A magnetron dual-arc additive manufacturing system and method thereof

Abstract

The application provides a magnetic control double-arc additive manufacturing system and a method thereof, a first double-welding gun and a second double-welding gun are both installed on a four-axis linkage system; each welding gun is respectively provided with a wire feeding device; each welding gun is provided with a wire through hole, and the welding wire fed by the wire feeding device enters the wire through hole; each welding gun is further respectively provided with an air passage ring, and the air passage ring is provided with a protective gas path; each welding gun is further respectively provided with a magnetic field ring through hole, and the lower end of the magnetic field ring through hole is provided with a pulse magnetic field generating device and a rod-shaped magnetic head; the pulse magnetic field generating device is controlled by a magnetic field controller; a powder laying lifting platform is provided with a temperature controller, and an upper surface is provided with a substrate; the substrate is respectively provided with a powder laying system at both ends, and the powder laying system is controlled by a powder laying control system. The welding speed and the deposition efficiency are high, the control system is simple, the arc pressure control precision is simple, accurate and controlled by a magnetic field, and the double arcs can be simultaneously or respectively ignited.

Description

Technical Field

[0001] This invention belongs to the field of welding technology, specifically relating to a magnetically controlled dual-arc additive manufacturing system and method. Background Technology

[0002] Problems with existing dissimilar metal materials: Existing transition layer structures have defects such as no gradient change in materials and structure, hard phase at the interface, stress concentration, and high manufacturing cost. Material-structure separation manufacturing process is prone to introducing manufacturing defects, complex assembly fixtures, poor interlayer bonding strength, difficulty in controlling composition and interlayer thickness, and unsatisfactory gradient function effect. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention proposes a magnetically controlled dual-arc additive manufacturing system and method, which features high welding speed and deposition efficiency, a simple control system, convenient and accurate arc voltage control that is controlled by a magnetic field, and dual arcs that can be started simultaneously or separately.

[0004] The specific technical solution is as follows:

[0005] A magnetically controlled dual-arc additive manufacturing system includes dual welding torches, namely a first dual welding torch and a second dual welding torch; both the first and second dual welding torches are controlled by an arc controller, and the dual welding torches are dual independent wire poles connected in parallel arcs, which can start arcs simultaneously or separately;

[0006] Both the first and second dual welding torches are mounted on the four-axis linkage system;

[0007] The four-axis linkage system includes a Z-axis adjustment slider, which is mounted on the four-axis linkage system via a fixed shaft; the Z-axis adjustment slider is equipped with a welding gun slide plate, which has a horizontal groove for slidingly connecting the first double welding gun and the second double welding gun to adjust the distance between the two guns; the four-axis linkage system is also equipped with a temperature measuring instrument.

[0008] Each welding torch is equipped with a wire feeding device, and each welding torch has a coaxially integrated wire through hole, vent ring and magnetic field coil through hole; the welding wire fed by the wire feeding device enters the wire through hole; the vent ring is equipped with a protective gas path, which is controlled by the gas path controller.

[0009] Each welding torch has a pulsed magnetic field generator and a rod-shaped magnetic head at the lower end of the magnetic field coil through hole; the pulsed magnetic field generator is controlled by a magnetic field controller; each welding torch also has an electromagnetic protective cover on the outside of the rod-shaped magnetic head.

[0010] It also includes a powder spreading lifting platform, which is located below the dual welding guns and is equipped with a temperature controller. The upper surface is covered with a substrate. Powder spreading systems are provided at both ends of the substrate, and the powder spreading systems are controlled by the powder spreading control system.

[0011] Furthermore, the axis of the wire through-hole is perpendicular to the horizontal plane; the axis of the magnetic field coil of the magnetic field generating device forms an angle of 30°±5° with the axis of the wire through-hole, the magnetic field coil extends two-thirds of the way out of the magnetic field coil through-hole, and the horizontal distance between the lowest point and the welding wire is limited to 5-8mm; the thickness between the magnetic field coil through-hole, the wire through-hole, and the ventilation ring is 3-5mm, and it is made of tungsten material. During additive forming, the welding wire rod elongates by 5-10mm.

[0012] A magnetically controlled dual-arc additive manufacturing method, employing the aforementioned magnetically controlled dual-arc additive manufacturing system; the method includes the following steps:

[0013] The first and second dual welding guns are respectively connected to the positive terminals of two power supplies, and the negative terminals of the power supplies are connected to the substrate. The two power supplies are independent of each other.

