A multi-material functionally graded annular component fused deposition additive manufacturing method

Abstract

The application relates to the field of additive manufacturing, and discloses a kind of multi-material function gradient annular component fused deposition additive manufacturing method, according to the material and function requirement of part, different fused deposition head, metal solution of different material and composite reinforcing phase powder of different material are selected, the base body of fused deposition head moves left and right along X axis, repeatedly moves up and down along Z axis, and materials are stacked layer by layer on the mandrel, and the forming of the part with function gradient material is realized by layer-by-layer accumulation forming.The preparation method provided by the application can meet the additive manufacturing of high-precision, high-quality, short-cycle and high-complexity aero-engine casing type rotary type components with the principle of "design function priority" as the premise, and can realize the additive manufacturing of engine casing type parts with function gradient material, the formed parts have high density, high interlayer bonding strength, long service life and low cost.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing technology, specifically to a fused deposition additive manufacturing method for multi-material functionally graded ring components. Background Technology

[0002] Aero engines are the core components of aircraft, and casings are among the main components of aero engines. Currently, casing materials are mostly made of high-temperature resistant and difficult-to-machine materials such as titanium alloys and high-temperature alloys. Some casings are also made of aluminum-magnesium alloys, stainless steel, or even composite materials. Aero engine casings have complex shapes and structures, and different types of aero engines have casings with different shapes and structures. A common casing structure is based on a rotating hub surface with circumferentially distributed columnar island bosses. The thinnest part of the component is only 2 to 3 mm thick, which is a complex thin-walled structure with multiple islands. Therefore, the casing is difficult to manufacture and the process is complex, often requiring a combination of technologies to complete its production. In casting manufacturing, integral precision casting technology is used; in titanium alloy forging manufacturing, isothermal die forging technology is used; in the milling of complex outer surfaces of the casing, four-axis and five-axis CNC milling and turning technology is used; in the turning of the inner surfaces and T-slots of the casing, CNC turning technology is used; when machining irregular holes in the ring-shaped parts of the casing, CNC laser technology is used; for casings with honeycomb sealing structures, honeycomb brazing and honeycomb surface EDM grinding technology are used; and for titanium alloy casings with welded structures, vacuum electron beam welding technology is used.

[0003] Additive manufacturing technology (also known as "3D printing") is a new technology that has emerged in recent years. Its core idea is to discretize a three-dimensional part into two layers, forming layered data. Based on the layered data of the part's 3D CAD model, the discrete molding materials are gradually bonded together to form layered cross-sections. These layers are then stacked to form a solid part, eliminating the need for molds and directly manufacturing the part, which can significantly reduce costs and shorten the development cycle. Traditional additive manufacturing methods, such as selective laser melting, direct metal sintering, laser net-beam forming, electron beam rapid prototyping, ion rapid prototyping, and arc deposition modeling, still suffer from insufficient interlayer bonding and insufficient density of the formed part when manufacturing complex thin-walled aero-engine casings with functional gradient characteristics. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a fused deposition modeling (FDM) additive manufacturing method for multi-material functionally graded ring components. This method solves the problems of insufficient interlayer bonding and insufficient density of formed parts that still exist in the manufacturing process of complex thin-walled aero-engine casings with functionally graded characteristics.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a fused deposition additive manufacturing method for multi-material functionally graded ring components, using a mandrel (10) rotating via a spindle and a fused deposition apparatus moving along the X and Z axes, comprising the following steps:

[0006] S1. The first layer is formed by selecting a fused deposition head according to the material and functional requirements of the part. With the energy source off, the molten metal is placed in the liquid accumulation channel. The composite reinforcing phase powder and inert gas are filled into the powder feeding channel. The molten metal in the liquid accumulation channel is deposited on the mandrel under the action of surface tension and capillary action. The inert gas forms a gas protective film on the surface of the forming layer near the molten pool. The composite reinforcing phase powder enters the molten pool and forms the forming layer together with the molten metal in the liquid accumulation channel.

[0007] S2. When forming the second layer, the energy source is turned on to generate an energy beam, which is irradiated onto the surface of the forming layer, causing the surface of the forming layer to remelt and form a molten pool. The molten metal is deposited on the mandrel under the action of surface tension and capillary action. The inert gas forms a gas protective film. The composite reinforcing phase powder enters the molten pool. After the molten pool is cooled, a new forming layer is formed.

[0008] S3. Based on the material and functional requirements of the part, select different fused deposition heads, metal solutions of different materials, and composite reinforcing phase powders of different materials. Repeat step S2 and form the part with functionally graded materials by layer-by-layer accumulation.

