Disclosure of Invention
In order to solve the technical problems, the application provides a manufacturing method of a binder-sprayed metal 3D printing airfoil surface.
The application is realized by the following technical scheme.
The application provides a manufacturing method of a binder spraying metal 3D printing airfoil surface, which is characterized in that the airfoil surface is divided into an upper die and a lower die, the upper die is a skin, the lower die is formed by 3D printing, and the process steps of the lower die are as follows:
s1, slicing the lower die model in a Magics software layer by layer, and obtaining contour data of each layer of section and a filling scanning path;
s2, printing equipment prints by using alloy powder to obtain a lower die primary blank;
s3, pre-sintering the lower die primary blank at a low temperature;
s4, performing high-temperature sintering;
and S5, polishing the plane of the lower die in the direction of the framework smoothly, and welding the upper die on the upper die.
And the thickness of each layer of the layered slice is 0.05-0.09mm, and the three-dimensional model of the upper die is divided from bottom to top.
The printing process of the printing equipment is as follows:
s21, adding alloy powder into a powder bin;
s22, pushing alloy powder to a printing bin by a leveling rod to form a powder layer;
s23, the ink-jet head sprays resin alloy powder for bonding according to the shape of the slice, and printing of one slice is completed;
s24, descending the printing bin by 0.05-0.09mm;
s25, repeating the steps S22-S24 until the printing of the primary blank is completed.
The moving speed of the leveling roller is 18-24mm/s, the thickness of the powder layer is 0.05-0.09mm, the ink jet quantity of the ink jet head is 40-45 mu l each time, the concentration of the resin is 22-25%, and the viscosity/tension ratio of the resin is 2.5/23.
The alloy powder comprises the following components in percentage by mass: 52.6%, nb:5.25%, mo:3.19%, cr:19.47%, al:0.51%, ti:0.91%, co:0.01%, B: < 0.005%, si:0.11%, mn: less than 0.005%, mg:0.0093%, C:0.024%, S: less than 0.003%, P less than 0.005%, fe: bal.
The particle size of the alloy powder is less than 25 mu m.
The low-temperature presintering is preceded by baking the primary blank for 4 hours at 20 ℃ and then sintering for 4 hours at 180-220 ℃.
The high-temperature sintering is carried out by heating at a wave band, firstly, heating to 250 ℃ at a speed of 3.5-4 ℃/min, preserving heat for 30min, then heating to 550 ℃ at a speed of 3.5-4 ℃/min, preserving heat for 50mmin, heating to 980 ℃ at a speed of 4-4.5 ℃/min, preserving heat for 50min, heating to 1250 ℃ at a speed of 5-5.5 ℃/min, preserving heat for 60min, heating to 1320 ℃ at a speed of 1.5-2 ℃/min, preserving heat for 120min, cooling to 1050 ℃ at a speed of 2.5-3 ℃/min, preserving heat for 90min, cooling to 750 ℃ at a speed of 1.7-2 ℃/min, preserving heat for 60min, cooling to 450 ℃ at a speed of 2.5-3 ℃/min, preserving heat for 50min, cooling to 120 ℃ at a speed of 3.5-4 ℃/min, preserving heat for 30min, and cooling to room temperature. In the furnace temperature rising process, the actual temperature of the part area needs a certain rising time at the temperature of the thermocouple displayed by the furnace temperature, if the rising of the temperature wave band is not adopted, the situation that the heated temperature of the part in the furnace does not reach the use display temperature, and the part does not reach the effect of complete sintering can occur. In the cooling process, if the cooling rate is too high, the deformation of the part can be caused, so that the sintering of the part fails. In the high-temperature sintering process, the adhesive resin overflows from the airfoil surface in a high-temperature environment, is pumped out of the furnace along with the vacuumizing process, and meanwhile, metal powder is metallurgically bonded in the high-temperature environment to form a compact solid airfoil surface part.
BNi82CrSiB solder is used in the welding process, the brazing temperature is 1105-1120 ℃, the brazing time is 30-50 min, and the brazing gap is 15-23 mu m.
The application has the beneficial effects that: by using the binder to spray the metal 3D printing technology, each slice does not need to be melted and formed, the airfoil is formed rapidly by using a bonding mode, then the compactness of the skeleton inside the airfoil is ensured by a sintering process, and compared with the traditional process, the working procedure and the processing time are reduced, and the processing cost is reduced.
