CN109746546B - Metal semi-molten stacking additive manufacturing method and equipment - Google Patents
Metal semi-molten stacking additive manufacturing method and equipmentDownload PDFInfo
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Translated fromChinese技术领域technical field
本发明涉及金属增材或3D打印制造技术，尤其涉及一种金属半熔融堆积增材制造方法及设备。The invention relates to metal additive or 3D printing manufacturing technology, in particular to a method and equipment for metal semi-melting deposition additive manufacturing.
背景技术Background technique
增材制造(又称3D打印)是对工件快速设计与加工制造需求的重要技术，获得了国际外的广泛关注，各种打印技术层出不穷。从材料的角度来说，增材制造可以分为金属增材制造和非金属增材制造。其中非金属增材制造目前以树脂材料的打印为主流，采用的方法主要有工艺熔融沉积制造(Fused Deposition Modeling:FDM)等，其核心原理是将树脂材料通过喷嘴加热熔融，沿预定轨迹堆积凝固而形成所要的形状，由于加热及控制的局限性，FDM可打印材料只局限于热塑性(尼龙、PLA和ABS等)材料，打印温度一般控制在200－300℃左右，对于不锈钢、钛合金等合金材料无能为力。金属材料的增材制造主要包括激光增材制造、电子束增材制造和电弧增材制造等。激光增材制造主要是激光选区熔化增材制造(SLM)技术，电子束增材制造主要是选区电子束熔化增材制造(EBM)技术。目前激光增材大都采用预铺粉或同步送粉的技术。电子束增材及电弧增材制造均可采用送粉或送丝增材的方法，电弧增材加工效率远高于前两种增材技术。Additive manufacturing (also known as 3D printing) is an important technology for the rapid design and processing of workpieces. It has received extensive attention from abroad and various printing technologies. From the perspective of materials, additive manufacturing can be divided into metal additive manufacturing and non-metal additive manufacturing. Among them, non-metal additive manufacturing currently takes the printing of resin materials as the mainstream. The main methods used are Fused Deposition Modeling (FDM), etc. The core principle is to heat and melt the resin material through a nozzle, and accumulate and solidify along a predetermined trajectory. To form the desired shape, due to the limitations of heating and control, FDM printable materials are limited to thermoplastic (nylon, PLA and ABS, etc.) materials, and the printing temperature is generally controlled at around 200-300 °C. For alloys such as stainless steel and titanium alloys Materials are powerless. The additive manufacturing of metal materials mainly includes laser additive manufacturing, electron beam additive manufacturing and arc additive manufacturing. Laser additive manufacturing is mainly laser selective melting additive manufacturing (SLM) technology, and electron beam additive manufacturing is mainly selective electron beam melting additive manufacturing (EBM) technology. At present, most of the laser additive materials use the technology of pre-spreading powder or synchronous powder feeding. Both electron beam additive manufacturing and arc additive manufacturing can use powder feeding or wire feeding additive methods, and the processing efficiency of arc additive manufacturing is much higher than the former two additive technologies.
对于采用铺粉或送粉的增材制造方法而言，存在粉末成本高、利用率低等问题，另外对工作条件要求很高，综合加工和维护成本高。尤其是当处于微重力环境(如空间站等)条件时，粉末无法自然堆积，熔化的金属内部会有大量气孔存在，使得该方法难以在微重力条件下使用。For the additive manufacturing method using powder spreading or powder feeding, there are problems such as high powder cost and low utilization rate. In addition, it has high requirements on working conditions and high comprehensive processing and maintenance costs. Especially when it is in a microgravity environment (such as a space station, etc.), the powder cannot be naturally accumulated, and there will be a large number of pores inside the molten metal, making this method difficult to use in microgravity conditions.
目前采用送丝方式的增材加工，无论其热源是激光、电子束或电弧，均需要将金属丝完全熔化并流入工件表面熔池的方式来实现增材制造。这个过程存在以下问题：At present, the wire feeding method of additive processing, no matter whether the heat source is laser, electron beam or arc, needs to completely melt the metal wire and flow into the molten pool on the surface of the workpiece to achieve additive manufacturing. This process has the following problems:
熔池中的熔融金属处于自由状态，凝固过程会因混入气体或缩孔形成孔隙，影响工件质量。The molten metal in the molten pool is in a free state, and during the solidification process, pores will be formed due to gas mixing or shrinkage cavities, which will affect the quality of the workpiece.
在重力条件下，受熔池尺寸的影响，通常适合水平方式堆积增材(打印倾斜结构时熔融金属容易流出熔池)。Under gravity conditions, affected by the size of the molten pool, it is usually suitable to stack the additive in a horizontal manner (the molten metal tends to flow out of the molten pool when printing inclined structures).
当处于微重力条件时，熔融金属会因表面张力作用停留在金属丝上或堆积在工件表面，加工控形能力差。When in microgravity conditions, the molten metal will stay on the wire or accumulate on the surface of the workpiece due to surface tension, resulting in poor process control.
