A stirring friction solid-phase additive manufacturing apparatus and method for laminated composite components

Abstract

This invention discloses an apparatus and method for manufacturing multilayer composite components using friction stir solid-state additive manufacturing. The apparatus comprises a segmented stirring pin and a multilayer additive structure that works in conjunction with it. The process includes the following steps: after cleaning the surface of the substrate to be soldered, an intermediate composite layer and a low-melting-point metal layer are sequentially stacked on its surface and clamped with a fixture; during the additive manufacturing process, the first segment of the segmented stirring pin passes through the intermediate composite layer and is pressed into the substrate, while the second segment is located within the low-melting-point metal layer in the additive layer; the segmented stirring pin moves along a predetermined trajectory to complete the additive manufacturing of the first layer of the multilayer structure. When multilayer or multi-pass additive manufacturing is required, the above steps are repeated. This invention avoids the problems of thick intermetallic compound layers in multilayer additive manufacturing of materials with large differences, and the problems of excessive frictional heat generation during high-melting-point material layer additive manufacturing causing remelting of low-melting-point materials, leading to reduced forming accuracy and performance degradation of the additive component.

Description

Technical Field

[0001] This invention belongs to the field of friction stir solid-state additive manufacturing technology, and particularly relates to an apparatus and method for manufacturing laminated composite components using friction stir solid-state additive manufacturing. Background Technology

[0002] The statements herein provide only background information in relation to this invention and do not necessarily constitute prior art.

[0003] With the continuous development of the economy and society, the applications of various metallic materials are becoming increasingly diversified, which places higher demands on the comprehensive performance of the materials themselves. Single materials are increasingly unable to meet the performance requirements under complex conditions, and the emergence of metal composite materials has provided a solution to this problem. Laminated metal composites, as a type of composite material, achieve complementarity while maintaining the properties of the parent metal, fully leveraging the performance and advantages of both materials. However, traditional methods for manufacturing laminated composites suffer from limitations imposed by workpiece shape, the need for high temperatures, and long processing times, severely restricting the fabrication of more laminated composite components.

[0004] Friction stir additive manufacturing (FSM) is a solid-state additive manufacturing technology that achieves additive manufacturing primarily through the stacking of materials. It operates at lower temperatures and possesses a forging-like effect, enabling strong metallurgical bonding between the laminated materials and reducing the formation of intermetallic compounds, thus improving component performance. Compared to molten metal additive manufacturing, FSM does not involve the melting and solidification of metals, effectively avoiding typical defects such as hot cracks and voids. It significantly addresses the drawbacks of molten metal additive manufacturing for lightweight metals like aluminum, magnesium, and titanium alloys, giving it unique advantages in the additive manufacturing of lightweight alloy structures.

[0005] However, when using friction stir additive manufacturing for high-melting-point materials such as copper, titanium, and steel, the high temperatures during the additive manufacturing process lead to severe wear on the stirring pins. Research has found that when using traditional friction stir solid-state additive manufacturing technology for multi-material laminated composite additive manufacturing, two problems arise: firstly, the large heat generated by the shoulder can easily cause excessive heat input; secondly, if the current additive layer is a high-melting-point material, the high frictional heat and high additive temperature can easily cause the low-melting-point metal material to melt and form intermetallic compounds, severely affecting the performance and dimensional accuracy of the additive structure. Therefore, existing conventional friction stir solid-state additive manufacturing technology is insufficient for achieving high-quality additive manufacturing of laminated composite components. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the purpose of this invention is to provide an apparatus and method for manufacturing laminated composite components using friction stir solid-state additive manufacturing.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0008] In a first aspect, the present invention provides a stir friction solid-state additive manufacturing apparatus for laminated composite components. The apparatus comprises a multi-segment stirring pin and a multi-layer additive structure therewith. The first segment of the multi-segment stirring pin is made of a wear-resistant and high-temperature resistant material, and the second segment is made of a high-toughness material. The second segment is located between the first segment and a shoulder, and the diameters of the first segment, the second segment, and the shoulder increase sequentially, forming a stepped shape.

[0009] The multilayer additive structure may contain dissimilar or homogeneous materials. The low-melting-point alloy layer in the additive layer is located outside the high-melting-point alloy layer. The thickness of the low-melting-point alloy layer in the additive layer is slightly greater than or equal to the length of the second section of the stirring pin (1-1.2 times the length of the second section of the stirring pin). This setting can prevent the second section of the stirring pin from directly contacting the high-melting-point alloy layer, reduce the wear of the second section of the stirring pin, and reduce heat input.

