度为700℃，喷嘴直径为6mm，冷凝台水平移动速度为260mm/s，阵列式喷嘴喷射面积为2m*5m，铸锭厚度为0.8m，经过60分钟制备出2m*5m*0.8m的大铸锭。铸锭组织致密，无宏观偏析，为全等 轴晶，晶粒平均尺寸60-90μm，沿铸锭横截面中心线1/4处及1/2处的金相照片分别如图6、图7所示。
上述具体实施可由本领域技术人员在不背离本发明原理和宗旨的前提下以不同的方式对其进行局部调整，本发明的保护范围以权利要求书为准且不由上述具体实施所限，在其范围内的各个实现方案均受本发明之约束。

Claims (10)

  1. 一种阵列喷射式大尺寸全等轴晶铝合金锭增材制造装备，其特征在于，包括：设置于常压腔内的带有阵列式喷嘴的液态喷铝机构和位于液态喷铝机构下方的设置于常压腔内的活动冷凝机构以及控制机构，其中：控制机构分别向释放机构发出上引指令，向活动冷凝机构发出三维移动指令，从而实现液态喷铝机构中的铝液根据预设路径以连续阵列液流的形式喷射至活动冷凝机构的表面并快速冷凝形成铸锭；
    所述的液态喷铝机构包括：释放机构、铝液腔以及阵列式喷嘴，其中：阵列式喷嘴设置于铝液腔的底部，释放机构与控制机构相连以控制铝液的喷射过程的开闭。
  2. 根据权利要求1所述的装置，其特征是，所述的常压腔上设有与控制机构相连的真空泵，通过真空泵以进一步调节内部气压；所述的常压腔与惰性气源相连，以向其内部提供惰性气体保护。
  3. 根据权利要求1所述的装置，其特征是，所述的释放机构包括上引装置和塞杆，其中：塞杆与阵列式喷嘴相匹配设置，上引装置分别与塞杆和控制机构相连以接收释放指令并控制塞杆上提以释放阵列式喷嘴。
  4. 根据权利要求1所述的装置，其特征是，所述的活动冷凝机构包括：正对阵列式喷嘴设置的冷凝台、竖直活动设置于冷凝台下的二维活动机构以及下引装置，其中：二维活动机构和下引装置分别与控制机构相连并接收二维移动指令和竖直移动指令从而实现三维移动。
  5. 根据权利要求1所述的装置，其特征是，所述的铝液腔内进一步设有与控制机构相连的腔内加热器。
  6. 根据权利要求1所述的装置，其特征是，所述的阵列式喷嘴的外部进一步设有喷嘴加热器。
  7. 根据权利要求4所述的装置，其特征是，所述的冷凝台内部设有冷却液流道。
  8. 根据权利要求1所述的装置，其特征是，所述的控制机构包括：运动控制单元和总控制单元，其中：运动控制单元与总控制单元相连并传输活动冷凝机构的运动信息，总控制单元分 别与释放机构和真空泵相连并传输释放机构运动和真空泵开闭的信息，与二维活动机构相连并传输二维活动机构的运动信息，与下引装置相连并传输下引装置的运动信息。
  9. 根据权利要求1所述的装置，其特征是，所述的阵列式喷嘴的喷嘴的行间距和列间距小于300mm，喷嘴孔径为0.2mm～30mm；单个喷嘴的单道次运动长度与喷嘴列间距相等，单个喷嘴的运动总宽度与喷嘴行间距相等。
  10. 一种根据上述任一权利要求所述装置的阵列喷射式大尺寸全等轴晶铝合金锭增材制造方法，其特征在于，包括以下步骤：
    步骤1、将塞杆放置在最低位，使喷嘴处于关闭状态；开启腔内加热器进行预热，预热到铝液温度后持续保温，打开进口闸门，使铝液流入铝液腔，通过液位仪控制铝液达到预设高度后关闭进口闸门，开启喷嘴加热器对喷嘴进行预热，将密闭冷凝腔密闭，开启真空泵将密闭冷凝腔抽真空；真空度达到要求后关闭真空泵，通过惰性气源充入惰性气体至预设压力；
    步骤2、开启冷却水，通过运动控制单元控制下引装置，使喷嘴到冷凝台的距离达到预设距离后，开启二维运动装置，使喷嘴相对冷凝台周期性重复运动；开启上引装置提起塞杆，使铝液进入喷嘴；开启真空泵，将密闭冷凝腔压力抽至小于1个大气压，铝液在上、密闭冷凝腔形成的负压作用下经喷嘴形成稳定液柱喷出，喷射到冷凝台上形成铸锭；铸锭制备开始后，控制下引装置向下移动冷凝台，铸锭制备过程中，随着铝液不断消耗，待铝液腔液位降低至警戒液位时，打开进口闸门补充铝液，至稳定水平后再关闭进口闸门；
    步骤3、铸锭制备完毕后，关闭塞杆阻断铝液从喷嘴流出，关闭二维运动装置和下引装置，关闭加热电源，待铸锭冷却后关闭冷却水，结束制备过程。
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