增材制造过程中，金属丝经过固-液-固的连续相变需要吸收和释放大量热量，造成打印后的工件温度很高，会造成内部应力不均匀，影响增材制造工件的质量，而且整个工件由金属丝全部融化再凝固而形成，消耗大量能量。In the process of additive manufacturing, the metal wire needs to absorb and release a lot of heat through the continuous phase transition of solid-liquid-solid, resulting in a high temperature of the printed workpiece, which will cause uneven internal stress and affect the quality of the additively manufactured workpiece. The whole workpiece is formed by melting and solidifying all the metal wires, which consumes a lot of energy.
如专利CN103752825A公开了一种利用金属熔融沉积成形薄壁结构件的装置及方法，其将金属丝材在加热管中加热至熔融态，并通过挤压方式沉积在预热基板上，逐层成型得到金属薄壁结构件。该专利所述的方法需要将金属丝材加热至熔融态，然后采用挤压方式通过喷嘴到达加工区域。熔融态的金属无法施加压力，并且需要将丝材整体加热至熔融态，仍无法克服前述采用熔融金属增材制造的不足。同样的，专利文献CN104874794A所公开的基于熔融沉积技术的金属3D产品生产方法也是采用高温加热棒将金属丝材加热至熔融状态，然后挤出喷头实现的增材加工方法，其仍未改变需要将丝材熔融及无法施加作用力于工件表面的特点。专利文献CN107008906A公开的一种用于3D金属打印机的电磁感应式快速金属熔化装置是基于中高频感应线圈对金属丝进行快速熔化的，熔化后的金属经喷嘴送出进行打印。其加热方法及金属状态均不同于本申请的内容，且电磁感应加热的速度不高，不同金属材料对电磁感应加热的敏感度也不同。专利文献CN106041087A所公开的基于连续纤维牵引的低熔点金属熔融沉积3D打印方法需要单独添加碳纤维、玻璃纤维、金属纤维或有机合成纤维等纤维丝，仅针对Bi、Sn、Pb或In基合金等低熔点金属，且加热金属的手段为在熔融腔内加热，与本申请的材料、加热方式、施加力的方法均有显著区别。专利文献CN106141373A公开了一种铝合金结构件的电弧3D打印设备及打印方法，该方法适应材料仅针对铝合金，并且采用电弧焊的方式实施增材打印。而电弧焊是依靠电弧在工件表面形成熔池，同时将焊丝熔化添加进熔池而实现的增材制造方法，该方法与本申请的不同之处在于：1)需要将焊丝完全熔化并在工件表面形成熔池；2)所添加材料为液相，造成增材打印时无法施加压力。如前所述，也是难以实现微重力环境及倾斜结构增材打印的。专利文献CN106425490B公开了一种增减材复合加工设备及其应用方法，该方法也是基于电弧焊实现的金属丝增材制造，与本申请的不同之处无需重述。专利文献CN106563804A公开了一种激光引导多金属熔融沉积增材制造工艺及设备，采用激光预热/熔化引导与熔融沉积增材，其加热方式、金属沉积形式均与本申请有本质区别，且无法施加压力。For example, patent CN103752825A discloses a device and method for forming thin-walled structural parts by metal fused deposition. The metal wire is heated to a molten state in a heating tube, and deposited on a preheated substrate by extrusion, forming layer by layer. A thin-walled metal structure is obtained. The method described in this patent entails heating the wire to a molten state and then extruding it through a nozzle to the processing area. The molten metal cannot exert pressure, and the entire wire needs to be heated to a molten state, which still cannot overcome the aforementioned shortcomings of additive manufacturing using molten metal. Similarly, the production method of metal 3D products based on fused deposition technology disclosed in the patent document CN104874794A is also an additive processing method realized by using a high-temperature heating rod to heat the metal wire to a molten state, and then extruding a nozzle. The characteristics of the melting of the wire and the inability to exert force on the surface of the workpiece. Patent document CN107008906A discloses an electromagnetic induction fast metal melting device for a 3D metal printer, which is based on a medium and high frequency induction coil to rapidly melt a metal wire, and the melted metal is sent out through a nozzle for printing. The heating method and metal state thereof are different from the content of the present application, and the speed of electromagnetic induction heating is not high, and different metal materials have different sensitivities to electromagnetic induction heating. The low-melting-point metal fused deposition 3D printing method based on continuous fiber pulling disclosed in the patent document CN106041087A requires the addition of carbon fibers, glass fibers, metal fibers or organic synthetic fibers and other filaments separately, only for low-temperature Bi, Sn, Pb or In-based alloys. The melting point metal, and the method of heating the metal is heating in the melting chamber, which is significantly different from the material, heating method, and force application method of the present application. Patent document CN106141373A discloses an arc 3D printing device and a printing method for aluminum alloy structural parts. The method is adapted to only target aluminum alloys, and uses arc welding to implement additive printing. The arc welding is an additive manufacturing method that relies on the arc to form a molten pool on the surface of the workpiece, and at the same time, the welding wire is melted and added into the molten pool. A molten pool is formed on the surface; 2) The added material is in liquid phase, which makes it impossible to apply pressure during additive printing. As mentioned earlier, it is also difficult to achieve additive printing in microgravity environments and inclined structures. The patent document CN106425490B discloses a composite processing equipment for adding and subtracting materials and an application method thereof. The method is also based on the metal wire additive manufacturing realized by arc welding, and the differences from this application need not be repeated. Patent document CN106563804A discloses a laser-guided multi-metal fused deposition additive manufacturing process and equipment, using laser preheating/melting guidance and fused deposition additive, the heating method and metal deposition form are essentially different from the application, and cannot be used. put pressure on.