[0010] During additive manufacturing, the second section of the stirring pin is located in the low-melting-point alloy layer, and the first section of the stirring pin is located in the high-melting-point alloy layer.

[0011] The thickness of the high-melting-point intermediate composite layer of the additive layer should be slightly less than or equal to the length of the first segment of the stirring pin (0.9-1 times the length of the first segment of the stirring pin), while the total length of the two segments of the stirring pin should be greater than or equal to the overall thickness of the additive layer. This setting is to ensure that the stirring pin can penetrate the additive layer during the additive manufacturing process, achieving effective additive manufacturing. To avoid incomplete welding defects in the additive layer, the sum of the total lengths of the first and second segments of the stirring pin should be slightly greater than or equal to the overall thickness of the additive layer (1-1.2 times the thickness of the additive layer).

[0012] In some embodiments, the first segment is made of tool steel, cemented carbide steel, titanium alloy, special wear-resistant steel, tungsten-based alloy, or wear-resistant composite material. The diameter of the first segment is 0.7-3 times the thickness of the overall additive layer.

[0013] In some embodiments, the second segment is made of tool steel or a nickel-based alloy. The diameter of the second segment is 1.5 to 3 times the diameter of the first segment.

[0014] In some embodiments, a stationary shoulder system is used for additive manufacturing. The stationary shoulder stirring needle has a small shoulder at its root, with a diameter slightly larger than the first segment, which is 1.05-1.5 times the diameter of the second segment. The stationary shoulder applies axial downward pressure to the additive part, forming a rigid constraint with the substrate, and its diameter is 1.5-3 times the diameter of the second segment.

[0015] In some embodiments, additive manufacturing is performed using a conventional shoulder, the diameter of which is approximately 1.5 to 3 times the diameter of the second segment.

[0016] In some embodiments, the multi-segment stirring needle is either a separate piece or a single piece.

[0017] In some embodiments, when the multi-segment stirring needle is a split type, the first segment and the second segment are connected by threads or interference fit.

[0018] In a second aspect, the present invention provides a method for manufacturing a multilayer composite component using friction stir solid-state additive manufacturing, comprising the following steps:

[0019] After cleaning the surface of the substrate to be soldered, the intermediate composite layer and the first additive layer are sequentially stacked on its surface and clamped with a fixture.

[0020] During the additive manufacturing process, the first segment of the multi-segment stirring needle passes through the intermediate composite layer and is pressed into the substrate, while the second segment is located within the first additive layer.

[0021] The multi-segment stirring needle moves along a set trajectory to complete the first layer of additive material.

[0022] This invention avoids direct contact between the stirring head shoulder and high-melting-point materials in the laminated composite component, which could lead to excessive heat generation and melting of the completed additive layers. It regulates the heat input during additive manufacturing to prevent the formation of excessively thick intermetallic compound layers between the laminated materials, thereby improving the mechanical properties of the laminated materials. The development of a multi-segment stirring pin reduces the use of expensive stirring pin materials (such as tungsten-rhenium alloys, PCBN, etc.), while increasing the service life of the stirring head and reducing additive manufacturing costs. In some embodiments, after the first layer of additive manufacturing is completed, a step of polishing the surface of the first additive layer is also included.

[0023] The stacked material placement method is to simultaneously stir and add two layers of material through friction additive manufacturing. By combining two layers of material and adding them simultaneously, the additive manufacturing efficiency can be improved, and an alternating stacked composite structure can be obtained after simultaneous additive manufacturing.

[0024] Preferably, when multi-layer additive manufacturing is required, the above steps are repeated.

[0025] In some embodiments, to avoid the second stirring pin coming into direct contact with the high-strength, high-melting-point composite layer, which could cause severe wear and overheating, the length of the second stirring pin is set to not exceed the thickness of the additive layer, and the second segment does not come into contact with the intermediate composite layer.

[0026] In some embodiments, when the multi-segment stirring pin is a separate type, the first additive layer is made of aluminum or magnesium; the intermediate composite layer is made of titanium, steel, nickel, copper, or a high-entropy alloy. This type of laminated material includes high-melting-point materials. During the additive manufacturing process, the lower first segment of the stirring pin needs to be in direct contact with the high-melting-point alloy; therefore, it is manufactured using wear-resistant and high-temperature-resistant tungsten-based alloys (such as tungsten-rhenium alloys) and PCBN materials to reduce wear on the stirring pin.

