阅读说明：本技术 一种激光诱导电弧震荡的多丝同步增材制造方法 (Multi-wire synchronous additive manufacturing method for laser-induced arc oscillation ) 是由 毕江 董国疆 赵长财 陈�光 于 2021-06-28 设计创作，主要内容包括：本发明公开了一种激光诱导电弧震荡的多丝同步增材制造方法。先设置激光器的激光功率、电弧焊机的电弧电流、保护气体流量、激光电弧间距和激光束摆动模式；之后根据焊丝直径确定焊丝的送丝速度,固定基板,调整激光器的激光头与基板之间的距离,再将激光器与电弧焊机的焊枪固定,调整所有焊丝的送进角度；通过激光束的周期性摆动,吸引电弧做规律性震荡,增大熔池尺寸和流动性,有利于多个焊丝熔化后熔滴进入熔池,提升增材过程的稳定性；结合激光摆动-电弧震荡的晶粒细化效果,显著提升增材效率的同时,提升了增材零件的力学性能和使役性能。(The invention discloses a multi-wire synchronous additive manufacturing method for laser-induced arc oscillation. Firstly, setting laser power of a laser, arc current of an arc welding machine, flow of protective gas, laser arc space and a laser beam swing mode; then determining the wire feeding speed of the welding wire according to the diameter of the welding wire, fixing the base plate, adjusting the distance between a laser head of the laser and the base plate, fixing the laser and a welding gun of the arc welding machine, and adjusting the feeding angles of all the welding wires; through the periodic oscillation of the laser beam, the electric arc is attracted to perform regular oscillation, the size and the fluidity of a molten pool are increased, a plurality of molten drops of the welding wires after being melted can enter the molten pool, and the stability of the material increase process is improved; by combining the grain refinement effect of laser oscillation-arc oscillation, the mechanical property and the labor-operating property of the additive part are improved while the additive efficiency is remarkably improved.)

1. A multi-wire synchronous additive manufacturing method for laser-induced arc oscillation is characterized by comprising the following steps of:

setting initial parameters; the initial parameters comprise laser power of a laser, arc current of an arc welding machine, flow of protective gas, laser arc distance and a laser beam swing mode;

determining the wire feeding speed of each welding wire according to different welding wire diameters;

fixing the polished substrate on a tool clamp, and adjusting the distance between a laser head of the laser and the substrate to enable the defocusing amount to be within a set range;

fixing a laser head of the laser with a welding gun of the electric arc welding machine according to the laser arc distance;

adjusting the feeding angles of all welding wires, wherein the feeding angles and the laser beams are distributed in an equal-angle annular shape;

controlling the arc striking of the welding gun according to the arc current, and controlling the laser to emit laser according to the laser power after the arc striking is carried out for a set time;

synchronously feeding a plurality of welding wires into a molten pool according to the wire feeding speed, adding protective gas according to the flow of the protective gas, and then performing additive manufacturing; the molten pool is a base material part which is melted into a pool shape due to welding arc heat;

and controlling the laser to swing according to the swing mode by using a welding robot so that the welding gun is periodically vibrated along with the laser.

2. The laser-induced arc oscillation multi-wire synchronous additive manufacturing method according to claim 1, wherein the arc welder performs additive manufacturing by using a non-metal inert gas (TIG) process, a Metal Inert Gas (MIG) process or a Cold Metal Transition (CMT) process.

3. The method of claim 1, wherein the welding wire is selected according to the alloy composition of the substrate, and the shielding gas is selected according to the material type of the welding wire.

4. The laser-induced arc oscillation multi-filament synchronous additive manufacturing method according to claim 1, wherein the laser power is 2000-5000W, the arc current is 50-200A, the laser arc interval is 2-5 mm, and the flow rate of the protective gas is 20-40L/min.

5. The laser-induced arc oscillation multi-wire synchronous additive manufacturing method according to claim 1, wherein the wire feeding speed is matched to be 0.5-8 m/min according to the diameter of the welding wire; the diameter of the welding wire is 0.8-2.4 mm.

6. The method of claim 1, wherein the laser beam oscillation mode is a line, a line 8, or an O-shape.

7. The method according to claim 1, wherein the substrate is an aluminum alloy substrate with dimensions of 400mm x200mm x20 mm.

8. The method of claim 1, wherein the laser is a fiber laser.

9. The method of claim 1, wherein the substrate is separated from the printed component by wire cutting after the component is printed.

