Method and device for preparing permalloy through Fe and Ni double wires

Abstract

The invention discloses a method and a device for preparing permalloy through Fe and Ni double wires, plasma additive manufacturing of the permalloy is carried out by adjusting wire feeding of the Fe wires and the Ni wires, and the permalloy with the low Ni content, the medium Ni content and the high Ni content can be obtained. The plasma arc is used as a heat source, wire feeding of the two wire guide cylinders in the clamping device is stable and reliable, the intersection point of double wires is stabilized in the center of the plasma arc in the additive manufacturing process, the wires can be effectively melted, material components of the wires can be well combined, and the component proportion of a sample is controlled through different wire feeding speeds. The processing range of sample preparation is large, the processing speed is high, and large permalloy parts with coarse grains in the material and good magnetic performance can be effectively prepared.

Description

Technical Field

[0001] The present invention relates to the technical field of permalloy preparation, and more specifically, to a method and device for preparing permalloy from Fe and Ni double wires. Background Art

[0002] Permalloy is a soft magnetic material based on Fe and Ni, with characteristics such as high magnetic permeability, high saturation magnetostriction, low magnetic energy loss, low coercivity, and constant magnetic permeability varying with temperature. Therefore, it is widely used in electronic equipment shielding, signal shielding protective covers in the aerospace and military fields. The traditional preparation method of permalloy is to use melting, casting and inlaying, and it is necessary to design the required models and structural parts. This method is time-consuming, laborious and costly, and still cannot meet the development of green and high-end magnetic performance materials. The traditional powder metallurgy casting and machining methods require secondary processing such as precision machining, grinding and drilling, and it is difficult to achieve mass production of micro and complex-shaped magnetic components. In addition, the traditional preparation process has disadvantages such as high energy consumption, large pollution and low production capacity, and cannot meet the demand for improving the overall economic benefits of high-tech industries. Therefore, using high-efficiency additive manufacturing technology to manufacture permalloy has broad development prospects.

[0003] For existing additive manufacturing technologies, for permalloy, additive manufacturing technologies using laser as the heat source, such as selective laser melting (SLM) and laser near-net shaping (LENS), are mostly used. Additive manufacturing is carried out by powder feeding or powder spreading methods, and generally has disadvantages such as low powder utilization rate, low deposition efficiency, high process cost, limited size of formed parts, and difficult control of forming defects, which greatly limit the application of permalloy in industrial production.

[0004] Chinese Patent [CN 112517659 B] proposes a method for processing titanium alloy wires for high-quality plasma arc / arc additive manufacturing, but it has not yet involved additive manufacturing using double wires. At the same time, Chinese Patent [CN 109759588A] proposes a rapid manufacturing method for manufacturing a large bimetallic part by combining the plasma arc additive process with the selective laser melting forming process, and has not yet involved the process of preparing magnetic materials with double wires.

[0005] Chinese Patent [CN 110722249 A] proposes a method for bimetallic arc additive manufacturing using a plasma heat source. The two wires of the bimetallic material used are nickel-based Inconel718 and copper-based ERCu welding wires, and it does not propose to prepare permalloy specimens using Fe wires and Ni wires.

[0006] Chinese Patent [CN 113352012 A] proposes a bypass plasma arc twin composite additive manufacturing device and method. This method effectively proves that the additive manufacturing device and method using plasma double wire composite can effectively improve the cladding rate. However, the two conductive nozzles involved in this method are not on the same horizontal line, and there are slightly differences in the height and angle of the welding wire with respect to the substrate, which is not suitable for preparing permalloy specimens with relatively uniform micro dimensions.

[0007] Chinese Patent [CN 108067715 B] proposes a robot plasma arc double cold wire feeding automatic additive manufacturing method and device. The wire feeding nozzles in the patent are placed side by side, and the position of the wire feeding nozzle can be adjusted. Although it ensures that the welding wires are melted into a molten pool simultaneously, the device is too heavy and prone to vibration during the additive manufacturing process, which affects the uniformity of dissimilar metal additive manufacturing. Therefore, it is not suitable for the additive manufacturing of double wire permalloy. Summary of the Invention

[0008] Aiming at the deficiencies of the existing technology, the present invention provides a method and device for preparing permalloy with Fe and Ni double wires, which can use plasma arc to deposit pure Fe wire and pure Ni wire to generate a high-temperature free arc with highly concentrated energy, enabling the double wires to be rapidly melted and deposited in a short time. At the same time, the feeding of the wire materials can be stably controlled, making its processing efficiency high, cost low, processing range large, and enabling the preparation of permalloy for large quantities of large parts.