[0027] In some embodiments, when the multi-segment stirring pin is integrally molded, the first additive layer and the intermediate composite layer are made of aluminum and magnesium, or dissimilar aluminum or dissimilar magnesium, respectively. These materials have relatively low melting points, and ordinary tool steel can be used to ensure sufficient strength for practical use. The integral design makes them easier to process and lowers costs.

[0028] In some embodiments, conventional shoulders are used for friction stir solid-state additive manufacturing of laminated composite components. Conventional shoulders can drive a large range of material flow, effectively improving additive manufacturing efficiency and reducing manufacturing costs. This is particularly suitable for additive manufacturing of similar / dissimilar aluminum alloys and similar / dissimilar magnesium alloys. It fully leverages the advantages of solid-state bonding technology in non-ferrous metals such as aluminum and magnesium alloys, enabling the development and synergy of comprehensive material properties.

[0029] In some embodiments, a stationary shoulder is used for friction stir solid-state additive manufacturing of laminated composite components. During the additive manufacturing process, the stationary shoulder does not rotate simultaneously with the stirring pin, which can greatly reduce the heat generation at the interface between the shoulder and the workpiece. This helps to reduce the temperature gradient in the thickness direction of the additive part, control the heat input of the additive manufacturing process, prevent the formation of excessively thick intermetallic compound layers between the laminated materials, solve the problems of excessively high temperature at the top of the additive part and uneven temperature distribution in the thickness direction, improve the anisotropy of the additive part, and enhance the overall performance of the component.

[0030] The beneficial effects achieved by one or more embodiments of the present invention described above are as follows:

[0031] This invention employs a multi-segment stirring pin for friction stir solid-state additive manufacturing of laminated composite components. This fully leverages the advantages of solid-state bonding technology in non-ferrous metals such as aluminum and magnesium alloys, achieving complementary properties between dissimilar materials and maximizing the strengths of each material. The development of the multi-segment stirring head facilitates the laminated composite manufacturing of high-strength, high-melting-point materials such as titanium and steel with lightweight materials such as aluminum and magnesium alloys, reducing costs in additive manufacturing and promoting the widespread application of additively manufactured components from various materials. The use of a stationary shoulder multi-segment stirring pin improves the temperature gradient along the thickness direction of the additive layer, reduces the anisotropy of the additive part, and enhances the overall performance of the component.

[0032] This invention is simple to operate, requires no large-scale modification of existing friction stir welding equipment, facilitates technology upgrades and equipment replacement, and is easy to rapidly industrialize.

[0033] The process and method of this invention are applicable to additive manufacturing of the same or different materials such as aluminum alloys, magnesium alloys, titanium alloys, and steel. They are particularly suitable for additive manufacturing of dissimilar laminated composite components. Attached Figure Description

[0034] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0035] Figure 1 Figure 1 is a schematic diagram of the process of manufacturing laminated composite components by friction stirring solid-state additive manufacturing using a multi-segment stirring needle according to an embodiment of the present invention. Figure 2a is a schematic diagram of the process of manufacturing laminated composite components by friction stirring solid-state additive manufacturing using a stationary shoulder multi-segment stirring needle, and Figure 3b is a schematic diagram of the process of manufacturing laminated composite components by friction stirring solid-state additive manufacturing using a conventional shoulder multi-segment stirring needle.

[0036] Figure 2 These are schematic diagrams of the multi-segment split-type and integral-type stirring needle structures according to embodiments of the present invention. Figure a shows a multi-segment split-type stirring needle, and Figure b shows a multi-segment integral-type stirring needle. The figures show a stationary shoulder stirring needle; conventional shoulder multi-segment stirring needles can still be divided into split-type and integral-type forms.

[0037] Figure 3 This is a schematic diagram of a multi-layer, multi-stage additive composite component structure according to an embodiment of the present invention;

[0038] Figure 4 This is a flowchart of the stirring friction solid-phase additive manufacturing process and method for the laminated composite component according to an embodiment of the present invention.