Detailed Description
The technical solution of the present application is further described below, but the scope of the claimed application is not limited to the above.
A manufacturing method of a binder spraying metal 3D printing airfoil surface divides the airfoil surface into an upper die and a lower die, wherein the upper die is a skin, the lower die is formed by 3D printing, and the lower die comprises the following process steps:
s1, slicing the lower die model in a Magics software layer by layer, and obtaining contour data of each layer of section and a filling scanning path;
s2, printing equipment prints by using alloy powder to obtain a lower die primary blank;
s3, pre-sintering the lower die primary blank at a low temperature;
s4, performing high-temperature sintering;
and S5, polishing the plane of the lower die in the direction of the framework smoothly, and welding the upper die on the upper die.
And the thickness of each layer of the layered slice is 0.05-0.09mm, and the three-dimensional model of the upper die is divided from bottom to top.
The printing process of the printing equipment is as follows:
s21, adding alloy powder into a powder bin;
s22, pushing alloy powder to a printing bin by a leveling rod to form a powder layer;
s23, the ink-jet head sprays resin alloy powder for bonding according to the shape of the slice, and printing of one slice is completed;
s24, descending the printing bin by 0.05-0.09mm;
s25, repeating the steps S22-S24 until the printing of the primary blank is completed.
The moving speed of the leveling roller is 18-24mm/s, the thickness of the powder layer is 0.05-0.09mm, the ink jet quantity of the ink jet head is 40-45 mu l each time, the concentration of the resin is 22-25%, and the viscosity/tension ratio of the resin is 2.5/23.
The alloy powder comprises the following components in percentage by mass: 52.6%, nb:5.25%, mo:3.19%, cr:19.47%, al:0.51%, ti:0.91%, co:0.01%, B: < 0.005%, si:0.11%, mn: less than 0.005%, mg:0.0093%, C:0.024%, S: less than 0.003%, P less than 0.005%, fe: bal.
The particle size of the alloy powder is less than 25 mu m.
The low-temperature presintering is preceded by baking the primary blank for 4 hours at 20 ℃ and then sintering for 4 hours at 180-220 ℃.
The high-temperature sintering is carried out by heating at a wave band, firstly, heating to 250 ℃ at a speed of 3.5-4 ℃/min, preserving heat for 30min, then heating to 550 ℃ at a speed of 3.5-4 ℃/min, preserving heat for 50mmin, heating to 980 ℃ at a speed of 4-4.5 ℃/min, preserving heat for 50min, heating to 1250 ℃ at a speed of 5-5.5 ℃/min, preserving heat for 60min, heating to 1320 ℃ at a speed of 1.5-2 ℃/min, preserving heat for 120min, cooling to 1050 ℃ at a speed of 2.5-3 ℃/min, preserving heat for 90min, cooling to 750 ℃ at a speed of 1.7-2 ℃/min, preserving heat for 60min, cooling to 450 ℃ at a speed of 2.5-3 ℃/min, preserving heat for 50min, cooling to 120 ℃ at a speed of 3.5-4 ℃/min, preserving heat for 30min, and cooling to room temperature.
BNi82CrSiB solder is used in the welding process, the brazing temperature is 1105-1120 ℃, the brazing time is 30-50 min, and the brazing gap is 15-23 mu m.
Example 1, as shown in fig. 2, shows an airfoil structure of the present application, which is divided into an upper mold and a lower mold during processing, the upper mold is a skin, the lower mold is provided with a supporting framework, the lower mold is formed by injecting a metal through 3D printing,
the alloy powder comprises the following components in percentage by mass: 52.6%, nb:5.25%, mo:3.19%, cr:19.47%, al:0.51%, ti:0.91%, co:0.01%, B: < 0.005, si:0.11%, mn: less than 0.005%, mg:0.0093%, C:0.024%, S: less than 0.003%, P less than 0.005%, fe: bal;
during processing, the three-dimensional model of the airfoil lower die is converted into an STL format and is imported into Magics software for layering and slicing, the layering thickness is set to be 0.05mm, the three-dimensional model is divided from bottom to top, a division schematic diagram is shown in fig. 3, the three-dimensional model is divided into two-dimensional interfaces, profile data of each section and filling scanning paths are obtained, and adhesive is selectively sprayed on the sheet model from bottom to top in the printing process, so that the three-dimensional part is stacked.