[0009] To achieve the above object, the present invention provides the following technical solutions: A method for preparing permalloy with Fe and Ni double wires, characterized by including the following steps

[0010] 1) Select Fe wire and Ni wire with a diameter of 1.2 mm and a purity greater than 99.9%; select a 304 stainless steel plate as the substrate;

[0011] 2) Pretreat the substrate, grind it with sandpaper, and then wipe the surface with alcohol to remove surface oil stains and oxides;

[0012] 3) Grind the tip of the tungsten electrode in the plasma welding torch to be sharp and smooth, ensure that the tip of the tungsten electrode is retracted about 1 mm inside the muzzle of the welding torch, and ensure that the axis of the tungsten electrode is perpendicular to the ground. The muzzle of the welding torch needs to be kept clean;

[0013] 4) Fix the pretreated substrate in the center of the workbench with a fixture. The Fe wire and Ni wire are respectively loaded into two wire feeding mechanisms. Through wire feeding, the intersection point of the two wire materials is located directly below the tungsten electrode, ensuring that this wire material intersection point can be melted at the center of the plasma arc during welding;

[0014] 5) Determine the process parameters by calculation, including: wire feeding speed, welding current, welding torch traveling speed, ion gas flow rate, shielding gas flow rate, and extension length;

[0015] 6) Draw the deposition path through CAD, export the corresponding program through welding software, and copy it to a USB flash drive for backup;

[0016] 7) Connect and start all experimental equipment and devices, and set the position of the plasma welding torch to the reset state;

[0017] 8) Input all preset process parameters and import the deposition path in the USB flash drive into the robot control cabinet;

[0018] 9) Start the running program. After the welding torch reaches the specified starting arc position, the plasma controller sends an arc starting signal, and use the high-frequency arc starting method to start a small arc at a safe position;

[0019] 10) Confirm that the arc starting is smooth and the center of the small arc is exactly opposite to the intersection of the two wires. The welding torch descends 30 mm in height to the specified safe position within 5 s. After waiting for 0.3 s, the shielding gas system outputs the shielding gas flow rate and ion gas flow rate that match the set values. At the same time, the small arc turns into a stable welding plasma arc. The robot control cabinet sends a control signal to the two-wire coordination controller to the two wire feeders, and the two wire materials start to be fed into the center of the plasma arc at the same time, and then the deposition is carried out according to the preset program;

[0020] 11) After the single-layer deposition is completed, the robot control cabinet sends a control signal to the two-wire coordination controller to stop the wire feeding of the two wire feeders. After waiting for 0.2 s, the plasma controller sends a signal to turn off the plasma arc. After waiting for 1 s, the gas supply module stops spraying the shielding gas. Then the welding torch moves up 30 mm to the safe position. The interlayer cooling time for each deposition layer is 5 min - 15 min. Measure the deposition height of this layer to confirm whether the preset deposition height of the next layer in the program is appropriate. If it is not appropriate, adjust the parameters, and then you can prepare to start the next layer of deposition;

[0021] 12) Repeat steps 10) and 11) in a loop until the required number of deposition layers is completed. After waiting for sufficient cooling time, loosen the substrate fixture, remove the specimen and polish the surface with an angle grinder to obtain a permalloy part.

[0022] The present invention is further set as: all the preset process parameters include: welding current 60 - 150 A, wire feeding speed 0.6 - 1.5 m / min, welding torch traveling speed 0.001 - 0.03 m / s, ion gas flow rate 0.5 - 1 L / min, shielding gas argon flow rate 15 - 20 L / min, the included angle between the Fe wire and the Ni wire is 15 - 20°; adjust the included angle between the welding wire and the substrate to 10 - 30°; adjust the extension length to 8 - 10 mm.