[0039] Among them, 1. Multi-segment stirring pin; 1-1. Multi-segment stirring pin with stationary shoulder; 1-2. Multi-segment stirring pin with conventional shoulder; 1-3. Separate stirring pin with stationary shoulder; 1-4. Integral stirring pin with stationary shoulder; 2. Stationary shoulder; 3. First additive layer; 3-1. Low melting point metal layer in the first additive layer; 3-2. High melting point intermediate composite layer in the first additive layer; 4. Substrate; 5. Multi-segment first-segment stirring pin; 6. Multi-segment second-segment stirring pin. Detailed Implementation

[0040] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0041] The present invention will be further described below with reference to the embodiments.

[0042] Example 1

[0043] This embodiment provides a method for friction-stirred solid-state additive manufacturing of laminated composite components using a multi-segment stirring pin with a static shoulder, such as... Figure 1As shown in Figure a, the additive component includes a multi-segment stirring pin 1, a stationary shoulder 2, a low-melting-point aluminum plate to be additively manufactured (first additive layer 3-1), a titanium plate to be additively manufactured with a high-melting-point intermediate composite layer (intermediate composite layer 3-2), and a substrate 4. The stationary shoulder 2 improves the temperature gradient in the thickness direction of the additive component. The multi-segment stirring pin 1-1 enables the additive manufacturing of high-melting-point materials. The material placement method allows for the stacking and composite of different materials, enabling the development of additive components that fully utilize the properties of both materials.

[0044] The stationary shoulder 2 is connected to the friction stir welding machine bracket via a connector and bolts, and it does not rotate during the welding process. At the same time, during the additive manufacturing process, the stationary shoulder 2 applies axial downward pressure to the additive part, forming a rigid constraint with the substrate to prevent additive metal from overflowing from the top of the additive part.

[0045] like Figure 2 As shown, multi-segment stirring pins can be divided into two types: separate multi-segment stirring pins 1-3 and integral multi-segment stirring pins 1-4. The separate multi-segment stirring pin 1-1 has a tool head 5 made of wear-resistant and high-temperature-resistant material (such as tungsten-rhenium alloy, PCBN, etc.) at its end. The tool head 5 is directly connected to the tool steel stirring pin via a threaded or clearance fit. The tool head 5 can be replaced according to actual needs. The integral stirring pin 1-4 is manufactured entirely of tool steel, exhibiting a stepped design, which reduces manufacturing costs.

[0046] The stacked material placement method is as follows: Figure 3 As shown, the additive component, after molding, forms a laminated composite material structure consisting of alternating low-melting-point aluminum plates and high-melting-point intermediate composite titanium plates. Simultaneous additive manufacturing of the aluminum alloy additive layer and the intermediate composite layer improves the efficiency of the additive process. Furthermore, the shoulder of the agitator does not directly contact the titanium plate, avoiding excessive heat generation from direct friction between the titanium alloy and the agitator shoulder, which could lead to the melting of the aluminum alloy in the additive component.

[0047] The following is a specific example of an additive manufacturing method for titanium / aluminum laminated composite components using the aforementioned apparatus:

[0048] refer to Figure 1 The two workpieces to be additively processed are dissimilar metals, consisting of a 0.5mm thick high-melting-point titanium alloy plate and a 3.5mm thick low-melting-point aluminum alloy plate. Before additive processing, the plates are polished to remove the surface oxide film. Then, the aluminum alloy plate is placed on top of the titanium plate, and both are placed on a substrate, with the titanium alloy plate serving as an intermediate composite layer.

[0049] refer to Figure 2The device employs a segmented, split-type stirring pin with a stationary shoulder. The shoulder has an outer diameter of 14mm and an inner diameter of 8mm. The multi-segment stirring pin has a split structure. The first segment (5) is made of tungsten-rhenium alloy with a diameter of 4mm and a length of 4mm. The second segment is made of tool steel with a diameter of 7.8mm and a length of 3.4mm, and its end has a 4mm diameter, 3mm deep circular hole for installing the first segment, ensuring that the first segment protrudes 1mm outward. The stirring head is installed on the welding machine, ensuring that the shoulder is flush with the root of the second segment of the stirring pin.

