A method for manufacturing a laminated array hole metal foil powder layup composite

Abstract

The application provides a laminated array hole metal foil powder laying composite material manufacturing method, and belongs to the field of additive manufacturing.The metal foil with a certain number of holes is used as the base material of the composite material, metal, ceramic and other powders are laid in the holes as the reinforcing body for lamination, digital slicing processing is used for integral forming, additive manufacturing is realized through sintering, and the composite material product is formed through diffusion reaction.The powder splashing in the laser additive manufacturing process is prevented, the forming quality of the parts is improved, the metal matrix composite material is anisotropic, the performance and realized function of each part are different, the application scene is greatly increased, the laminated additive manufacturing process is optimized, the cost and time are saved, the manufacturing speed is fast, the comprehensive mechanical properties of the manufactured composite material are excellent, meanwhile, the remaining base material and reinforcing body material are not mixed, the raw material recovery rate is high, and the cost of additive manufacturing is effectively reduced.

Description

Technical Field

[0001] This invention belongs to the field of additive manufacturing, specifically relating to a method for manufacturing a composite material of stacked array hole metal foil powder. Background Technology

[0002] Additive manufacturing technology is a novel fabrication technology widely used in high-performance automobiles, aerospace, medical devices, and other fields. Compared with traditional manufacturing technologies, additive manufacturing can perfectly fabricate structurally complex parts without complex processes and equipment. It offers advantages such as shorter production cycles, material savings, and suitability for producing complex-shaped parts, improving material productivity and utilization. Currently, there are few additive manufacturing technologies capable of printing metal matrix composites; the main forming materials are filaments, powders, and sheet materials (metal foil). Filaments are inexpensive, but the surface quality of the parts is poor. Powders can form complex, high-performance metal parts, but they are expensive, flammable, explosive, and difficult to store. Sheet materials (metal foil) offer fast forming speeds and low prices, and there are no issues with mixing or recycling, but the surface quality of the formed products is poor. To obtain complex, high-performance metal matrix composites while saving costs, metal foil and powder can be used together as forming materials. Currently, there is a lack of additive manufacturing technologies that combine metal foil and powder as forming materials. Summary of the Invention

[0003] To address the problems of poor quality of formed parts, simple structure of prepared parts, and high manufacturing cost in existing technologies, this invention provides a method for manufacturing composite materials with stacked array hole metal foil powder. The aim is to save costs and resources, ensure safety and efficiency, improve manufacturing speed, and produce metal matrix composite materials with complex structures and excellent performance.

[0004] The objective of this invention is achieved through the following technical solution:

[0005] A method for manufacturing a multilayer arrayed perforated metal foil powder composite material comprises the following steps:

[0006] Step 1: Prepare metal foil, and prepare perforated metal foil;

[0007] An inert gas is filled into a sealed forming chamber. A layer of metal foil of a certain thickness is laid on a flat substrate in the sealed forming chamber. A certain number of holes are made in the metal foil. According to the requirements of the composite material, the holes are made in a regular array arrangement. The perforated metal foil is then adsorbed onto the substrate.

[0008] Step 2: Prepare composite material preforms;

[0009] Perforated metal foil is used as the matrix of the composite material. Powder is laid inside the holes as a reinforcement. The powder is leveled using a scraper system to ensure that the thickness of the powder and the metal foil are consistent. Another layer of perforated metal foil is then laid on the matrix, with the perforations offset from or partially overlapping the holes in the previous layer, but not completely overlapping. Reinforcing powder is then laid inside the holes in this matrix layer, and the powder is leveled again using a scraper system to ensure that the thickness of the powder and the metal foil are consistent. This process of laying perforated metal foil and reinforcing powder is repeated until the predetermined thickness is achieved, resulting in a pre-made composite material.

[0010] Step 3: Prepare metal-based composite materials;

[0011] The composite material preform obtained in S2 is pressurized to compact the metal foil and ceramic powder. The pressure range is 10-150 MPa. Under argon protection, it is sintered in a sintering furnace at a sintering temperature of 300-2000℃ to form a metal matrix composite product through diffusion reaction.

[0012] In this invention, the thickness of the metal foil in step S1 is 1 micrometer to 10 millimeters.

[0013] In this invention, the opening pattern of the metal foil in step S1 is determined according to the requirements of the composite material and is carried out according to a predetermined diameter, density, spacing, and array pattern.

[0014] In this invention, the opening pattern of the metal foil is such that the center of the opening is located at the corner of a square substrate or at each corner of a honeycomb-shaped regular hexagonal substrate.