[0023] The present invention is further configured such that: the surfacing path includes:

[0024] Linear path: When programming, it is necessary to locate the linear positions of the starting arc point and the ending arc point, and the path is assisted by the welding program plug-in to generate the path.

[0025] Curvilinear path: When programming, it is necessary to calculate the radius of curvature, the length and width within the unit welding cycle, and the path is assisted by the welding program plug-in to generate the path.

[0026] The present invention further provides a device for preparing permalloy with Fe and Ni dual wires, characterized in that: the wire feeding mechanism includes a clamping device 1, the clamping device 1 is arranged on the welding arm of the robot, and the clamping device 1 is used for clamping the Fe wire and the Ni wire and controlling the included angle between the Fe wire and the Ni wire.

[0027] The present invention is further configured such that: the clamping device 1 includes a mounting seat 2, a rotatable first adjusting rod 3 and a second adjusting rod 4 are arranged on the mounting seat 2, wire guiding cylinders 5 are arranged at the ends of the first adjusting rod 3 and the second adjusting rod 4, the first adjusting rod 3 and the second adjusting rod 4 are linked by a sector gear, a second rotary encoder and a second motor are arranged on the first adjusting rod 3, and the second motor can drive the first adjusting rod 3 to rotate.

[0028] The present invention is further configured such that: a limiting cylinder 501 and a plurality of wire guiding pieces 502 distributed in a ring shape are arranged at the front end of the wire guiding cylinder 5, and the plurality of wire guiding pieces 502 are arranged inside the limiting cylinder 501.

[0029] The present invention is further configured such that: an annular air duct 7 is arranged between the wire guiding cylinder 5 and the limiting cylinder 501, a blowing device is arranged inside the clamping device 1, the blowing device is communicated with the annular air duct 7, and the blowing device is connected to an external protective gas feeding module for blowing out the protective gas.

[0030] The present invention is further configured such that: the clamping device 1 includes an adjusting seat 6, a rotating shaft 601 is arranged on the adjusting seat 6, a first rotary encoder and a first motor for driving the rotating shaft to rotate are arranged on the rotating shaft 601, and the mounting seat 2 is installed on the rotating shaft 601.

[0031] The present invention is further configured such that: the clamping device 1 further includes a controller, and the controller is electrically connected to the first rotary encoder, the second rotary encoder, the first motor and the second motor as follows:

[0032] In summary, the present invention has the following beneficial effects:

[0033] 1. Compared with the traditional process of using smelting and melting and laser powder melting to additively manufacture permalloy, the plasma arc can provide a higher energy density than traditional manufacturing methods, can quickly melt Fe and Ni materials, has better bonding, helps to improve the quality of the workpiece and reduce the processing time and cost.

[0034] 2. The double-wire feeding technology is adopted, and the processing can melt two wire materials simultaneously at the intersection of the double wires, effectively reducing the molten pool size to improve the forming speed and quality. At the same time, the cost of the wire materials is lower than that of metal powder, and the wire feeding speed can be directly changed according to requirements to flexibly control the component ratio of the workpiece.

[0035] 3. The clamping device can automatically adjust the wire to a specified angle, and at the same time, the wire angle is monitored in real time during the feeding process. When the wire angle deviation occurs, it can be automatically adjusted in a timely manner to ensure that the wire angle always remains within the specified angle range, and the feeding is stable, so that the intersection of the double wires is stably located at the center of the plasma arc during the surfacing process, the wire materials are effectively melted, and defects such as pores and cracks are greatly reduced.

[0036] 4. The clamping device in the wire feeding mechanism cooperates with the plasma arc robot to have a large processing range, and the workpiece can be formed quickly, and large-sized permalloy components can be prepared quickly and effectively. Brief Description of the Drawings

[0037] Figure 1 is a schematic diagram of the principle of the method of the present invention;

[0038] Figure 2 is a schematic diagram of the path of the method of the present invention;

[0039] Figure 3 is a schematic diagram of the welding test of the present invention;

[0040] Figure 4 is a schematic diagram of the overall structure of the clamping device of the device of the present invention;

[0041] Figure 5 is a schematic diagram of the linkage structure of the first adjusting rod and the second adjusting rod of the device of the present invention;

[0042] Figure 6 is a schematic diagram of the front-end structure of the wire guide tube of the device of the present invention.