[0050] During additive manufacturing, the shoulder surface is flush with the upper surface of the workpiece 3 to be additively manufactured. The first section of the stirring pin protrudes 1mm to ensure it can penetrate the intermediate titanium plate and press into the substrate. Start the machine, set the stirring head speed to 800rpm, the pressing speed to 10mm / min, and the traveling speed to 60mm / min. The pressing depth is set so that the shoulder contacts the upper surface of the workpiece, at which point the tip of the stirring pin presses into the surface of the component to be additively manufactured by 4.4mm. After reaching the preset depth, hold for 15s for preheating, then travel along the preset trajectory at the set traveling speed to complete the first layer of additive manufacturing. Subsequently, perform the second layer of additive manufacturing, and so on, completing multiple layers of additive manufacturing as needed. After completing the first layer of additive manufacturing, grind or mill the upper surface of the additive layer to make it flat. Then, similar to the first layer, perform the additive manufacturing of the second layer of laminated material until the additive manufacturing of the titanium / aluminum laminated composite component is completed. Then, withdraw the stirring head 1 and turn off the welding machine power.

[0051] Example 2

[0052] This embodiment discloses a method based on Figure 2 The method described in b, which employs a conventional multi-segment stirring pin for friction stir solid-state additive manufacturing of laminated composite components, uses a 4mm thick 2024 aluminum alloy as the base material, a 1mm thick ZK61 magnesium alloy as the intermediate composite plate material, and a 3mm thick AZ31B magnesium alloy as the low-melting-point additive layer material. An integral stirring pin is used for friction stir additive manufacturing. The shoulder diameter is 14mm, and the stirring pin is cylindrical with a right-hand thread. The overall pin length is 4.2mm, with the first segment being 1.2mm long and 6mm in diameter, and the second segment being 3mm long and 10mm in diameter. The shoulder diameter is 18mm. The stirring pin rotation speed is 1200rpm, the welding speed is 50mm / min, the stirring head tilt angle is 2.5°, and the shoulder deflection is 0.1mm.

[0053] The specific additive manufacturing process includes the following steps:

[0054] Step 1: Before welding, grind the surface of the workpiece to be welded to remove the oxide film, and clean it with alcohol to remove surface oil and impurities.

[0055] Step 2: Clamp the substrate, intermediate composite layer, and aluminum alloy additive layer in order from bottom to top using a fixture.

[0056] Step 3: Connect the stationary shoulder stirring head to the main shaft of the friction stir welding machine, adjust the X-axis, Y-axis and Z-axis coordinates of the welding machine, and complete the adjustment of the downward pressure.

[0057] Step four: Add material to the first layer, then adjust the welding machine coordinates and perform the second layer welding. Repeat the above steps to perform multiple welding passes until the entire board has completed effective additive material addition in all areas.

[0058] Step 5: Grind, polish or mill the upper surface of the aluminum alloy additive layer, and then repeat steps 1 to 4 above to perform the second additive layer.

[0059] Step six: Repeat step five to add multiple layers, such as the third and fourth layers, until the component requirements are met. Once the additive manufacturing is complete, turn off the power.

[0060] Example 3

[0061] This embodiment discloses a method for friction stir solid-state additive manufacturing of laminated composite components using a multi-segment stirring pin with a stationary shoulder, based on the method described in Embodiment 1. In this embodiment, the matrix material is 4mm thick 2024 aluminum alloy, the intermediate composite plate material is 1mm thick TA1 titanium alloy, and the low-melting-point alloy additive layer material is 3mm thick 6061 aluminum alloy. A split-type stirring pin is used for friction stir additive manufacturing. The stationary shoulder diameter is 18mm, and the stirring pin is cylindrical with a right-hand thread. The overall pin length is 4.2mm, with the tool steel portion having a diameter of 10mm and a length of 3mm, and the tungsten-rhenium alloy portion having a diameter of 6mm and an outward protrusion length of 1.2mm. The stirring pin rotation speed is 800rpm, the welding speed is 120mm / min, and the stirring head tilt angle is 2.5°.

[0062] The specific additive manufacturing process includes the following steps:

[0063] Step 1: Before welding, grind the surface of the workpiece to be welded to remove the oxide film, and clean it with alcohol to remove surface oil and impurities.

[0064] Step 2: Clamp the substrate, intermediate composite layer, and aluminum alloy additive layer in order from bottom to top using a fixture.

[0065] Step 3: Connect the stationary shoulder stirring head to the main shaft of the friction stir welding machine, adjust the X-axis, Y-axis and Z-axis coordinates of the welding machine, and complete the adjustment of the downward pressure.