[0015] In this invention, the predetermined thickness range in step S2 is 2-10000 layers of metal foil.

[0016] In this invention, the metal foil in step S1 includes Al, Mg, Cu, Ti, Ni and their alloys, as well as steel materials.

[0017] In this invention, the reinforcing powder in step S2 includes various metals, alloys, and ceramic powders.

[0018] Compared with the prior art, the features and beneficial effects of the present invention are as follows:

[0019] This invention relates to a method for manufacturing a composite material of a multilayer array of perforated metal foil. Based on laser additive manufacturing technology, the method combines perforated metal foil and metal / ceramic powder, and then uses digital slicing to form an integral shape. Additive manufacturing is achieved through pressure and sintering, and composite material products are formed through diffusion reaction. This method prevents powder splashing during the laser additive manufacturing process, improves the forming quality of parts, and the anisotropy of the metal matrix composite material means that the performance and functions of each part are different, which greatly expands the application scenarios. Attached Figure Description

[0020] Figure 1 This is a flowchart of the process method of the present invention;

[0021] Figure 2 This is a structural diagram of the perforated metal foil of Example 1;

[0022] Figure 3 This is a structural diagram of the perforated metal foil in Example 2;

[0023] Figure 4 This is a structural diagram of the perforated metal foil in Example 3;

[0024] Figure 5 This is a three-dimensional structural diagram of the part in Example 4;

[0025] Figure 6 This is a structural diagram of the perforated metal foil of Example 4. Detailed Implementation

[0026] Example 1

[0027] In this embodiment, Al metal foil is used as the matrix of the composite material and SiC powder is used as the reinforcement of the composite material. With the help of additive manufacturing technology, high-performance parts are prepared.

[0028] like Figure 1 As shown, a method for manufacturing a multilayer arrayed perforated metal foil powder composite material is carried out according to the following steps.

[0029] S1. Prepare metal foil and prepare perforated metal foil;

[0030] A sealed forming chamber is filled with inert helium gas. A layer of Al metal foil with a thickness of 10μm and a size of 60mm×40mm is laid flat on a flat substrate, according to... Figure 2 The method involves creating three 10mm diameter circular holes in an Al metal foil to attach the perforated Al metal foil to a substrate.

[0031] S2. Preparation of composite material preforms;

[0032] SiC powder with a purity of 99.99% and an average particle size of 100 nm was placed in a ball mill and ground at 800 rpm for 5 hours. It was then dried in a vacuum oven at 60°C for 3 hours. A layer of SiC powder was spread inside a circular hole, and the powder was leveled using a scraper system (ZXG-I) to ensure the thickness of the SiC powder and Al metal foil were consistent. A layer of Al metal foil with a thickness of 10 μm and a size of 60 mm × 40 mm was then laid on top of the previous layer of Al metal foil. Figure 2The process involves creating three 10mm diameter holes in an Al metal foil, then layering reinforcing SiC powder inside these holes. A scraper system is then used to smooth the powder, ensuring that the thickness of the SiC powder and the Al metal foil remains consistent. This process is repeated for a total of 1000 layers to obtain the aluminum-based composite preform.

[0033] S3. Preparation of metal-based composite materials;

[0034] The obtained aluminum-based composite material preforms were compacted with metal foil and ceramic powder using a small tabletop electric continuous pressing machine at a pressure of 50 MPa and sintered at 500 °C to form composite material products through diffusion reaction.

[0035] Example 2

[0036] In this embodiment, Al and Ti metal foils are used as the matrix of the composite material, and Al2O3 powder and SiC powder are used as the reinforcement of the composite material. With the help of additive manufacturing technology, high-performance parts are prepared.

[0037] like Figure 1 As shown, a method for manufacturing a multilayer arrayed perforated metal foil powder composite material is carried out according to the following steps.

[0038] S1. Prepare metal foil and prepare perforated metal foil;

[0039] A sealed forming chamber is filled with inert neon gas. A layer of Al metal foil with a thickness of 0.5 mm and a size of 50 mm × 50 mm is laid flat on a flat substrate. Figure 3 According to the opening pattern of Al, 13 circular holes with a diameter of 10mm are opened on the Al metal foil. The vacuum adsorption platform is used to evacuate the vacuum and adsorb the Al metal foil onto the substrate.