[0043] Reference numerals: 1, clamping device; 2, mounting seat; 3, first adjusting rod; 4, second adjusting rod; 5, wire guide tube; 501, limiting tube; 502, wire guiding piece; 6, adjusting seat; 601, rotating shaft; 7, annular air duct. Detailed Description of the Invention

[0044] The present invention will be further described in detail below with reference to the accompanying drawings.

[0045] This embodiment discloses a method for preparing permalloy by using Fe and Ni double wires, as Figures 1-3 shown,

[0046] Embodiment 1:

[0047] It is possible to carry out the additive manufacturing test of permalloy with a curved path having a width of 15 mm - 18 mm. The specific steps are as follows:

[0048] 1) Select Fe wire and Ni wire with a diameter of 1.2 mm and a purity greater than 99.9%; select a 304 stainless steel plate as the substrate, polish the substrate, clean it with alcohol, and dry it for later use;

[0049] 2) Polish the tungsten electrode and fix it at a position 1 mm inside the muzzle of the welding torch. Fix the pretreated substrate at the center of the common workbench with a fixture. Load the Fe wire and Ni wire into two wire feeding mechanisms respectively. By adjusting the position of the wires, make the intersection point of the two wires be directly below the tungsten electrode;

[0050] 3) As a preferred method, the preset process parameters are: Fe wire feeding speed: 1.1 m / min; Ni wire feeding speed: 1.0 m / min; welding torch speed: 0.015 m / s; welding current: 110 A; dry extension length: 8 mm; argon gas flow rate: 15 L / min; ion gas flow rate: 1 L / min; interlayer waiting time: 10 min;

[0051] 4) Draw the deposition path through CAD, export the corresponding program through welding software, and copy it to a USB flash drive for later use.

[0052] 5) Connect and start all experimental equipment and devices, and set the position of the plasma arc welding torch to the reset state;

[0053] 6) Input all the preset process parameters and import the preset deposition path in the USB flash drive into the robot control cabinet;

[0054] 7) Start the running program. After the welding torch reaches the specified starting arc position, the plasma controller sends an arc starting signal, and use the high-frequency arc starting method to start a small arc at a safe position;

[0055] 8) Confirm that the arc starting is smooth and the center of the small arc is directly opposite to the intersection point of the two wires. The welding torch descends 30 mm in height to the specified safe position within 5 s. After waiting for 0.3 s, the protection gas system outputs a protection gas flow rate and an ion gas flow rate that match the set values. At the same time, the small arc turns into a stable welding plasma arc. The robot control cabinet sends a control signal to the double-wire coordination controller to the two wire feeding machines, and the two wire materials start to be fed into the center of the plasma arc at the same time, and then deposit according to the preset program;

[0056] 9) After the single-layer deposition is completed, the robot control cabinet sends a control signal to the twin-wire coordination controller to stop the wire feeding of the two wire feeders. After waiting for 0.2 s, the plasma controller sends a signal to turn off the plasma arc. After waiting for 1 s, the gas supply module stops spraying the shielding gas. Then, the welding torch moves up 30 mm to a safe position. The interlayer cooling time for each deposition layer is 5 min - 15 min. Measure the height of this layer of deposition to confirm whether the preset height of the next deposition layer in the program is appropriate. If necessary, other parameters such as the wire feeding speed and current can also be adjusted. Then, it is possible to prepare to start the next layer of deposition.

[0057] 10) Repeat steps 8) and 9) in a loop until the deposition is completed. After sufficient cooling time, loosen the substrate fixture, remove the specimen, and polish the surface.