Technical Field

The invention relates to the technical field of additive manufacturing, in particular to a multi-wire synchronous additive manufacturing method for laser-induced arc oscillation.

Background

With the development of the aviation industry, the components gradually tend to be light in weight, personalized in shape and integrated in structural function, and complicated aviation components are manufactured by adopting the traditional machining technology, so that the process is multiple, the machining period is long, and the machining precision and the service performance of parts are difficult to ensure. The processing problem is well solved by the additive manufacturing technology (3D printing), and the additive manufacturing technology can be used for laminating aviation complex components from bottom to top, so that the processing precision and the forming efficiency of parts can be greatly improved; the utilization rate of the raw materials is close to one hundred percent, and the material waste is avoided; the printed parts can be directly used only by a small amount of surface treatment, and the method has obvious advantages for processing and manufacturing small-batch complex parts in the aviation industry.

At present, the metal additive manufacturing technology mainly comprises a fuse wire additive manufacturing technology taking wire materials as raw materials and a powder feeding and powder laying additive manufacturing technology taking powder as raw materials. The fuse wire additive manufacturing technology has the advantages of unlimited processing size, good printing effect and the like, and has wide application prospect in the manufacturing of large and complicated aviation components. The fuse additive manufacturing technology is mainly classified into a laser fuse, an arc fuse and an electron beam fuse according to a difference of a heat source. Among them, laser fuses and arc fuses are widely used because of their high efficiency, low equipment cost, easy automation, and the like. However, the laser fuse wire additive has higher requirement on equipment precision, while the arc fuse wire additive has shallower melting depth and lower welding efficiency.

Disclosure of Invention

The invention provides a multi-wire synchronous additive manufacturing method for laser-induced arc oscillation, which aims to improve additive manufacturing efficiency, mechanical properties and service performance of additive parts.

In order to achieve the purpose, the invention provides the following scheme:

a method of laser-induced arc oscillation multi-filament synchronous additive manufacturing, the method comprising:

setting initial parameters; the initial parameters comprise laser power of a laser, arc current of an arc welding machine, flow of protective gas, laser arc distance and a laser beam swing mode;

determining the wire feeding speed of each welding wire according to different welding wire diameters;

fixing the polished substrate on a tool fixture, and adjusting the distance between a laser head of the laser and the substrate to enable the defocusing amount to be within a set range;

fixing a laser head of the laser and a welding gun of the electric arc welding machine according to the laser arc distance;

adjusting the feeding angles of all welding wires, wherein the feeding angles and the laser beams are distributed in an equal-angle annular shape;

controlling the arc striking of the welding gun according to the arc current, and controlling the laser to emit laser according to the laser power after the arc striking is carried out for a set time;

synchronously feeding a plurality of welding wires into a molten pool according to the wire feeding speed, adding protective gas according to the flow of the protective gas, and then performing additive manufacturing; the molten pool is a base material part which is melted into a pool shape due to welding arc heat;

and controlling the laser to swing according to the swing mode by using a welding robot so that the welding gun is periodically vibrated along with the laser.

Preferably, the electric arc welder is additive manufactured using a non-TIG, MIG or CMT process.

Preferably, the welding wire is selected according to the alloy composition of the base plate, and the shielding gas is selected according to the material type of the welding wire.

Preferably, the laser power is 2000-5000W, the arc current is 50-200A, the laser arc distance is 2-5 mm, and the flow of the protective gas is 20-40L/min.

Preferably, the wire feeding speed is matched to be 0.5-8 m/min according to the diameter of the welding wire; the diameter of the welding wire is 0.8-2.4 mm.

Preferably, the laser beam wobble pattern is in-line, 8-line or O-line.

Preferably, the substrate is an aluminum alloy substrate, and the substrate size is 400mm x200mm x20 mm.

Preferably, the laser is a fiber laser.

Preferably, after printing the component, the substrate is separated from the printing component by wire cutting.

According to the specific embodiment provided by the invention, the invention discloses the following technical effects:

the invention discloses a multi-wire synchronous additive manufacturing method for laser-induced arc oscillation, which attracts an electric arc to perform regular oscillation through the periodic oscillation of a laser beam, can obviously increase the size and the fluidity of a molten pool, is beneficial to a plurality of molten drops of welding wires to enter the molten pool after being melted and improves the stability of an additive process; and by simultaneously feeding a plurality of metal wires, chemical components of the additive alloy can be effectively regulated and controlled through the selection of the metal wire types and the change of the wire feeding speed, and the mechanical property and the labor performance of the additive part can be improved while the additive efficiency is remarkably improved by combining the grain refining effect of laser oscillation-electric arc oscillation.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.