[0040] S2. Preparation of composite material preforms;

[0041] The ceramic powders, SiC powder with a purity of 99.99% and an average particle size of 40 nm and Al2O3 powder with a purity of 99.9% and an average particle size of 1 μm, were placed in a ball mill and ground at 700 rpm for 4 hours. They were then dried in a vacuum oven at 60℃ for 3 hours. A layer of SiC powder was spread inside a circular hole, and the powder was leveled using a scraper system to ensure the thickness of the SiC powder and Al metal foil were consistent. A Ti metal foil with a thickness of 0.5 mm and a size of 50 mm × 50 mm was then spread on top of the Al metal foil. Figure 3Following the pattern of opening holes, 12 circular holes with a diameter of 10mm are made on the Ti metal foil. Al₂O₃ powder, a reinforcing agent, is then placed inside these holes. A scraper system is used to level the powder, ensuring the thickness of the Al₂O₃ powder and the Ti metal foil are consistent. Finally, a layer of Al metal foil with a thickness of 0.5mm and a size of 50mm × 50mm is placed on top of the Ti metal foil. Figure 3 According to the opening pattern, 13 circular holes with a diameter of 10mm are opened on the Al metal foil. The reinforcing agent SiC powder is then laid in the holes of the Al metal foil layer. The powder is then leveled with a scraper system to make the thickness of the SiC powder and the Al metal foil consistent. A total of 3 layers are laid to obtain the aluminum-titanium composite preform.

[0042] S3. Preparation of metal-based composite materials;

[0043] The obtained aluminum-titanium-based composite material preforms were compacted with metal foil and ceramic powder using a small benchtop electric continuous pressing machine at a pressure range of 100 MPa and sintered at 600 °C to form composite material products through diffusion reaction.

[0044] Example 3

[0045] In this embodiment, Au metal foil, Ni metal foil, Pt metal foil and Pd metal foil are used as the matrix of the composite material, and Mo powder is used as the reinforcement of the composite material. With the help of additive manufacturing technology, high-performance parts are prepared.

[0046] like Figure 1 As shown, a method for manufacturing a multilayer arrayed perforated metal foil powder composite material is carried out according to the following steps.

[0047] S1. Prepare metal foil and prepare perforated metal foil;

[0048] A sealed forming chamber is filled with inert helium gas. A 100μm thick Au metal foil with dimensions of 40mm × 40mm is laid flat on a flat substrate, according to... Figure 4 According to the opening pattern, two circular holes with a diameter of 20mm are made in the Au metal foil to adsorb the Au metal foil onto the substrate.

[0049] S2. Preparation of composite material preforms;

[0050] Mo powder with a purity of 99.99% and an average particle size of 1 μm was placed in a ball mill and ground at 700 rpm for 2 hours. It was then dried in a vacuum oven at 60°C for 2 hours. A layer of Mo powder was spread in a circular hole, and the powder was leveled using a scraper system to ensure the thickness of the Mo powder and Au metal foil were consistent. A Ni metal foil with a thickness of 100 μm and a size of 40 mm × 40 mm was then spread on top of the Au metal foil. Figure 4Following the pattern of opening holes, two 20mm diameter circular holes are made in the Ni metal foil. Mo powder, the reinforcing agent, is then deposited inside these holes. A scraper system is used to level the powder, ensuring the thickness of the Mo powder and Ni metal foil is consistent. Finally, a 100μm thick Pt metal foil, measuring 40mm x 40mm, is deposited on top of the Ni metal foil. Figure 4 Following the pattern of opening holes, two 20mm diameter circular holes are made in the Pt metal foil. Mo powder, the reinforcing agent, is then laid inside these holes. A scraper system is used to level the powder, ensuring the thickness of the Mo powder and Pt metal foil is consistent. Finally, a 100μm thick Pd metal foil, measuring 40mm x 40mm, is laid on top of the previous Pt metal foil. Figure 4 Following the pore-opening pattern, two 20mm diameter circular holes are made in the Pd metal foil. Mo powder, the reinforcing agent, is then laid inside the holes of the Pd metal foil layer. The powder is then leveled using a scraper system to ensure that the thickness of the Mo powder and the Pd metal foil are consistent. A total of four layers are laid: Au metal foil, Ni metal foil, Pt metal foil, Pd metal foil, and Mo powder, to obtain the composite material preform.

[0051] S3. Preparation of metal-based composite materials;

[0052] The obtained composite material preforms are compacted with metal foil and ceramic powder using a small tabletop electric continuous pressing machine at a pressure range of 30 MPa and sintered at 1000 °C to form composite material products through diffusion reaction.