[0058] Example 2:

[0059] The present invention provides a method for preparing permalloy by using twin-wire plasma arc additive manufacturing, which can conduct an additive manufacturing experiment of permalloy with a straight path width of 6 mm - 8 mm. The specific steps are as follows:

[0060] 1) Select Fe wires and Ni wires with a diameter of 1.2 mm and a purity greater than 99.9%; select a 304 stainless steel plate as the substrate. After polishing the substrate, clean it with alcohol and dry it for standby.

[0061] 2) Polish the tungsten electrode and fix it at a position 1 mm inside the muzzle of the welding torch. Fix the pretreated substrate on the center of the common workbench with a fixture. Load the Fe wires and Ni wires into two wire feeding mechanisms respectively. By adjusting the position of the wires, make the intersection point of the twin wires be directly below the tungsten electrode.

[0062] 3) As a preferred method, the preset process parameters are: Fe wire feeding speed: 1.1 m / min; Ni wire feeding speed: 1.0 m / min; welding torch speed: 0.001 m / s; welding current: 90 A; stickout length: 8 mm; argon gas flow rate: 15 L / min; ion gas flow rate: 1 L / min; interlayer waiting time: 5 min;

[0063] 4) Draw the deposition path through CAD, export the corresponding program through welding software, and copy it to a USB flash drive for standby.

[0064] 5) Connect and start all experimental equipment and devices, and set the position of the plasma welding torch to the reset state;

[0065] 6) Input all the preset process parameters and import the preset deposition path in the USB flash drive into the robot control cabinet;

[0066] 7) Start running the program. After the welding torch reaches the specified arc starting position, the plasma controller sends an arc starting signal, and use the high-frequency arc starting method to start a small arc at a safe position;

[0067] 8) Confirm that the arc starting is smooth and the center of the small arc is exactly opposite to the intersection of the two wires. The welding torch descends 30 mm in height within 5 s to reach the specified safe position. After waiting for 0.3 s, the shielding gas system outputs the shielding gas flow rate and ion gas flow rate that match the set values. At the same time, the small arc turns into a stable welding plasma arc. The robot control cabinet sends a control signal to the two-wire coordination controller to the two wire feeders, and the two wire materials start to be fed into the center of the plasma arc simultaneously, and then the surfacing is carried out according to the preset program;

[0068] 9) After the single-layer surfacing is completed, the robot control cabinet sends a control signal to the two-wire coordination controller to stop the wire feeding of the two wire feeders. After waiting for 0.2 s, the plasma controller sends a signal to turn off the plasma arc. After waiting for 1 s, the gas supply module stops spraying the shielding gas. Then the welding torch moves up 30 mm to the safe position. The interlayer cooling time of each surfacing layer is 5 min - 15 min. Measure the height of this layer of surfacing to confirm whether the preset height of the next layer of surfacing in the program is appropriate. If it is inappropriate, adjust the parameters, and then you can prepare to start the next layer of surfacing;

[0069] Repeat steps 8) and 9) until the surfacing is completed. After sufficient cooling time, loosen the substrate fixture, remove the specimen and polish the surface.

[0070] Among them, in the wire feeding mechanism, the ends of the wire conduits of the two wire feeders are respectively connected to the clamping device and fixed on the same fixture, and at the same time, ensure that the Fe wire and the Ni wire are on the same horizontal line; the wire feeding speed can be adjusted through the wire feeder and the two-wire control system to control the Fe and Ni contents;

[0071] Set the surfacing path planning: Use the plasma arc robot to control the welding torch to collect the three-dimensional positions of the arc starting point and the arc ending point on the substrate. First, determine the x-axis and y-axis positions of the arc starting point and the arc ending point, and then determine the safe machining position of the z-axis height. After taking the points, in the CAD drawing, according to the collected coordinates of the arc starting point and the arc ending point, connect the two corresponding points into a straight line, and use this as the coordinate axis to set the specific surfacing path. After completion, export the path program and copy it to the USB flash drive for backup.