[0066] Step four: Add material to the first layer, then adjust the welding machine coordinates and perform the second layer welding. Repeat the above steps to perform multiple welding passes until the entire board has completed effective additive material addition in all areas.

[0067] Step 5: Grind, polish or mill the upper surface of the aluminum alloy additive layer, and then repeat steps 1 to 4 above to perform the second additive layer.

[0068] Step six: Repeat step five to add multiple layers, such as the third and fourth layers, until the component requirements are met. Once the additive manufacturing is complete, turn off the power.

[0069] Example 4

[0070] This embodiment discloses a method for friction stir solid-state additive manufacturing of laminated composite components using a conventional multi-segment stirring pin with a conventional shoulder, based on the method described in Embodiment 2. In this embodiment, the matrix material is a 3mm thick 7075 aluminum alloy, the intermediate composite plate material is a 1.5mm thick AZ31B magnesium alloy, and the low-melting-point alloy additive layer material is a 2.5mm thick 6061 aluminum alloy. An integral stirring pin is used for friction stir additive manufacturing. The shoulder diameter is 20mm, and the stirring pin is cylindrical without threads, with an overall pin length of 4.2mm. The first segment of the stirring pin has a diameter of 6mm and a length of 2mm, and the second segment has a diameter of 10mm and a length of 2.6mm. The stirring pin rotation speed is 1000rpm, the welding speed is 200mm / min, and the stirring head tilt angle is 2.5°.

[0071] The specific additive manufacturing process includes the following steps:

[0072] Step 1: Before welding, grind the surface of the workpiece to be welded to remove the oxide film, and clean it with alcohol to remove surface oil and impurities.

[0073] Step 2: Clamp the substrate, the intermediate composite magnesium alloy layer, and the first aluminum alloy layer in order from bottom to top using a clamp.

[0074] Step 3: Connect the stationary shoulder stirring head to the main shaft of the friction stir welding machine, adjust the X-axis, Y-axis and Z-axis coordinates of the welding machine, and complete the adjustment of the downward pressure.

[0075] Step four: Add material to the first layer, then adjust the welding machine coordinates and perform the second layer welding. Repeat the above steps to perform multiple welding passes until the entire board has completed effective additive material addition in all areas.

[0076] Step 5: Grind, polish or mill the upper surface of the aluminum alloy additive layer, and then repeat steps 1 to 4 above to perform the second additive layer.

[0077] Step six: Repeat step five to add multiple layers, such as the third and fourth layers, until the component requirements are met. Once the additive manufacturing is complete, turn off the power.

[0078] Example 5

[0079] This embodiment discloses a method for friction stir solid-state additive manufacturing of laminated composite components using a conventional multi-segment stirring pin with a conventional shoulder, based on the method described in Embodiment 2. In this embodiment, the matrix material is 6mm thick AA6061 aluminum alloy, the intermediate composite plate material is 1.0mm thick QP690 steel, and the aluminum alloy additive layer material is 2.5mm thick 6061 aluminum alloy. A split-type stirring pin is used for friction stir additive manufacturing. The conventional shoulder diameter is 14mm, and the stirring pin is cylindrical with a right-hand thread. The overall pin length is 3.8mm, with the tool steel portion having a diameter of 8mm and a length of 2.3mm, and the tungsten-rhenium alloy portion having a diameter of 5mm. The first segment has an outward protrusion length of 1.5mm. The stirring pin rotation speed is 1000rpm, the welding speed is 100mm / min, the stirring head tilt angle is 2.5°, and the shoulder depressor is 0.15mm.

[0080] The specific additive manufacturing process includes the following steps:

[0081] Step 1: Before welding, grind the surface of the workpiece to be welded to remove the oxide film, and clean it with alcohol to remove surface oil and impurities.

[0082] Step 2: Clamp the substrate, the intermediate composite layer QP690 steel, and the first layer 6061 aluminum alloy in order from bottom to top using a clamp.

[0083] Step 3: Connect the stationary shoulder stirring head to the main shaft of the friction stir welding machine, adjust the X-axis, Y-axis and Z-axis coordinates of the welding machine, and complete the adjustment of the downward pressure.

[0084] Step four: Add material to the first layer, then adjust the welding machine coordinates and perform the second layer welding. Repeat the above steps to perform multiple welding passes until the entire board has completed effective additive material addition in all areas.