[0009] S4. Remove the part obtained in S3 from the mandrel, and after grinding and polishing, obtain the finished part.

[0010] Preferably, in the method, when the part does not need to have functionally graded material properties, a single fused deposition head, the same molten metal, and the same reinforcing phase powder can be used to complete the fused deposition manufacturing of a part made of a single material.

[0011] Preferably, the inert gas is argon or nitrogen.

[0012] Preferably, the speed at which the molten deposition head moves along the molten deposition direction is 0.02 to 5 m / s.

[0013] Preferably, the rate at which the molten metal enters the molten pool is 2 to 50 g / min.

[0014] Preferably, the flow rate of the inert gas is 5 to 100 L / min.

[0015] Preferably, the distance between the molten deposition head and the surface of the formed layer is 10–200 μm.

[0016] Preferably, the thickness of the gas protective film is 30–500 μm.

[0017] Preferably, the diameter of the reinforcing phase powder is 15-300 μm, and the falling speed of the reinforcing phase powder along the powder feeding channel is 10-60 g / min.

[0018] Preferably, the fused deposition apparatus includes an energy source, a fused deposition head substrate, an energy beam, and a fused deposition head;

[0019] The molten deposition head includes a liquid accumulation channel, a powder delivery channel, and a gas guide groove. An energy source is located at the top center of the molten deposition head substrate, which generates an energy beam. The molten deposition head has a liquid accumulation channel and a powder delivery channel. The liquid accumulation channel is distributed from top to bottom, and its lower part is inclined towards the energy beam direction to form an oblique nozzle shape. The liquid accumulation channel and the powder delivery channel are located in the same plane.

[0020] Preferably, 2 to 4 molten deposition heads are evenly distributed in a ring on the molten deposition head substrate.

[0021] Preferably, the energy source includes, but is not limited to, a laser head or an arc generator, and the energy beam includes, but is not limited to, a laser beam or an arc.

[0022] Preferably, the diameter of the liquid accumulation channel is 50–200 μm.

[0023] Preferably, the diameter of the powder feeding channel is 0.1 to 1 mm.

[0024] This invention provides a fused deposition modeling (FDM) additive manufacturing method for multi-material functionally graded ring-shaped components. It offers the following advantages:

[0025] 1. This invention generates an energy beam from an energy source to form a molten pool on the surface of the forming layer. Molten metal and reinforcing phase powder are then directly melted into the molten pool. Simultaneously, during the melting process, an inert gas forms a protective gas film between the molten pool and the bottom surface of the molten deposition head, preventing the molten metal from being oxidized and ensuring that the coating powder can smoothly enter the molten pool. The molten metal in the accumulating channel directly melts and deposits on the surface of the forming layer near the molten pool under surface tension and capillary action, forming a reliable metallurgical bond. Furthermore, the flow of molten metal in the accumulating channel is not easily affected by external interference and pressure fluctuations.

[0026] 2. The method provided by this invention can meet the requirements of additive manufacturing of high-precision, high-quality, short-cycle, and highly complex aero-engine casing parts with the principle of "design function first". At the same time, it can realize additive manufacturing of engine casing parts made of functionally graded materials. The manufactured parts have high density, high interlayer bonding strength, long service life, and low cost. Attached Figure Description

[0027] Figure 1This is a schematic diagram illustrating the principle of the present invention.

[0028] Among them, 1. Energy source; 2. Fused deposition head substrate; 3. Energy beam; 4. Fused deposition head; 5. Liquid accumulation channel; 6. Powder feeding channel; 7. Gas guide groove; 8. Molten pool; 9. Forming layer; 10. Mandrel; 11. Glove box; 12. Parts. Detailed Implementation

[0029] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] Example:

[0031] Please see the appendix Figure 1 This invention provides a method for fused deposition additive manufacturing of multi-material functionally graded ring components, which uses a mandrel 10 that rotates via a spindle and a fused deposition apparatus that moves along the X and Z axes.

[0032] Specifically, the fused deposition apparatus includes an energy source 1, a fused deposition head substrate 2, an energy beam 3, and a fused deposition head 4;

[0033] In this embodiment, an energy source 1 is provided at the top center of the fused deposition head substrate 2. The energy source 1 generates an energy beam 3, which provides energy for metal melting additive forming. The energy source 1 can be an energy source such as a laser head and an arc generator. Other energy sources include plasma and ultrasound. The energy beam 3 generated by the energy source 1 includes, but is not limited to, a laser beam or an arc.