And then, importing the sliced three-dimensional model, the profile data of each section and the filling scanning path into printing equipment, adding the dried powder into a powder bin, importing the model data which are sliced in layers into computer control software, and starting the adhesive jet printing of the airfoil model part.
The printing process is as follows: 1. pushing powder from the powder bin to the print bin by movement of the leveling roller;
2. the ink jet head moves and sprays resin to bond powder through a filling scanning path obtained by slicing data of software; resin concentration: 22%, ink amount: 40ul, leveling roller moving speed: 18mm/s, powder layer thickness: 0.05mm, viscosity/tension ratio of resin: 2.5/23.
3. After the printing of the previous layer is completed, the forming bin descends by 0.05mm, the leveling roller pushes powder from the powder bin to the printing bin, and the printing of the next layer is started until the printing of the part is completed.
And (3) sintering at low temperature: and after printing, baking the primary blank for 4 hours at 20 ℃, drying the resin, then sintering for 4 hours at a low temperature of 180 ℃, and cleaning alloy powder on the primary blank.
High-temperature sintering: firstly, the temperature is raised to 250 ℃ at the speed of 3.5 ℃/min, the temperature is kept for 30min, then the temperature is raised to 550 ℃ at the speed of 3.5 ℃/min, the temperature is kept for 50mmin, the temperature is raised to 980 ℃ at the speed of 4 ℃/min, the temperature is kept for 50min, the temperature is raised to 1250 ℃ at the speed of 5 ℃/min, the temperature is kept for 60min, the temperature is raised to 1320 ℃ at the speed of 1.5 ℃/min, the temperature is kept for 120min, the temperature is lowered to 1050 ℃ at the speed of 2.5 ℃/min, the temperature is kept for 90min, the temperature is lowered to 750 ℃ at the speed of 1.7 ℃/min, and the temperature is lowered to room temperature at room temperature.
Brazing: after the airfoil surface part is sintered and taken out, firstly polishing a plane of the airfoil surface towards the skeleton direction to be smooth, then adopting BNi82CrSiB solder to weld the other half of the airfoil surface with the airfoil surface, wherein the welding parameters are that the welding temperature is 1105 ℃, the brazing time is 30min, the brazing gap is 15 mu m, and finally the airfoil surface part product is formed after the brazing is finished, and the compactness of the lower die is 92% after testing.
Example 2, using the same three-dimensional model and alloy soot material as in example 1,
and during processing, converting the three-dimensional model of the airfoil lower die into an STL format, and importing the STL format into Magics software for layering and slicing, wherein the layering thickness is set to be 0.07mm.
And then, importing the sliced three-dimensional model, the profile data of each section and the filling scanning path into printing equipment, adding the dried powder into a powder bin, importing the model data which are sliced in layers into computer control software, and starting the adhesive jet printing of the airfoil model part.
The printing process is as follows: 1. pushing powder from the powder bin to the print bin by movement of the leveling roller;
2. the ink jet head moves and sprays resin to bond powder through a filling scanning path obtained by slicing data of software; resin concentration: 22%, ink amount: 42ul, leveling roller movement speed: 20mm/s, powder layer thickness: 0.07mm, viscosity/tension ratio of resin: 2.5/23.
3. After the printing of the previous layer is completed, the forming bin descends by 0.07mm, the leveling roller pushes powder from the powder bin to the printing bin, and the printing of the next layer is started until the printing of the part is completed.
And (3) sintering at low temperature: and after printing, baking the primary blank for 4 hours at 20 ℃, drying the resin, then sintering for 4 hours at a low temperature of 200 ℃, and cleaning alloy powder on the primary blank.
High-temperature sintering: firstly, the temperature is raised to 250 ℃ at the speed of 3.7 ℃/min, the temperature is kept for 30min, then the temperature is raised to 550 ℃ at the speed of 3.7 ℃/min, the temperature is kept for 50mmin, the temperature is raised to 980 ℃ at the speed of 4.2 ℃/min, the temperature is kept for 50min, the temperature is raised to 1250 ℃ at the speed of 5.3 ℃/min, the temperature is raised to 1320 ℃ at the speed of 1.8 ℃/min after the temperature is kept for 60min, the temperature is kept for 120min, the temperature is lowered to 1050 ℃ at the speed of 2.7 ℃/min, the temperature is kept for 90min, the temperature is lowered to 750 ℃ at the speed of 1.9 ℃/min, and the temperature is lowered to the room temperature under the room temperature condition.