[0085] Step 5: Grind, polish or mill the upper surface of the aluminum alloy additive layer, and then repeat steps 1 to 4 above to perform the second additive layer.

[0086] Step six: Repeat step five to add multiple layers, such as the third and fourth layers, until the component requirements are met. Once the additive manufacturing is complete, turn off the power.

[0087] Example 6

[0088] This embodiment discloses a method for friction stir solid-state additive manufacturing of laminated composite components using a multi-segment stirring pin with a stationary shoulder, based on the method described in Embodiment 1. In this embodiment, the matrix material is a 3mm thick 7075 aluminum alloy, the intermediate composite plate material is a 2.0mm thick magnesium-based composite material, and the aluminum alloy additive layer material is a 2.0mm thick 6061 aluminum alloy. A split-type stirring pin is used for friction stir additive manufacturing. The stationary shoulder diameter is 16mm, and the stirring pin is cylindrical with a right-hand thread. The overall pin length is 4.2mm, with the tool steel portion having a diameter of 10mm and a length of 1.7mm, and the tungsten-rhenium alloy portion having a diameter of 6mm and an outward protrusion length of 2.5mm. The stirring pin rotation speed is 800rpm, the welding speed is 180mm / min, and the stirring head tilt angle is 2°.

[0089] The specific additive manufacturing process includes the following steps:

[0090] Step 1: Before welding, grind the surface of the workpiece to be welded to remove the oxide film, and clean it with alcohol to remove surface oil and impurities.

[0091] Step 2: Clamp the substrate, the intermediate composite layer magnesium-based composite material, and the first layer aluminum alloy in a bottom-up order using a clamp.

[0092] Step 3: Connect the stationary shoulder stirring head to the main shaft of the friction stir welding machine, adjust the X-axis, Y-axis and Z-axis coordinates of the welding machine, and complete the adjustment of the downward pressure.

[0093] Step four: Add material to the first layer, then adjust the welding machine coordinates and perform the second layer welding. Repeat the above steps to perform multiple welding passes until the entire board has completed effective additive material addition in all areas.

[0094] Step 5: Grind, polish or mill the upper surface of the aluminum alloy additive layer, and then repeat steps 1 to 4 above to perform the second additive layer.

[0095] Step six: Repeat step five to add multiple layers, such as the third and fourth layers, until the component requirements are met. Once the additive manufacturing is complete, turn off the power.

[0096] Example 7

[0097] This embodiment discloses a method for friction stir solid-state additive manufacturing of laminated composite components using a multi-segment stirring pin with a stationary shoulder, based on the method described in Embodiment 1. In this embodiment, the matrix material is 5mm thick AA1050 aluminum alloy, the intermediate composite plate material is 1.0mm thick T2 copper, and the aluminum alloy additive layer material is 2.0mm thick AA1060 aluminum alloy. A split-type stirring pin is used for friction stir additive manufacturing. The stationary shoulder diameter is 12mm, and the stirring pin is cylindrical with a right-hand thread. The overall pin length is 3.2mm, with the tool steel portion having a diameter of 8mm and a length of 1.8mm, and the tungsten-rhenium alloy portion having a diameter of 6mm and an outward protrusion length of 1.4mm. The stirring pin rotation speed is 800rpm, the welding speed is 200mm / min, and the stirring head tilt angle is 2°.

[0098] The specific additive manufacturing process includes the following steps:

[0099] Step 1: Before welding, grind the surface of the workpiece to be welded to remove the oxide film, and clean it with alcohol to remove surface oil and impurities.

[0100] Step 2: Clamp the substrate, the intermediate composite layer copper alloy, and the first layer aluminum alloy in order from bottom to top using a clamp.

[0101] Step 3: Connect the stationary shoulder stirring head to the main shaft of the friction stir welding machine, adjust the X-axis, Y-axis and Z-axis coordinates of the welding machine, and complete the adjustment of the downward pressure.

[0102] Step four: Add material to the first layer, then adjust the welding machine coordinates and perform the second layer welding. Repeat the above steps to perform multiple welding passes until the entire board has completed effective additive material addition in all areas.

[0103] Step 5: Grind, polish or mill the upper surface of the aluminum alloy additive layer, and then repeat steps 1 to 4 above to perform the second additive layer.

[0104] Step six: Repeat step five to add multiple layers, such as the third and fourth layers, until the component requirements are met. Once the additive manufacturing is complete, turn off the power.