发明内容SUMMARY OF THE INVENTION
为了克服现有技术的不足，本发明的目的在于提供一种金属半熔融堆积增材制造方法及设备。In order to overcome the deficiencies of the prior art, the purpose of the present invention is to provide a metal semi-molten deposition additive manufacturing method and equipment.
本发明的目的在于提出一种基于电弧进行金属丝半熔融堆积增材制造的方案，方案采用电弧将金属丝加热至外熔内固的半熔融状态，并采用逐层沉积的方式打印出工件，打印过程中内部固态金属丝起到引导和支撑作用，使该方法不仅适应用重力环境，而且可用于微重力(包括完全失重)环境下的增材制造，并可在接触工件表面过程中施加一定的压力从而减少气孔并提高工件质量。The purpose of the present invention is to propose a scheme for metal wire semi-melting deposition additive manufacturing based on an electric arc. The scheme adopts an arc to heat the metal wire to a semi-melting state of external melting and internal solidification, and prints the workpiece by layer-by-layer deposition. The internal solid metal wire acts as a guide and support during the printing process, making the method not only suitable for use in gravity environments, but also for additive manufacturing in microgravity (including complete weightlessness) environments, and can be applied in the process of contacting the workpiece surface. pressure to reduce porosity and improve workpiece quality.
本发明的技术方案如下：The technical scheme of the present invention is as follows:
一种金属半熔融堆积增材制造方法，方法包括以下步骤：A metal semi-molten stacking additive manufacturing method, the method comprises the following steps:
①将要打印的工件三维模型在设计辅助软件进行分层切片，生成每层的预定轨迹并输送给控制系统，控制系统设定送丝速度和送丝压力以及电源的供电参数；①The 3D model of the workpiece to be printed is sliced in layers in the design assistant software, and the predetermined trajectory of each layer is generated and sent to the control system. The control system sets the wire feeding speed and wire feeding pressure and the power supply parameters of the power supply;
②出丝嘴定位至加工初始位置，预热工作台；② The wire nozzle is positioned to the initial processing position, and the worktable is preheated;
③在控制系统控制下，送丝模块将金属丝送入出丝嘴金属丝从送丝模块进入出丝嘴；③Under the control of the control system, the wire feeding module feeds the wire into the wire outlet, and the wire enters the wire outlet from the wire feeding module;
④金属丝到达引弧模块附近时，电源发出引弧脉冲，工作介质击穿形成电弧；④ When the metal wire reaches the vicinity of the arc-striking module, the power supply sends out an arc-striking pulse, and the working medium breaks down to form an arc;
⑤送丝模块按设定速度持续送丝，金属丝经出丝嘴向工作台进给，在此过程中电源继续保持电流输出，同时引弧模块绕出丝嘴以设定速度旋转，电弧持续加热金属丝，使得金属丝表面迅速熔化而中间部分仍为固态的固、液两相特征；⑤ The wire feeding module continuously feeds the wire at the set speed, and the metal wire is fed to the worktable through the wire outlet. During this process, the power supply continues to maintain the current output, and at the same time, the arc ignition module rotates around the wire outlet at the set speed, and the arc continues Heating the metal wire makes the surface of the metal wire melt rapidly and the middle part is still solid with solid and liquid two-phase characteristics;
⑥送丝模块将外部被电弧熔化的金属丝送入沉积区域，并施加一定压力，金属丝冷却并与基体或工件结合凝固；⑥ The wire feeding module sends the metal wire melted by the external arc into the deposition area, and applies a certain pressure, the metal wire cools and solidifies with the base or workpiece;
⑦保持送丝-加热过程，同时控制系统控制运动机构沿预定轨迹运动，直至此轨迹加工完成；⑦Keep the wire feeding-heating process, and at the same time, the control system controls the motion mechanism to move along the predetermined trajectory until the processing of this trajectory is completed;
⑧送丝模块停止送丝，切断金属丝或通过电弧将金属丝熔断；⑧ The wire feeding module stops wire feeding, cuts off the wire or fuses the wire through the arc;
⑨运动机构到达下一条轨迹起点；⑨ The motion mechanism reaches the starting point of the next track;
⑩送丝模块继续工作，重复步骤⑤-⑦，直至完成所有增材打印工作。⑩ The wire feeding module continues to work, and repeat steps ⑤-⑦ until all additive printing work is completed.