[0014] The wire feeding devices of the first and second double welding guns are configured as required to feed the welding wire from the spool into the welding torch arc to melt and enter the corresponding additive layer area.

[0015] According to the layering path, select the arc starting point on the substrate, pre-circulate the shielding gas for 3-5 seconds, then turn on the power, and perform the first layer of overlay welding according to the weld bead layout. Layer by layer, until the last layer of part is printed, turn off the welding power to terminate the arc, and continue to circulate the shielding gas for 2-5 seconds.

[0016] The welding wire is any one of low-carbon steel, copper and copper alloys, aluminum and aluminum alloys, or stainless steel wire, with a diameter of 0.6-1.6 mm.

[0017] The substrate material is carbon steel or aluminum alloy.

[0018] This invention relates to wire arc additive manufacturing (WAAM), an advanced digital manufacturing technology that utilizes the principle of layer-by-layer cladding. Using the electric arc generated by welding machines such as MIG, TIG, and PA welding as the heat source, metal parts are gradually formed from lines to surfaces to volumes under program control, based on a three-dimensional digital model. It boasts advantages such as high deposition efficiency, high wire utilization, short overall manufacturing cycle, low cost, fewer restrictions on part size, and ease of part repair. Furthermore, it possesses the capability for in-situ composite manufacturing and forming large-sized parts. Compared to traditional casting, forging, and other additive manufacturing technologies, it is more advanced. Compared to casting and forging processes, it eliminates the need for molds, has a shorter overall manufacturing cycle, higher flexibility, and enables digital, intelligent, and parallel manufacturing. It responds quickly to design changes and is particularly suitable for manufacturing small batches of diverse products. WAAM produces materials with superior microstructure and mechanical properties compared to traditional casting techniques and saves raw materials, especially precious metals, compared to forging.

[0019] Compared to additive manufacturing technologies that use lasers and electron beams as heat sources, it offers advantages such as higher deposition rates and lower manufacturing costs. Compared to laser-based additive manufacturing, it is less sensitive to metallic materials and can form materials with high laser reflectivity, such as aluminum alloys and copper alloys. Compared to SLM and electron beam additive manufacturing technologies, arc additive manufacturing also has the advantage that the size of manufactured parts is not limited by the size of the forming cylinder and vacuum chamber, making it even suitable for on-site field operations.

[0020] This invention utilizes a dual welding torch equipped with a magnetic field generator. The dual torches can slide in an adjustable groove, allowing for adjustment of the distance between the two arc torches and the distance between the two welding wires, thus controlling the manufacturing process. Optimal distance control achieves stable arc process parameters. A thermometer is fixed in the center of the adjustable groove to collect temperature data during the additive manufacturing process. The use of a magnetically controlled dual arc significantly improves additive manufacturing efficiency. Furthermore, by clamping different metal wires, the dual welding torches can directly manufacture dissimilar materials, achieving adjustable composition. An external magnetic field constrains the arc, and the droplet size and micro-melt pool structure are controlled by adjusting the magnetic field generator, reducing interfacial bonding stress and improving forming accuracy. A liftable worktable is equipped with a cooling and heating element to achieve heating and cooling during the forming process. After a layer of metal wire is deposited along the additive path, the four-axis motion system raises the welding torch by one layer height, providing space for the next additive layer until all layers are deposited. During this process, the powder-laying system rises to the appropriate height according to design requirements and lays a layer of alloy powder, which is then melted by the molten wire layer. This system is a highly efficient device suitable for the integrated manufacturing of dual-gradient functional structures based on metallic materials and structures. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the structure of the present invention;

[0023] Figure 2 This is the present invention. Figure 1 A schematic diagram of the AA cross-section;

[0024] Figure 3 This is a schematic diagram of the four-axis linkage system of the present invention.

[0025] In the diagram, 100 is the first double welding torch, 200 is the second double welding torch, 1 is the wire feeder, 2 is the protective gas path, 3 is the gas path controller, 4 is the welding wire, 5 is the magnetic field generator, 6 is the magnetic field controller, 7 is the arc controller, 8 is the four-axis linkage system, 81 is the fixed axis, 82 is the Z-axis adjustment slider, 83 is the welding torch slide plate, 84 is the chute, 9 is the powder spreading control system, 10 is the powder spreading lifting platform, 11 is the temperature controller, 12 is the powder spreading system, 13 is the electromagnetic protection cover, 14 is the substrate, 15 is the rod-shaped magnetic head, 16 is the ventilation ring, 17 is the magnetic field coil through hole, 18 is the wire through hole, 19 is the thermometer, 20 is the dissimilar metal layer, and 21 is the molten droplet. Detailed Implementation

[0026] 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.