[0053] Example 4

[0054] In this embodiment, Ti metal foil is used as the matrix of the composite material and Al2O3 powder is used as the reinforcement of the composite material. Digital slicing is used to form an integral shape, and additive manufacturing is achieved through sintering to prepare parts with better performance.

[0055] like Figure 1 As shown, a method for manufacturing a multilayer arrayed perforated metal foil powder composite material is carried out according to the following steps.

[0056] S1. Prepare metal foil and prepare perforated metal foil;

[0057] according to Figure 5 The workpiece shape is computer-modeled, and then sliced ​​into layers based on the computer model. Each layer is 0.5 mm thick. An inert helium gas is filled into a sealed forming chamber. A 0.5 mm thick Ti metal foil, the size identified by the computer model, is then laid flat on a flat substrate. Figure 6 Elliptical holes are made in the Ti metal foil to adsorb the Ti metal foil onto the substrate.

[0058] S2. Preparation of composite material preforms;

[0059] Al2O3 powder with a purity of 99.99% and an average particle size of 100nm was placed in a ball mill and ground at 700rpm for 2 hours. Then it was dried in a vacuum oven at 60℃ for 2 hours. A layer of Al2O3 powder was spread in an elliptical hole and the powder was leveled using a scraper system to ensure that the thickness of the Al2O3 powder and the Ti metal foil were consistent. Another layer of Ti metal foil with a thickness of 0.5mm was spread on the previous layer of Ti metal foil, and Al2O3 powder was spread again. The above processing procedure was repeated until the metal parts were sliced ​​and stacked.

[0060] S3. Preparation of metal-based composite materials;

[0061] The obtained composite material preforms are compacted with metal foil and ceramic powder using a small tabletop electric continuous pressing machine at a pressure range of 80 MPa and sintered at 1200 °C to form composite material products through diffusion reaction.

[0062] In summary, this invention, based on additive manufacturing technology, combines perforated metal foil and metal / ceramic powder, layering them to obtain a composite material preform. This preform is then pressurized and sintered, forming the final composite product through a diffusion reaction. This process prevents powder spattering during laser additive manufacturing, improves the forming quality of parts, and increases manufacturing speed. The anisotropy of the metal matrix composite material, with different properties and functions in each part, greatly expands its application scenarios.

Claims

1. A method for manufacturing a composite material of stacked arrayed perforated metal foil, characterized in that, Follow these steps: Step 1: Prepare metal foil. Prepare perforated metal foil. Fill the sealed forming chamber with inert gas. Lay a layer of metal foil of a certain thickness on the flat substrate of the sealed forming chamber. Make a certain number of holes in the metal foil. The holes are circular or elliptical. Make the holes regularly according to the predetermined diameter, density, spacing and array arrangement according to the requirements of the composite material. Adsorb the perforated metal foil onto the substrate. Step 2: Prepare composite material preforms. Use perforated metal foil as the matrix of the composite material. Spread powder in the holes as reinforcement. Use a scraper system to level the powder and keep the thickness of the powder and metal foil consistent. Spread another layer of perforated metal foil on the matrix layer. The perforation position is offset from or partially overlaps with the perforation of the previous layer, but not completely overlaps. Spread reinforcement powder in the holes of this layer. Use a scraper system to level the powder again and keep the thickness of the powder and metal foil consistent. Repeat this process of spreading metal foil and reinforcement powder until the predetermined thickness is reached to obtain the composite material preform. Step 3: Prepare metal matrix composite material. Pressurize and sinter the composite material preform obtained in Step 2 to form metal matrix composite product through diffusion reaction.

2. The method for manufacturing a multilayer arrayed perforated metal foil powder composite material according to claim 1, characterized in that, The thickness of the metal foil is 1 micrometer to 10 millimeters.

3. The method for manufacturing a multilayer arrayed perforated metal foil powder composite material according to claim 1, characterized in that, The metal foil includes Al, Mg, Cu, Ti, Ni and their alloys.

4. The method for manufacturing a multilayer arrayed perforated metal foil powder composite material according to claim 1, characterized in that, The metal foil includes steel.

5. The method for manufacturing a multilayer arrayed perforated metal foil powder composite material according to claim 1, characterized in that, The predetermined thickness range is 2-10000 layers of metal foil.

6. The method for manufacturing a multilayer arrayed perforated metal foil powder composite material according to claim 1, characterized in that, In step 3, the pressure range for pressurization is 10-150 MPa.

7. The method for manufacturing a multilayer arrayed perforated metal foil powder composite material according to claim 1, characterized in that, In step 3, sintering is carried out in a sintering furnace under argon protection at a temperature of 300-2000℃.

Images