优选的，在步骤③中，若选用的金属丝自带产生保护气体的药皮，则不开启工作介质的供给；若选用的金属丝不带产生保护气体的药皮，则由介质管道向介质喷嘴输送工作介质，并由介质喷嘴喷出工作介质进入金属丝和引弧模块之间。Preferably, in step (3), if the selected metal wire has its own coating for generating protective gas, the supply of the working medium is not turned on; The nozzle conveys the working medium, and the working medium is ejected from the medium nozzle and enters between the wire and the arc striking module.
优选的，在步骤⑤中，引弧模块绕出丝嘴以1000rpm的设定速度旋转。Preferably, in step ⑤, the arc striking module rotates around the wire nozzle at a set speed of 1000 rpm.
本发明还提供了一种实施上述金属半熔融堆积增材制造方法的设备，设备包括送丝模块、出丝嘴、电源、引弧模块、介质喷嘴、运动机构、控制系统、工件和工作台。工件设置在工作台上，所述送丝模块、出丝嘴、引弧模块、介质喷嘴和运动机构可调整的设置在机架上；其中运动机构的上部与机架连接并在三轴自由度以上可调的运动，所述送丝模块连接至所述运动机构的下方，在所述送丝模块的输出端设置出丝嘴；所述介质喷嘴和引弧模块通过支撑输送组件侧面正对所述出丝嘴的出丝端设置；电源通过送电附件与所述运动机构的上端连接并向运动机构、送丝模块、介质喷嘴和引弧模块供电；所述控制系统与送丝模块、引弧模块和运动机构信号连接，并控制电弧状态及检测、电源输出电流、送丝模块和引弧模块的相对运动。The present invention also provides a device for implementing the above-mentioned metal semi-molten deposition additive manufacturing method. The device includes a wire feeding module, a wire outlet, a power source, an arc striking module, a medium nozzle, a motion mechanism, a control system, a workpiece and a workbench. The workpiece is set on the worktable, and the wire feeding module, the wire nozzle, the arc striking module, the medium nozzle and the moving mechanism are adjustable on the frame; the upper part of the moving mechanism is connected with the frame and has three-axis degrees of freedom. For the above adjustable movement, the wire feeding module is connected to the lower part of the moving mechanism, and a wire outlet is set at the output end of the wire feeding module; Describe the setting of the wire outlet end of the wire nozzle; the power supply is connected to the upper end of the motion mechanism through the power transmission accessory and supplies power to the motion mechanism, the wire feeding module, the medium nozzle and the arc striking module; the control system is connected to the wire feeding module, the wire feeding module, the The arc module is connected with the motion mechanism signal, and controls the arc state and detection, the output current of the power supply, and the relative movement of the wire feeding module and the arc striking module.
优选的，引弧模块通过送电附件与电源输出端连通；不加工时，引弧模块与送丝模块、金属丝及出丝嘴断开绝缘；加工时，金属丝、电弧、引弧模块、电源及送电附件共同构成电弧放电回路，并在金属丝与引弧模块之间产生电弧。Preferably, the arc-striking module is connected to the output end of the power supply through the power transmission accessory; when not in processing, the arc-striking module is disconnected from the wire feeding module, the wire and the wire nozzle; during processing, the wire, the arc, the arc-striking module, The power supply and power transmission accessories together form an arc discharge circuit, and an arc is generated between the wire and the arc striking module.
优选的，所述引弧模块包括导电材料制成的引弧部，用于引弧和维持电弧。Preferably, the arc striking module includes an arc striking portion made of conductive material for striking and maintaining the arc.
优选的，所述引弧部由金属、合金或石墨材料制成。Preferably, the arc striking portion is made of metal, alloy or graphite material.
优选的，引弧模块的引弧方式包括接触引弧和击穿引弧。Preferably, the arc striking method of the arc striking module includes contact arc striking and breakdown arc striking.
优选的，引弧模块到金属丝或出丝嘴出丝端的中心的距离可调整，用以控制电弧弧长。Preferably, the distance from the arc striking module to the center of the wire or the wire end of the wire nozzle can be adjusted to control the arc length of the arc.
优选的，送丝模块包括内置运动单元，通过所述内置运动单元将金属丝推送入出丝嘴，所述内置运动单元在控制系统的控制下出丝速度可调。Preferably, the wire feeding module includes a built-in motion unit through which the wire is pushed into the wire outlet, and the wire-feeding speed of the built-in motion unit is adjustable under the control of the control system.