[0072] Regarding the surfacing path, this patent provides the following two ideas. 1) Straight path: The straight line connecting the collected coordinates of the arc starting point and the arc ending point can be directly used as the surfacing path. Taking the distance between the two points as 60 mm as an example, during processing, the starting point is at the arc starting point, and it travels straight for 60 mm to the arc ending point. When using the straight path for welding, the weld width is relatively narrow, and the welding torch travels along the straight path. 2) Curved path: Taking the sine wave path as an example, set the 0 - 2π interval as a cycle, take the 0 - π half cycle, and set the path curve with a width of 5 mm and a height of 8 mm for this half cycle. Then there are a total of 60 mm / 5 mm * 2 = 6 sine cycles. When using the curved path for welding, the weld width is relatively wide, and the welding torch travels along an "S" - shaped path.

[0073] The specific equipment models adopted are as follows:

[0074] Specifically adopted, wire - type plasma arc additive manufacturing platform: The welding robot is a KR 20 R1810 - 2 Kuka robot, the welding power source is a Hypertherm power source Transmig 550i, a plasma arc controller, and a Jinan Handa WF - 007A automatic wire - feeding arc welding machine.

[0075] Based on the above - mentioned method, a device for preparing permalloy with Fe and Ni dual - wires is provided. As Figures 3-6 shown, it includes a clamping device 1. The clamping device 1 is fixedly arranged on the welding arm of the robot through a fixture. The wire - feeding mechanism conveys the welding wires to the clamping device 1. The clamping device 1 is used for clamping the Fe wire and the Ni wire and controlling the included angle between the Fe wire and the Ni wire.

[0076] Furthermore, the clamping device 1 includes a mounting base 2. A rotatable first adjusting rod 3 and a second adjusting rod 4 are arranged on the mounting base 2. Guide wire cylinders 5 are arranged at the ends of the first adjusting rod 3 and the second adjusting rod 4. The first adjusting rod 3 and the second adjusting rod 4 are linked by a sector gear. A second rotary encoder and a second motor are arranged on the first adjusting rod 3. The second motor can drive the first adjusting rod 3 to rotate; with the above - mentioned structure, in the initial state, the two guide wire cylinders 5 on the first adjusting rod 3 and the second adjusting rod 4 are arranged in parallel. When starting to work, the second motor is used to control the rotation of the first adjusting rod. The first adjusting rod drives the second adjusting rod to rotate synchronously through the sector gear, so as to realize the control of the included angle between the two guide wire cylinders 5. The feedback of the angle of the included angle is fed back by the second rotary encoder. Among them, the wire - feeding included angle of Fe and Ni is basically 15° - 20°. During the working process, the rotation angle of the first adjusting rod 3 is also detected by the second rotary encoder, so as to ensure that the range of the included angle always remains within the required range.

[0077] Furthermore, a limiting cylinder 501 and a plurality of wire - guiding pieces 502 distributed in a ring shape are arranged at the front end of the guide wire cylinder 5. The plurality of wire - guiding pieces 502 are arranged inside the limiting cylinder 501; in the above - mentioned structure, the welding wire is sent out from the wire - feeding mechanism and enters the guide wire cylinder 5. The wire - guiding pieces 502 are arranged in a ring shape, with gaps on the circumferential side and having elasticity. Since the welding wire will shake during the conveying process, the wire - guiding pieces 502 are set to enable the welding wire to have a certain tolerance during the movement process, avoiding the welding wire being stuck at the outlet due to shaking. The limiting cylinder 501 is arranged on the outside to limit the excessive deviation of the wire - guiding pieces 502. Generally speaking, it is sufficient that the limiting cylinder restricts the range of the shaking angle of the welding wire to within 3°.

[0078] Furthermore, an annular air duct 7 is provided between the wire guide cylinder 5 and the limiting cylinder 501. A blowing device is arranged inside the clamping device 1. The blowing device is communicated with the annular air duct 7 and is connected to an external protective gas supply module for blowing out the protective gas. With the above structure, the protective gas is directly blown out from the gap. Firstly, the protective gas is directly blown out from the position of the welding wire, and the gas will flow along the welding wire, so that it is more concentrated at the welding position. When the electric arc is struck, the stability of the electric arc is good, the ionization voltage is relatively low, and the weld formation is beautiful. Secondly, the annular air duct 7 blows out from between the limiting cylinder 501 and the wire guide cylinder 5, and the wire guide piece 502 is located inside the limiting cylinder 501. In this way, when the protective gas is blown out, an annular air cavity is formed. The wire guide piece 502 is inside the air cavity. When the welding wire shakes, the welding wire will drive the wire guide piece 502 to deflect. At this time, the annular air duct 7 will be compressed at the outlet by the deflected wire guide piece 502, so that the gas flow rate at this place is accelerated and the pressure is reduced. At this time, the gas at other positions in the annular air duct 7 is in a relatively high-pressure state, and the gas flows from high pressure to low pressure, so as to push the deflected wire guide piece 502 open again, making the wire guide piece 502 reset, and further resetting the deflected welding wire, so that the shaking of the welding wire is stabilized through the structure of the annular air duct 7, and the wire feeding effect is better and more stable.