Fig. 1 is a flowchart of a multi-filament synchronous additive manufacturing method of laser-induced arc oscillation according to embodiment 1;

FIG. 2 is a schematic diagram of laser-induced arc oscillation multi-filament synchronous additive repair;

FIG. 3 is a comparison graph of microstructures of an electric arc additive and multi-wire synchronous additive aluminum alloy part;

FIG. 4 is a comparison graph of air hole defects of an aluminum alloy part subjected to laser additive and multi-wire synchronous additive.

Description of the symbols:

1-shielding gas, 2-laser head, 3-welding wire, 4-electric arc, 5-substrate, 6-molten pool and 7-printing part.

Detailed Description

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, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

The purpose of the invention is

In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.

Example 1

As shown in fig. 1, the present embodiment discloses a method for manufacturing a multi-filament synchronous additive for laser-induced arc oscillation, the method comprising:

s1: setting the laser power of the laser, the arc current of the arc welding machine, the flow of the protective gas, the laser arc distance and the laser beam swing mode.

S2: and determining the wire feeding speed of each welding wire according to different diameters of the welding wires.

S3: and fixing the polished substrate on a tool clamp, and adjusting the distance between a laser head of the laser and the substrate to enable the defocusing amount to be within a set range.

S4: and fixing a laser head of the laser and a welding gun of the electric arc welding machine according to the laser arc distance.

S5: the feeding angles of all welding wires are adjusted to be distributed in an equal angle ring shape with the laser beams.

S6: and controlling the arc striking of the welding gun according to the arc current, and controlling the laser to emit laser according to the laser power after the arc striking is carried out for a set time.

S7: and synchronously feeding a plurality of welding wires into the molten pool according to the wire feeding speed, adding shielding gas according to the flow of the shielding gas, and then performing additive manufacturing.

S8: and controlling the laser to swing according to the swing mode by using a welding robot so that the welding gun is periodically vibrated along with the laser.

Specifically, the electric arc welder uses non-metal inert gas welding TIG, metal inert gas welding MIG or cold metal transition CMT process for additive manufacturing, wherein the CMT welding is optimal because the droplet transition is more stable.

Specifically, the defocusing amount is-5 to +5 mm.

Specifically, welding wires are selected according to alloy components of the substrate, shielding gas is selected according to the material type of the welding wires, Ar protection is adopted for aluminum alloy, and N protection is adopted for stainless steel₂And protection, wherein the titanium alloy and the high-temperature alloy are protected by Ar or He.

Specifically, the laser power is 2000-5000W, the arc current is 50-200A, the laser arc distance is 2-5 mm, and the flow of the protective gas is 20-40L/min.

Specifically, the wire feeding speed is matched to be 0.5-8 m/min according to the diameter of the welding wire; the diameter of the welding wire is 0.8-2.4 mm.

Specifically, the laser beam swing pattern is in-line, 8-line, or O-line.

Specifically, after the printing of the member is completed, the substrate is separated from the printing member by wire cutting.

Example 2

As shown in fig. 2, the printed part can be subjected to additive repair by the method in example 1.

Setting the laser power of the laser, the arc current of the arc welding machine, the flow of the protective gas, the laser arc distance and the laser beam swing mode.

And determining the wire feeding speed of each welding wire according to different diameters of the welding wires.

Fixing the polished substrate 5 on a tool fixture, placing a printing part 7 to be repaired on the substrate 5, and adjusting the distance between the laser head 2 and the substrate 5 to enable the defocusing amount to be within a set range.

And fixing the laser head 2 with a welding gun of the electric arc welding machine according to the laser arc distance.

The feeding angles of all the welding wires 3 are adjusted to be distributed in an equal angle ring shape with the laser beams.

And controlling the arc striking 4 of the welding gun according to the arc current, and controlling the laser to emit laser according to the laser power after the arc striking is carried out for a set time.

And synchronously feeding a plurality of welding wires into the molten pool 6 according to the wire feeding speed, adding the shielding gas 1 according to the flow of the shielding gas, and then performing additive manufacturing.

And controlling the laser to swing according to the swing mode by using a welding robot so that the welding gun is periodically vibrated along with the laser.

The periodic oscillation is shown in fig. 2 (b).

The method is typically used for repairing worn parts, such as aircraft blades.