优选的，送丝模块在于推送金属丝的同时对金属丝施加推力从而对增材制造表面施加压力，根据金属丝尺寸、送丝速度和加工要求的不同，施加压力范围为0.01N-500N。Preferably, the wire feeding module pushes the wire while pushing the wire to exert pressure on the surface of the additive manufacturing. According to the wire size, wire feeding speed and processing requirements, the applied pressure ranges from 0.01N to 500N.
优选的，出丝嘴内部有供金属丝通过的孔，以便于金属丝进入及导向，所述孔的上部具有上大下小的倒锥形扩口，出丝嘴为耐磨材料制成。Preferably, there is a hole inside the wire outlet for the wire to pass through, so as to facilitate the entry and guidance of the wire, the upper part of the hole has an inverted conical flaring with a large upper and a lower small, and the wire outlet is made of wear-resistant material.
优选的，所述耐磨材料为陶瓷、合金钢或复合材料。Preferably, the wear-resistant material is ceramic, alloy steel or composite material.
优选的，金属丝的主体为金属或金属基复合材料。Preferably, the main body of the metal wire is metal or metal matrix composite material.
优选的，金属丝的表面设置一层能产生保护气体的药皮。Preferably, a layer of drug skin capable of generating protective gas is provided on the surface of the metal wire.
优选的，由介质喷嘴供给的工作介质为低电导率或绝缘的介质，所述工作介质的形式为气体和/或液体，所述工作介质在高电场场强下被击穿而产生电弧。Preferably, the working medium supplied by the medium nozzle is a low-conductivity or insulating medium, the working medium is in the form of gas and/or liquid, and the working medium is broken down under high electric field strength to generate an arc.
优选的，所述工作介质由介质管道输送至金属丝与引弧模块之间，或由金属丝表面层材料受热气化生成。Preferably, the working medium is transported between the metal wire and the arc striking module by a medium pipeline, or is generated by heating and gasifying the surface layer material of the metal wire.
优选的，电源用于输出引弧和保持电弧的电流，电源的输出电流为500mA-5000A可调。Preferably, the power supply is used for outputting the current for striking and maintaining the arc, and the output current of the power supply is adjustable from 500mA to 5000A.
优选的，设备包括至少一套送丝模块，金属丝为多种材质及型号。Preferably, the equipment includes at least one set of wire feeding modules, and the metal wires are of various materials and types.
相比现有技术，本发明的有益效果在于：Compared with the prior art, the beneficial effects of the present invention are:
1.直接采用金属丝进行半熔融堆积打印，摆脱了对金属粉末的依赖，可依托机床或机器人平台实现增材制造，并可极大提高金属构件3D打印的速度，缩短工件加工时间和制造成本。1. Directly use metal wire for semi-melting deposition printing, get rid of the dependence on metal powder, and can rely on machine tools or robot platforms to achieve additive manufacturing, which can greatly improve the speed of 3D printing of metal components, shorten workpiece processing time and manufacturing costs .
2.相比感应加热、电阻加热及燃烧加热等加热方式，电弧具有温度高、能量密度大、能量转换效率高、易获得等明显优势，可实现金属丝的快速加热，保证加工的连续性和稳定性，适合在地面及太空微重力等多种环境连续工作。2. Compared with heating methods such as induction heating, resistance heating and combustion heating, the arc has obvious advantages such as high temperature, high energy density, high energy conversion efficiency, and easy access, which can realize rapid heating of metal wires and ensure the continuity of processing. Stability, suitable for continuous work in various environments such as ground and space microgravity.
3.相比激光增材打印方式，本方法除不需要金属粉末外，也避免了激光金属增材打印所必须的产生激光的系统，减少了装置复杂性。另外，电弧的能量转换效率远高于激光但成本要低得多。3. Compared with the laser additive printing method, this method not only does not require metal powder, but also avoids the laser generating system necessary for the laser metal additive printing, and reduces the complexity of the device. In addition, the energy conversion efficiency of arc is much higher than that of laser but the cost is much lower.
4.可用于打印的金属丝适用材料范围广，从低熔点金属(含合金)到高熔点金属以及金属基复合材料均可应用，并且可采用多种材料打印一个工件，从而获得比单一材料性能更优异的工件。4. The metal wire that can be used for printing is suitable for a wide range of materials, from low melting point metals (including alloys) to high melting point metals and metal matrix composite materials, and can use a variety of materials to print a workpiece, so as to obtain better performance than a single material. better workpiece.