Brazing: after the airfoil surface part is sintered and taken out, firstly, polishing a plane of the airfoil surface towards the skeleton direction to be smooth, then adopting BNi82CrSiB solder to weld the other half of the airfoil surface with the airfoil surface, wherein the welding parameters are that the welding temperature is 1110 ℃, the brazing time is 45min, the brazing gap is 20 mu m, and finally the airfoil surface part product is formed after the brazing is finished, and the compactness of the lower die is 95% after testing.
Example 3, using the same three-dimensional model and alloy soot material as in example 1,
and during processing, converting the three-dimensional model of the airfoil lower die into an STL format, and importing the STL format into Magics software for layering and slicing, wherein the layering thickness is set to be 0.09mm.
And then, importing the sliced three-dimensional model, the profile data of each section and the filling scanning path into printing equipment, adding the dried powder into a powder bin, importing the model data which are sliced in layers into computer control software, and starting the adhesive jet printing of the airfoil model part.
The printing process is as follows: 1. pushing powder from the powder bin to the print bin by movement of the leveling roller;
2. the ink jet head moves and sprays resin to bond powder through a filling scanning path obtained by slicing data of software; resin concentration: 25% of ink: 45ul, leveling roller moving speed: 24mm/s, powder layer thickness: 0.09mm, viscosity/tension ratio of resin: 2.5/23.
3. After the printing of the previous layer is completed, the forming bin descends by 0.09mm, the leveling roller pushes powder from the powder bin to the printing bin, and the printing of the next layer is started until the printing of the part is completed.
And (3) sintering at low temperature: and after printing, baking the primary blank for 4 hours at 20 ℃, drying the resin, then sintering for 4 hours at a low temperature of 220 ℃, and cleaning alloy powder on the primary blank.
High-temperature sintering: firstly, the temperature is raised to 250 ℃ at the speed of 4 ℃/min, the temperature is kept for 30min, then the temperature is raised to 550 ℃ at the speed of 4 ℃/min, the temperature is kept for 50mmin, the temperature is raised to 980 ℃ at the speed of 4.5 ℃/min, the temperature is raised to 1250 ℃ at the speed of 5.5 ℃/min after the temperature is kept for 50min, the temperature is raised to 1320 ℃ at the speed of 2 ℃/min after the temperature is kept for 60min, the temperature is lowered to 1050 ℃ at the speed of 3 ℃/min after the temperature is kept for 120min, the temperature is lowered to 750 ℃ at the speed of 2 ℃/min after the temperature is kept for 90min, and the temperature is lowered to room temperature under the room temperature condition.
Brazing: after the airfoil surface part is sintered and taken out, firstly polishing a plane of the airfoil surface towards the skeleton direction to be smooth, then adopting BNi82CrSiB solder to weld the other half of the airfoil surface with the airfoil surface, wherein the welding parameters are that the welding temperature is 1120 ℃, the brazing time is 50min, the brazing gap is 23 mu m, and finally the airfoil surface part product is formed after the brazing is finished, and the compactness of the lower die is 93% after testing.
Example 4 the airfoil lower mold was formed using the materials and process of example 3, sintered at different temperatures, first heated to 250deg.C at a rate of 4deg.C/min, held for 30min, then heated to 650deg.C at a rate of 4deg.C/min, held for 50mmin, heated to 1080deg.C at a rate of 4.5 deg.C/min, held for 50min, heated to 1340 deg.C at a rate of 5.5 deg.C/min, held for 60min, held for 120min, cooled to 950 deg.C at a rate of 3deg.C/min, held for 90min, cooled to 750deg.C at a rate of 2deg.C/min, and cooled to room temperature at room temperature. The zone of the airfoil lower die is collapsed. Tensile properties as shown in FIG. 6, it is seen that the tensile strength, yield strength, elongation are all higher than the sintered airfoil lower die of example 4 using the stage temperature rise and temperature of the present application of example 3.
Table 1 comparison of lower die properties of sintered airfoils for example 3 and example 4
| Temperature (. Degree. C.) | Tensile strength (MPa) | Yield strength (MPa) | Elongation (%) |
| Example 4 | 750.53 | 560.13 | 14.30％ |
| Example 3 | 870.35 | 756.67 | 8.02％ |