Example 3

A 6061 aluminum alloy substrate was additively manufactured using the method of example 1.

Fixing the polished 6061 aluminum alloy substrate on a tool clamp, wherein the size of the substrate is 400mm x200mm x20mm, and adjusting the distance between a laser head and the substrate to enable the defocusing amount to be +2 mm.

And secondly, selecting ER5556, ER5087 and ER4047 welding wires with the diameter of 1.2mm, fixing the laser head and the welding gun by using a special clamp, and adjusting the feeding angle of the welding wires to form equal-angle annular distribution with the laser beams.

Setting process parameters including setting laser power to 3000W, setting arc current to about 100A, setting laser arc space to 3mm, selecting Ar gas as protective gas, setting flow to 30L/min, and setting wire feeding speed to 2m/min, 2m/min and 0.5m/min respectively.

And step four, adjusting the laser beam swing mode to be an 8-shaped mode.

And fifthly, controlling welding by the welding robot according to technological parameters, firstly carrying out arc striking, then controlling the laser to emit laser and start wire feeding after the arc is stabilized for 2s, and controlling the laser head and the welding gun to move together to finish the additive manufacturing process.

Example 4

The TC4 titanium alloy substrate was additively manufactured using the method of example 1.

Fixing the polished TC4 titanium alloy substrate on a tool fixture, wherein the size of the substrate is 400mm x200mm x12mm, and adjusting the distance between a laser head and the substrate to enable the defocusing amount to be-1 mm.

And secondly, selecting ER1100, ERTi-1 and SA14047 welding wires with the diameter of 1.0mm, fixing a laser head and a welding gun by using a special clamp, and adjusting the feeding angle of the welding wires to form equal-angle annular distribution with the laser beams.

Setting process parameters including setting laser power to 4000W, setting arc current to 120A, setting laser arc space to 4mm, selecting Ar gas as protective gas, setting flow to 25L/min, and setting wire feeding speed to 1m/min, 1m/min and 2m/min respectively.

And step four, adjusting the laser beam swing mode to be an O-shaped mode.

And fifthly, controlling welding by the welding robot according to technological parameters, firstly carrying out arc striking, then controlling the laser to emit laser and start wire feeding after the arc is stabilized for 2s, and controlling the laser head and the welding gun to move together to finish the additive manufacturing process.

Comparing the arc additive manufacturing method, the laser additive manufacturing method and the multi-wire synchronous additive manufacturing method in the embodiment 1, the method can achieve the following advantages: .

Fig. 3 (a) is a microstructure diagram of additive manufacturing using an arc, and fig. 3 (b) is a microstructure diagram of additive manufacturing using the method in example 1. Comparing the microstructure of the aluminum alloy parts in (a) and (b) in 3, it can be found that the grain size of the alloy is obviously refined by adopting the method, and the mechanical property of the member can be obviously improved by the fine-grain strengthening effect.

Fig. 4 (a) is a diagram of a void defect produced by additive manufacturing using a laser, and fig. 4 (b) is a diagram of a void defect produced by additive manufacturing using the method of example 1. Comparing the air hole defects of the aluminum alloy parts in (a) and (b) in FIG. 4, it can be found that the inside of the alloy has no air hole defects basically by adopting the method.

TABLE 1 comparison table of mechanical properties

Method of implementation	Tensile Properties (part 1)	Tensile Property (part 2)	Tensile Property (part 3)
				Laser-electric arc	321MPa	309MPa	313MPa
Electric arc	240MPa	241MPa	227MPa
				Laser	251MPa	243MPa	239MPa

As can be seen from table 1, the tensile properties of the material can be enhanced by using the laser-arc welding method (i.e. the laser-induced arc oscillation multi-filament synchronous additive manufacturing method of the present application).

The embodiment discloses a multi-wire synchronous additive manufacturing method for laser-induced arc oscillation, wherein the arc is attracted to perform regular oscillation through the periodic oscillation of a laser beam, so that the size and the fluidity of a molten pool can be remarkably increased, molten drops can enter the molten pool after a plurality of welding wires are melted, and the stability of an additive process is improved; and by simultaneously feeding a plurality of metal wires, chemical components of the additive alloy can be effectively regulated and controlled through the selection of the metal wire types and the change of the wire feeding speed, and the mechanical property and the service performance of printing parts can be improved while the additive efficiency is remarkably improved by combining the grain refining effect of laser oscillation-electric arc oscillation.

The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to assist in understanding the core concepts of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.