5.电弧加热的研究机理已经较为成熟，温度、弧长可控，通过采用可靠的技术手段实现金属丝表面熔化而内部仍为固体状态，可避免其他弧焊及电弧熔融增材打印等方法需要将电极丝完全熔化而带来的无法直接在加工区域施加压力的问题，可利用中间固态金属丝携带表面熔融金属到达指定区域并在对成型表面施加一定的压力。本申请可缓解或避免采用完全熔融方式造成工件孔隙率高，在微重力环境下熔融金属因表面张力无法脱离电极丝或失重悬浮等问题。5. The research mechanism of arc heating is relatively mature, and the temperature and arc length are controllable. By using reliable technical means to achieve melting of the surface of the metal wire while the interior is still in a solid state, it can avoid the need for other methods such as arc welding and arc melting additive printing. For the problem that the electrode wire cannot be directly applied to the processing area due to the complete melting of the electrode wire, the intermediate solid metal wire can be used to carry the surface molten metal to the designated area and exert a certain pressure on the forming surface. The present application can alleviate or avoid problems such as high porosity of the workpiece caused by the complete melting method, and the molten metal cannot be separated from the electrode wire or suspended in weightlessness due to surface tension in a microgravity environment.
附图说明Description of drawings
图1为本发明一种金属半熔融堆积增材制造设备的工作原理示意图；Fig. 1 is a schematic diagram of the working principle of a metal semi-molten deposition additive manufacturing equipment according to the present invention;
图2为一种金属半熔融堆积增材制造设备的结构示意图。FIG. 2 is a schematic structural diagram of a metal semi-molten deposition additive manufacturing equipment.
图中：1、送丝模块；2、金属丝；3、出丝嘴；4、电源；5、引弧模块；6、电弧；7、工作台；8、运动机构；9、控制系统；10、工作介质；11、工件；12、送电附件；13、介质喷嘴。In the figure: 1. Wire feeding module; 2. Metal wire; 3. Wire nozzle; 4. Power supply; 5. Arc striking module; 6. Arc; 7. Workbench; 8. Movement mechanism; 9. Control system; 10 , working medium; 11, workpiece; 12, power transmission accessories; 13, medium nozzle.
具体实施方式Detailed ways
下面结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.
需要说明的是，当组件被称为“固定于”另一个组件，它可以直接在另一个组件上或者也可以存在居中的组件。当一个组件被认为是“连接”另一个组件，它可以是直接连接到另一个组件或者可能同时存在居中组件。当一个组件被认为是“设置于”另一个组件，它可以是直接设置在另一个组件上或者可能同时存在居中组件。本文所使用的术语“垂直的”、“水平的”、“左”、“右”以及类似的表述只是为了说明的目的。It should be noted that when a component is referred to as being "fixed to" another component, it can be directly on the other component or there may also be a centered component. When a component is considered to be "connected" to another component, it can be directly connected to the other component or there may be a co-existence of an intervening component. When a component is considered to be "set on" another component, it may be directly set on the other component or there may be a co-existing centered component. The terms "vertical," "horizontal," "left," "right," and similar expressions are used herein for illustrative purposes only.
除非另有定义，本文所使用的所有的技术和科学术语与属于本发明的技术领域的技术人员通常理解的含义相同。本文中在本发明的说明书中所使用的术语只是为了描述具体的实施例的目的，不是旨在于限制本发明。本文所使用的术语“及/或”包括一个或多个相关的所列项目的任意的和所有的组合。Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terms used herein in the description of the present invention are for the purpose of describing specific embodiments only, and are not intended to limit the present invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
一、零部件位置或连接关系1. Parts location or connection relationship
参见图2，一种金属半熔融堆积增材制造设备，设备包括送丝模块1、出丝嘴3、电源4、引弧模块5、介质喷嘴13、运动机构8、控制系统9、工件11和工作台7。2, a metal semi-molten deposition additive manufacturing equipment, the equipment includes a wire feeding module 1, a wire nozzle 3, a
工件11设置在工作台7上，送丝模块1、出丝嘴3、引弧模块5、介质喷嘴13和运动机构8可调整的设置在机架上。送丝模块1连接至运动机构8的下方，在送丝模块1的输出端设置出丝嘴3；介质喷嘴13和引弧模块5通过支撑输送组件侧面正对出丝嘴3的出丝端设置；电源4通过送电附件12与运动机构8的上端连接并向运动机构8、送丝模块1、介质喷嘴13和引弧模块5供电；控制系统9与送丝模块1、引弧模块5和运动机构8信号连接，并控制电弧状态及检测、电源输出电流、送丝模块1和引弧模块5的相对运动。引弧模块5通过送电附件12与电源4输出端连接。The
其中，送丝模块1包括内置运动单元，通过内置运动单元将金属丝2推送入出丝嘴3，内置运动单元在控制系统9的控制下出丝速度可调。送丝模块1在推送金属丝2的同时对金属丝2施加推力从而对增材制造表面施加压力，根据金属丝尺寸、送丝速度和加工要求的不同，施加压力范围为0.01N-500N。The wire feeding module 1 includes a built-in motion unit through which the
金属丝2的主体为金属或金属基复合材料。针对不同加工需求，金属丝2的表面还可设置一层能产生保护气体的药皮。The main body of the
出丝嘴3内部有供金属丝2通过的孔，以便于金属丝进入及导向，孔的上部具有上大下小的倒锥形扩口，出丝嘴为耐磨材料制成。耐磨材料优选为但不局限于陶瓷、合金钢或复合材料等耐磨材料。Inside the wire outlet 3 is a hole for the
电源4为多档位参数可调供电，供电电流的大小可根据加工速度和金属丝的性质进行匹配调节。进一步的，电源4用于输出引弧和保持电弧的电流，电源4的输出电流为500mA-5000A可调。The
引弧模块5包括导电材料制成的引弧部，用于引弧和维持电弧。引弧部优选但不限于金属、合金或石墨等材料制成。引弧模块5的引弧方式包括接触引弧和击穿引弧。The arc striking module 5 includes an arc striking part made of conductive material for striking and maintaining the arc. The arc striking portion is preferably, but not limited to, made of materials such as metal, alloy, or graphite. The arc striking method of the arc striking module 5 includes contact arc striking and breakdown arc striking.