[0079] Furthermore, the clamping device 1 includes an adjusting seat 6. A rotating shaft 601 is arranged on the adjusting seat 6. A first rotary encoder and a first motor for driving the rotating shaft to rotate are arranged on the rotating shaft 601. The mounting seat 2 is mounted on the rotating shaft 601. The first motor drives the rotating shaft to rotate for adjusting the included angle between the two welding wires with respect to the substrate. In this embodiment, the adjustment range is 15 - 45°; the first rotary encoder is used to detect the size of the included angle and monitor it in real time during operation for automatic adjustment to ensure the accurate wire feeding angle of the welding wire.

[0080] Furthermore, the clamping device 1 further includes a controller, and the controller is electrically connected to the first rotary encoder, the second rotary encoder, the first motor, and the second motor. The controller pre-inputs the required angle and the allowed error for self-adjustment during the working process.

[0081] Through the above methods and devices, a permalloy with better bonding strength can be obtained. By changing the wire feeding speed, the component ratio of the workpiece can be flexibly controlled, and the preparation is flexible. At the same time, the wire feeding of the device is more stable, the quality of the workpiece is improved, and defects such as pores and cracks are significantly reduced.

[0082] The above are only the preferred embodiments of the present invention and are not used to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the design concept of the present invention shall be included within the protection scope of the present invention.

Claims

1. A method for preparing permalloy by using Fe and Ni double wires, characterized in that: Including the following steps 1) Select Fe wires and Ni wires with a diameter of 1.2 mm and a purity greater than 99.9% as the welding wires; Select a 304 stainless steel plate as the substrate; 2) Pretreat the substrate, grind it with sandpaper, and then wipe the surface with alcohol to remove surface oil and oxides; 3) Grind the tip of the tungsten electrode in the plasma welding torch to be sharp and smooth, ensure that the tip of the tungsten electrode retracts about 1 mm at the muzzle of the welding torch, and ensure that the axis of the tungsten electrode is perpendicular to the ground. The muzzle of the welding torch needs to be kept clean; 4) Fix the pretreated substrate at the center of the workbench with a fixture. Load the Fe wire and Ni wire into two wire feeding mechanisms respectively. Through wire feeding, make the intersection of the two wire materials be directly below the tungsten electrode, and ensure that this wire material intersection can be melted at the center of the plasma arc during welding; 5) Determine the process parameters through calculation, including: wire feeding speed, welding current, welding torch travel speed, ion gas flow rate, shielding gas flow rate, stickout length; 6) Draw the cladding path through CAD, export the corresponding program through welding software, and copy it to a USB flash drive for backup; 7) Connect and start all experimental equipment and devices, and set the position of the plasma welding torch to the reset state; 8) Input all preset process parameters and import the cladding path in the USB flash drive to the robot control cabinet; 9) Start the running program. After the welding torch reaches the specified arc starting position, the plasma controller sends an arc starting signal, and use the high-frequency arc starting method to start a small arc at a safe position; 10) Confirm that the arc starting is smooth and the center of the small arc is directly opposite to the intersection of the two wires. The welding torch descends 30 mm in height to the specified safe position within 5 s. After waiting for 0.3 s, the shielding gas system outputs a shielding gas flow rate and an ion gas flow rate that match the set values. At the same time, the small arc turns into a stable welding plasma arc. The robot control cabinet sends a control signal to the two-wire coordination controller to the two wire feeding machines, and the two wire materials start to be fed into the center of the plasma arc at the same time, and then perform cladding according to the preset program; 11) After the single-layer cladding is completed, the robot control cabinet sends a control signal to the two-wire coordination controller to the two wire feeding machines to stop wire feeding. After waiting for 0.2 s, the plasma controller sends a signal to turn off the plasma arc. After waiting for 1 s, the gas supply module stops spraying the shielding gas. Then the welding torch moves up 30 mm to the safe position. The interlayer cooling time for each cladding layer is 5 min - 15 min. Measure the cladding height of this layer to confirm whether the preset cladding height of the next layer in the program is appropriate. If it is not appropriate, adjust the parameters, and then you can prepare to start the next layer of cladding; 12) Repeat steps 10) and 11) in a loop until the required number of cladding layers is completed. After waiting for enough cooling time, loosen the substrate fixture, remove the sample and use a grinder to polish the surface to obtain a permalloy part.