[0034] Furthermore, the molten deposition head 4 is provided with a liquid accumulation channel 5 and a powder delivery channel 6;

[0035] In this embodiment, the liquid accumulation channel 5 is distributed from top to bottom, and its lower part is inclined towards the energy beam 3 to form an oblique nozzle shape. The liquid accumulation channel 5 and the powder feeding channel 6 are located in the same plane.

[0036] The inner surface of the air outlet of the powder feeding channel 6 is smoothly transitioned, which can guide the inert gas entering the powder feeding channel 6 to be sprayed out along the bottom of the molten deposition head 4 along the gas guide groove 7, forming a gas protective film on the surface of the forming layer 9 near the molten pool 8 to prevent the molten metal from oxidizing.

[0037] As needed, 2 to 4 molten deposition heads 4 can be evenly distributed in a ring on the molten deposition head substrate 2, and each molten deposition head 4 can work independently.

[0038] It should be noted that the roughness of the bottom surface of the molten deposition head 4 is preferably Ra0.1 to 0.3; the diameter of the liquid accumulation channel 5 is preferably 50 to 200 μm; and the diameter of the powder feeding channel 6 is preferably 0.1 to 1 mm.

[0039] refer to Figure 1 The present invention provides a fused deposition modeling (FDM) additive manufacturing method for multi-material functionally graded ring components, comprising the following steps:

[0040] 1) First, place the fused deposition apparatus and casing-type parts 12 in the glove box 11. Install the mandrel 10 below the fused deposition head substrate 2, so that the center line of the energy beam 3 is exactly at the highest position of the outline edge of the mandrel 10. The center line of the energy beam 3 is perpendicular to the center line of the mandrel 10. The energy source 1 generates the energy beam 3. The direction of the energy beam 3 is vertically downward. The center line of the energy beam 3 is perpendicular to the center line of the part 12. During the fused deposition process, the part 12 is cut into annular thin layers. The annular thin layer data is generated by the computer. The mandrel 10 can rotate. The fused deposition head substrate 2 moves left and right along the X-axis and up and down along the Z-axis to realize the layer-by-layer accumulation and forming of the part 12.

[0041] 2) During the formation of the first layer, energy source 1 does not generate energy beam 3. Based on the material and functional requirements of part 12, one fused deposition head 4 on the fused deposition head substrate 2 is selected to be in working condition, while the other fused deposition heads 4 are in non-working condition. By adjusting the vertical height of the fused deposition head 4, the bottom end face of the fused deposition head 4 is brought into contact with the contour surface of the mandrel 10. The molten metal is placed into the accumulation channel 5, and then the composite reinforcing phase powder and inert gas are introduced into the powder feeding channel 6. Through the rotation of the mandrel 10 and the left and right movement of the fused deposition head substrate 2, the molten metal is accumulated... The molten metal in the liquid channel 5 is deposited onto the mandrel 10 under surface tension and capillary action, and smoothed by the bottom end face of the molten deposition head 4. The inert gas in the powder feeding channel 6 flows out through the gas guide groove 7 at the bottom of the molten deposition head 4, forming a gas protective film on the surface of the forming layer 9 near the molten pool 8 to prevent oxidation of the molten metal. The composite reinforcing phase powder in the powder feeding channel 6 enters the molten pool 8 and forms the forming layer 9 together with the molten metal in the liquid accumulation channel 5, completing the forming of the first layer of material. The first layer and the mandrel 10 are reliably bonded without metallurgy.

[0042] 3) When forming the second layer, energy source 1 is turned on to generate energy beam 3. Energy beam 3 irradiates the surface of the forming layer 9, causing the surface of the forming layer 9 to remelt and form a molten pool 8. Pressure is applied to the molten metal in the liquid accumulation channel 5, causing the molten metal to enter the molten pool 8. Then, composite reinforcing phase powder and inert gas are filled into the powder feeding channel 6. With the rotation of the mandrel 10 and the left and right movement of the molten deposition head substrate 2, the molten metal in the liquid accumulation channel 5 melts and deposits on the mandrel 10 under the action of surface tension and capillary action, and is smoothed by the bottom end face of the molten deposition head 4. The inert gas in the powder feeding channel 6 flows out through the gas guide groove 7 at the bottom of the molten deposition head 4, forming a gas protective film on the surface of the forming layer 9 near the molten pool 8 to prevent oxidation of the molten metal. The composite reinforcing phase powder in the powder feeding channel 6 enters the molten pool 8. After the molten pool 8 is cooled, a new forming layer 9 is formed. A reliable metallurgical bond is formed between the old and new forming layers 9, the microstructure transition is uniform, and no interlayer interface is formed.