此外，引弧模块5到金属丝2或出丝嘴3出丝端的中心的距离可调整，用以控制电弧弧长。In addition, the distance from the arc striking module 5 to the center of the
可替换的，引弧模块5可采用环状引弧部，所述环状引弧部将金属丝2包围在中间，因此，无需金属丝2和引弧模块5的相对转动。Alternatively, the arc striking module 5 may adopt an annular arc striking portion, and the annular arc striking portion encloses the
可替换的，可通过送丝模块1实现金属丝2的旋转，无需引弧模块5和出丝嘴3的相对转动。Alternatively, the
运动机构8的上部与机架连接，其可实现三轴以上的可调节的运动并定位，包括但不限于带控制系统的机床和带控制系统的机器人。The upper part of the
工作介质10由介质管道输送至金属丝2与引弧模块5之间，或由金属丝2表面层材料受热气化生成。The working
当为介质管道输送工作介质10时，由介质喷嘴13供给的工作介质10为低电导率或绝缘的介质，工作介质10的形式为气体和/或液体，工作介质10在高电场场强下被击穿而产生电弧。When the working
为了实现快速加工制造，设备包括至少一套送丝模块1，金属丝2为多种材质及型号。In order to realize rapid processing and manufacturing, the equipment includes at least one set of wire feeding modules 1, and the
二、工作原理2. Working principle
参见图1，采用电弧6将金属丝2加热至外熔内固的半熔融状态，并采用逐层沉积的方式打印出工件，打印过程中内部固态金属丝2起到引导和支撑作用，方案不仅适应用重力环境，而且可用于微重力环境下的增材制造，并可在接触工件表面过程中施加一定的压力从而减少气孔并提高工件质量。Referring to Figure 1, the arc 6 is used to heat the
具体的，在控制系统9的指令下，送丝模块1将金属丝2送入出丝嘴3，电源4输出引弧电流击穿引弧模块5与金属丝2之间的工作介质10，并输出稳弧电流以保持形成的电弧6。在加工过程中，引弧模块5绕金属丝2旋转或仅金属丝2做旋转运动以达到金属丝2在圆周方向均获得加热效果，可替换的方案为引弧模块5的引弧部为环形布置并将金属丝围绕在中间，从而取消相对运动的附加装置；利用电弧等离子体的高温将金属丝2表面迅速熔化(但中间部分仍为固态)；工作时，金属丝2、电弧6、引弧模块5、电源4及送电附件12共同构成电弧放电回路；工件11及工作台7不属于放电回路。送丝模块1及出丝嘴3在运动机构8带动下沿预定轨迹运动并持续将具有固、液两相特征的金属丝2送出出丝嘴3到达加工工作台7的加工区域并施加作用力，金属丝2的表面熔融成分与工件11结合并冷却，完成一层或一条轨迹的打印后，运动机构8控制送丝模块1及出丝嘴3至下一层或下一条轨迹起始位置，重复上述打印过程，直至完成工件的打印。Specifically, under the instruction of the control system 9, the wire feeding module 1 feeds the
三、增材制造施工方法或步骤3. Additive manufacturing construction methods or steps
本发明还提供了一种金属半熔融堆积增材制造方法，方法包括以下步骤：The present invention also provides a metal semi-molten stacking additive manufacturing method, the method comprising the following steps:
①将要打印的工件三维模型在设计辅助软件进行分层切片，生成每层的预定轨迹并输送给控制系统9，控制系统9设定送丝速度和送丝压力以及电源4的供电参数；①The three-dimensional model of the workpiece to be printed is sliced in layers in the design auxiliary software, and the predetermined trajectory of each layer is generated and sent to the control system 9, and the control system 9 sets the wire feeding speed and wire feeding pressure and the power supply parameters of the
②出丝嘴3定位至加工初始位置，预热工作台7；② The wire nozzle 3 is positioned to the initial processing position, and the
③在控制系统9控制下，送丝模块1将金属丝2送入出丝嘴3金属丝2从送丝模块1进入出丝嘴3；③ Under the control of the control system 9, the wire feeding module 1 sends the
④金属丝2到达引弧模块5附近时，电源4发出引弧脉冲，工作介质10击穿形成电弧6；④ When the
⑤送丝模块1按设定速度持续送丝，金属丝2经出丝嘴3向工作台7进给，在此过程中电源4继续保持电流输出，同时引弧模块5绕出丝嘴3以设定速度旋转，电弧6持续加热金属丝2，使得金属丝2表面迅速熔化而中间部分仍为固态的固、液两相特征；⑤ The wire feeding module 1 continuously feeds the wire at the set speed, and the
⑥送丝模块1将外部被电弧熔化的金属丝2送入沉积区域，并施加一定压力，金属丝2冷却并与基体或工件11结合凝固；⑥ The wire feeding module 1 sends the
⑦保持送丝-加热过程，同时控制系统9控制运动机构8沿预定轨迹运动，直至此轨迹加工完成；⑦ Keep the wire feeding-heating process, while the control system 9 controls the
⑧送丝模块1停止送丝，切断金属丝2或通过电弧6将金属丝2熔断；⑧Wire feeding module 1 stops wire feeding, cuts off
⑨运动机构8到达下一条轨迹起点；⑨ The