2. The method for preparing permalloy by using Fe and Ni double wires according to claim 1, wherein: All the preset process parameters include: welding current 60 - 150 A, wire feeding speed 0.6 - 1.5 m / min, welding torch traveling speed 0.001 - 0.03 m / s, ion gas flow rate 0.5 - 1 L / min, protective gas argon flow rate 15 - 20 L / min, angle between Fe wire and Ni wire 15 - 20°; adjust the angle between the welding wire and the substrate to 10 - 30°; adjust the extended length to 8 - 10 mm.

3. The method for preparing permalloy by using Fe and Ni double wires according to claim 1, characterized in that: The described surfacing path includes: Linear path: When programming, it is necessary to locate the linear positions of the starting arc point and the ending arc point, and the path is assisted by the welding program plug-in to generate the path. Curvilinear path: When programming, it is necessary to calculate the radius of curvature, the length and width within a unit welding cycle, and the path is assisted by the welding program plug-in to generate the path.

4. An apparatus for preparing permalloy with Fe and Ni double wires, characterized in that: The wire feeding mechanism includes a clamping device (1), the clamping device (1) is arranged on the welding arm of the robot, and the clamping device (1) is used to clamp the Fe wire and the Ni wire and control the angle between the Fe wire and the Ni wire.

5. The device for preparing permalloy by using Fe and Ni double wires according to claim 4, characterized in that: The clamping device (1) includes a mounting base (2), a rotatable first adjusting rod (3) and a second adjusting rod (4) are arranged on the mounting base (2), wire guiding cylinders (5) are arranged at the ends of the first adjusting rod (3) and the second adjusting rod (4), the first adjusting rod (3) and the second adjusting rod (4) are linked by a sector gear, a second rotary encoder and a second motor are arranged on the first adjusting rod (3), and the second motor can drive the first adjusting rod (3) to rotate.

6. The device for preparing permalloy by using Fe and Ni double wires according to claim 5, characterized in that: A limiting cylinder (501) and a number of wire guiding pieces (502) distributed in a ring shape are arranged at the front end of the wire guiding cylinder (5), and the number of the wire guiding pieces (502) is arranged inside the limiting cylinder (501).

7. An apparatus for preparing permalloy by using Fe and Ni double wires according to claim 6, characterized in that: An annular air channel (7) is arranged between the wire guiding cylinder (5) and the limiting cylinder (501), a blowing device is arranged inside the clamping device (1), the blowing device is communicated with the annular air channel (7), and the blowing device is connected to the external protective gas supply module for blowing out the protective gas.

8. The device for preparing permalloy with Fe and Ni double wires according to claim 5, characterized in that: The clamping device (1) includes an adjusting base (6), a rotating shaft (601) is arranged on the adjusting base (6), a first rotary encoder and a first motor for driving the rotating shaft to rotate are arranged on the rotating shaft (601), and the mounting base (2) is mounted on the rotating shaft (601).

9. The device for preparing permalloy with Fe and Ni double wires according to claim 8, characterized in that: The clamping device (1) further includes a controller, and the controller is electrically connected to the first rotary encoder, the second rotary encoder, the first motor and the second motor.

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