[0105] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A stir friction solid-state additive manufacturing apparatus for laminated composite components, characterized in that: A multi-segment stirring pin and its matching multi-layer additive structure are described. The first segment of the multi-segment stirring pin is made of a wear-resistant and high-temperature-resistant material, and the second segment is made of a high-toughness material. The second segment is located between the first segment and the shoulder. The diameters of the first segment, the second segment, and the shoulder increase sequentially, forming a stepped shape. The first segment of the multi-segment stirring pin is made of tool steel, cemented carbide steel, titanium alloy, special wear-resistant steel, tungsten-based alloy, or wear-resistant composite material. The second segment of the multi-segment stirring pin is made of tool steel or nickel-based alloy. The multilayer additive structure contains dissimilar or homogeneous materials. In the additive layer, the low-melting-point alloy layer is located above the high-melting-point alloy layer, and the thickness of the low-melting-point alloy layer is greater than or equal to the length of the second section of the stirring needle. During additive manufacturing, the second section of the stirring pin is located in the low-melting-point alloy layer, the first section of the stirring pin is located in the high-melting-point alloy layer, and the shoulder of the stirring head does not directly contact the high-melting-point alloy layer of the intermediate composite layer. The ratio of the thickness of the low-melting-point alloy layer in the additive layer to the length of the second section of the stirring pin is 1:0.9-1; the ratio of the thickness of the high-melting-point composite layer in the additive layer to the length of the first section of the stirring pin is 1:1-1.2; the ratio of the sum of the total lengths of the first and second sections of the stirring pin to the thickness of the multilayer additive structure is 1-1.2:1; the diameters of the first section, the second section, and the shoulder increase sequentially in a stepped manner, with the diameter of the first section being 0.7-3 times the overall thickness of the additive layer; the diameter of the second section being 1.5-3 times the diameter of the first section; and the diameter of the stirring head shoulder being 1.05-1.5 times the diameter of the second section of the stirring pin.

2. The apparatus for manufacturing laminated composite components using friction stir solid-state additive manufacturing according to claim 1, characterized in that: When using a stationary shoulder, the diameter of the stationary shoulder of the stirring head should be 1.5-3 times the diameter of the second section of the stirring needle.

3. The apparatus for manufacturing laminated composite components using friction stir solid-state additive manufacturing according to claim 1, characterized in that: During additive manufacturing, the gap between the interface between the first and second sections of the stirring pin and the top of the intermediate composite layer is 0-2mm to prevent the second section of the stirring pin from inserting into the intermediate composite layer.

4. The apparatus for manufacturing laminated composite components using friction stir solid-state additive manufacturing according to claim 1, characterized in that: The multi-segment stirring needle can be either a separate piece or a single piece. When the strength, hardness, and melting point of the two layers of the laminated composite material are not significantly different, a multi-segment integrally molded stirring needle is used; when the strength, hardness, and melting point of the two layers are significantly different, a multi-segment split stirring needle is used; when the multi-segment stirring needle is split, the first segment and the second segment are connected by threads or interference fit.

5. A method for manufacturing laminated composite components using friction stir solid-state additive manufacturing apparatus as described in claim 1, characterized in that: Includes the following steps: After cleaning the surface of the substrate to be soldered, a high melting point intermediate composite layer and a low melting point metal additive layer are sequentially stacked on its surface and clamped with a fixture. During the additive manufacturing process, the first segment of the multi-segment stirring needle passes through the intermediate composite layer and is pressed into the substrate, while the second segment is located within the low-melting-point metal layer. The multi-segment stirring needle moves along a set trajectory to complete the first layer of additive manufacturing; After the first layer of additive manufacturing is completed, the surface of the first layer of additive manufacturing needs to be polished. Repeat the above steps when multi-layer, multi-pass additive manufacturing is required.

6. The method for manufacturing laminated composite components using friction stir solid-state additive manufacturing according to claim 5, characterized in that: When the multi-segment stirring pin is a separate type, the material of the low-melting-point metal layer is aluminum or magnesium alloy; the material of the intermediate composite layer is titanium, steel, nickel, copper or high-entropy alloy; when the multi-segment stirring pin is integrally formed, the materials of the low-melting-point metal layer and the intermediate composite layer are aluminum and magnesium or dissimilar aluminum or dissimilar magnesium, respectively.

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