[0043] 4) Based on the material and functional requirements of part 12, select different fused deposition heads 4, put metal solutions of different materials into the liquid accumulation channel 5, and introduce composite reinforcing phase powders of different materials into the powder feeding channel 6. Repeat step 3), and realize the manufacturing of part 12 with functionally graded materials by layer-by-layer accumulation. When part 12 does not need to have functionally graded material properties, the fused deposition manufacturing of part 12 of a single material can be completed by using one fused deposition head 4, molten metal and reinforcing phase powder.

[0044] 5) Remove the obtained part 12 from the mandrel 10, and after grinding and polishing, the finished part 12 is obtained.

[0045] In the preparation method of this embodiment...

[0046] The inert gas is argon or nitrogen;

[0047] Energy source 1 can be an energy source such as a laser head and an electric arc generator, and other energy sources include plasma, ultrasound, etc.; the energy beam 3 generated by energy source 1 includes, but is not limited to, a laser beam or an electric arc.

[0048] The velocity of the molten deposition head substrate 2 moving along the molten deposition direction is 0.02-5 m / s;

[0049] The rate at which molten metal enters the molten pool 8 is 2–50 g / min;

[0050] The flow rate of the inert gas is 5–100 L / min;

[0051] The thickness of the gas protective film is 30–500 μm;

[0052] The diameter of the reinforcing phase powder is 15-300 μm, and the falling speed of the reinforcing phase powder along the powder feeding channel 6 is 10-60 g / min;

[0053] The distance between the molten deposition head 4 and the surface of the forming layer 9 is 10–200 μm.

[0054] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for fused deposition modeling (FDM) additive manufacturing of multi-material functionally graded ring components, comprising a mandrel (10) rotating via a spindle and a fused deposition apparatus moving along the X and Z axes, characterized in that, Includes the following steps: S1. The first layer is formed by selecting a molten deposition head (4) according to the material and functional requirements of the part (12). With the energy source (1) off, the molten metal is placed in the liquid accumulation channel (5). The composite reinforcing phase powder and inert gas are filled into the powder feeding channel (6). The molten metal in the liquid accumulation channel (5) is deposited on the mandrel (10) under the action of surface tension and capillary action. The inert gas forms a gas protection film on the surface of the forming layer (9) near the molten pool (8). The composite reinforcing phase powder enters the molten pool (8) and forms the forming layer (9) together with the molten metal in the liquid accumulation channel (5). S2. When forming the second layer, the energy source (1) is turned on to generate an energy beam (3) which irradiates the surface of the forming layer (9) to remelt the surface of the forming layer (9) to form a molten pool (8). The molten metal melts and deposits on the mandrel (10) under the action of surface tension and capillary action. The inert gas forms a gas protective film. The composite reinforcing phase powder enters the molten pool (8). After the molten pool (8) is cooled, a new forming layer (9) is formed. S3. Based on the material and functional requirements of the part (12), select different fused deposition heads (4), metal solutions of different materials and composite reinforcing phase powders of different materials, repeat step S2, and form the part (12) with functional gradient materials by layer-by-layer accumulation. S4. Take the part (12) obtained in S3 off the mandrel (10), and after grinding and polishing, obtain the finished part (12); The fused deposition apparatus includes an energy source (1), a fused deposition head substrate (2), an energy beam (3), and a fused deposition head (4). The molten deposition head (4) includes a liquid accumulation channel (5), a powder feeding channel (6), and a gas guide groove (7). An energy source (1) is provided at the top center of the molten deposition head substrate (2), and the energy source (1) generates an energy beam (3). The molten deposition head (4) has a liquid accumulation channel (5) and a powder feeding channel (6). The liquid accumulation channel (5) is distributed from top to bottom, and its lower part is inclined towards the energy beam (3) to form an oblique nozzle shape. The liquid accumulation channel (5) and the powder feeding channel (6) are located in the same plane.

2. The fused deposition modeling additive manufacturing method for a multi-material functionally graded ring component according to claim 1, characterized in that, In the method, when the part (12) does not need to have functionally graded material properties, a single material part (12) can be manufactured by fused deposition using a single fused deposition head (4), the same molten metal and the same reinforcing phase powder.

3. The fused deposition modeling additive manufacturing method for a multi-material functionally graded ring component according to claim 1, characterized in that, Two to four molten deposit heads (4) are evenly distributed in a ring on the molten deposit head substrate (2).

4. The fused deposition modeling additive manufacturing method for a multi-material functionally graded ring component according to claim 1, characterized in that, The energy source (1) includes, but is not limited to, a laser head or an electric arc generator, and the energy beam (3) includes, but is not limited to, a laser beam or an electric arc.

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