⑩送丝模块1继续工作，重复步骤⑤-⑦，直至完成所有增材打印工作。⑩ Wire feed module 1 continues to work, and repeat steps ⑤-⑦ until all additive printing work is completed.
进一步的，在步骤③中，若选用的金属丝2自带产生保护气体的药皮，则不开启工作介质10的供给；若选用的金属丝2不带产生保护气体的药皮，则由介质管道向介质喷嘴13输送工作介质10，并由介质喷嘴13喷出工作介质10进入金属丝2和引弧模块5之间。Further, in step 3, if the selected
进一步的，在步骤⑤中，引弧模块5绕出丝嘴3以1000rpm的设定速度旋转。Further, in step ⑤, the arc striking module 5 rotates around the wire nozzle 3 at a set speed of 1000 rpm.
上述方案解决了目前金属增材制造中存在的不足和实际的制造需求，提出采用电弧加热金属丝至半熔融状态，并进行送丝堆积增材制造的方案，在此过程中可利用金属丝中间的固态相对已加工表面施加作用力以减少内部缺陷，提高加工时的运动精度以及工件质量和加工效率。该方案采用电弧作为加热手段，而电弧的产生及施加的方式、金属丝的状态变化、成形过程中力的施加方式均有很大的创新，不仅适用于地面环境的金属增材制造，也是面向未来太空制造的一种新型增材制造方案。The above solution solves the current deficiencies in metal additive manufacturing and the actual manufacturing needs, and proposes the use of arc heating of the metal wire to a semi-molten state, and wire feeding and accumulation of additive manufacturing. In this process, the middle of the metal wire can be used. The solid state exerts a force against the machined surface to reduce internal defects, improve the motion accuracy during machining, as well as workpiece quality and machining efficiency. This scheme uses arc as a heating method, and the generation and application of the arc, the state change of the wire, and the application of force during the forming process are all very innovative. It is not only suitable for metal additive manufacturing in the ground environment, but also for metal additive manufacturing in the ground environment. A new additive manufacturing solution for future space manufacturing.
前述对本发明的具体示例性实施方案的描述是为了说明和例证的目的。这些描述并非想将本发明限定为所公开的精确形式，并且很显然，根据上诉教导，可以进行很多改变及变化。对示例性实施例进行选择和描述的目的在于解释本发明的特定原理及其实际应用，从而使得本领域的技术人员能够实现并利用本发明的各种不同的示例性实施方案以及各种不同的选择和改变，即根据以上描述的技术方案以及构思，本领域的技术人员能够做出其它各种相应的改变以及形变，而所有的这些改变以及形变都应该属于本发明权利要求的保护范围之内。The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. These descriptions are not intended to limit the invention to the precise form disclosed, and obviously many changes and variations are possible in light of the teachings appealed. The exemplary embodiments were chosen and described for the purpose of explaining certain principles of the invention and their practical applications, to thereby enable others skilled in the art to make and utilize various exemplary embodiments and various different aspects of the invention. Selection and change, that is, according to the technical solutions and ideas described above, those skilled in the art can make other various corresponding changes and deformations, and all these changes and deformations should belong to the scope of protection of the claims of the present invention .
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| CN118720382B (en)* | 2024-07-24 | 2025-09-16 | 华中科技大学 | Compression roller device, additive manufacturing equipment and additive manufacturing method |
| CN119261207A (en)* | 2024-10-18 | 2025-01-07 | 西安交通大学 | A coaxial dual-state in-situ material extrusion 3D printing interlayer reinforcement method |
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