[0027] like Figure 1 and Figure 2 As shown, a magnetically controlled dual-arc additive manufacturing system includes dual welding torches, namely a first dual welding torch 100 and a second dual welding torch 200; both the first dual welding torch 100 and the second dual welding torch 200 are controlled by an arc controller 7.

[0028] The first double welding torch 100 and the second double welding torch 200 are both mounted on the four-axis linkage system 8;

[0029] Each welding torch is equipped with a wire feeding device 1; each welding torch is provided with a wire through hole 18, and the welding wire 4 fed in by the wire feeding device 1 enters the wire through hole 18.

[0030] Each welding torch is also equipped with a ventilation ring 16, and the ventilation ring 16 is equipped with a protective gas path 2, which is controlled by a gas path controller 3.

[0031] Each welding torch is also provided with a magnetic field coil through hole 17. The lower end of the magnetic field coil through hole 17 is provided with a pulse magnetic field generator 5 and a rod-shaped magnetic head 15. The pulse magnetic field generator 5 is controlled by a magnetic field controller 6. Each welding torch is also provided with an electromagnetic protective cover 13 on the outside of the rod-shaped magnetic head 15.

[0032] It also includes a powder spreading lifting platform 10, which is located below the dual welding gun and is equipped with a temperature controller 11. A substrate 14 is provided on the upper surface; a powder spreading system 12 is provided at both ends of the substrate 14, and the powder spreading system 12 is controlled by the powder spreading control system 9.

[0033] like Figure 3As shown, the four-axis linkage system 8 includes a Z-axis adjustment slider 82, which is mounted on the four-axis linkage system 8 via a fixed shaft 81; the Z-axis adjustment slider 82 is provided with a welding gun slide plate 83, which is provided with a horizontal slide groove 84 for sliding connection of the first double welding gun 100 and the second double welding gun 200; the four-axis linkage system 8 is also provided with a temperature measuring instrument 19.

[0034] The axis of the wire through-hole 18 is perpendicular to the horizontal plane; the axis of the magnetic field coil of the magnetic field generating device 5 forms an angle of 30°±5° with the axis of the wire through-hole 18, the magnetic field coil extends two-thirds of the way out of the magnetic field coil through-hole 17, and the horizontal distance between the lowest point and the welding wire 4 is limited to 5-8mm; the thickness between the magnetic field coil through-hole 17, the wire through-hole 18, and the ventilation ring 16 is 3-5mm, and it is made of tungsten material. During additive forming, the rod of the welding wire 4 extends by 5-10mm.

[0035] The distance between the first double welding torch 100 and the second double welding torch 200 can be adjusted by the slide groove 84 to adjust the double arc distance, optimize the double wire distance and magnetic field distance. At the same time, when the first double welding torch 100 and the second double welding torch 200 are equipped with dissimilar metal welding wires, the integrated direct forming of dissimilar metal structures and materials can be realized.

[0036] The arc controller 7 is used to send electrical signals to the dual arc gun to start and extinguish the arc. The dual arcs can start simultaneously or separately, and control the process parameters of the arc.

[0037] The magnetic field controller 6 is used to generate a magnetic field and adjust the magnetic field parameters to optimize the electric arc, stir the molten pool, increase the melting depth, refine the grains, and improve the interfacial bonding stress.

[0038] The gas path controller 3 adjusts the supply of inert gas to provide a protective gas hood during the additive manufacturing process, maximizing the isolation from the oxidizing environment.

[0039] The powder spreading lifting platform 10 has a built-in temperature controller 11, which controls the temperature during the additive manufacturing process by controlling the switching of the heating resistor and the cooling water channel. At the same time, according to the layering path and height of the part, for each layer of additive manufacturing, the four-axis linkage system 8 drives the dual welding gun to lift one layer. The powder spreading system 12 is lifted one layer under the action of the powder spreading lifting platform 10. After the powder spreading system 12 evenly spreads a layer of alloy powder, the dual electric arc wires continue to melt to form droplets 21 and deposit along the planned path until the last layer of the part is additively formed, that is, the dissimilar metal layer 20 is formed.

[0040] The first dual welding torch 100 and the second dual welding torch 200 can work simultaneously or independently. When working simultaneously, they should be started 2-3 seconds apart, waiting for the arcs from both starts to stabilize.

[0041] A magnetron-controlled dual-arc additive manufacturing method includes the following steps:

[0042] The first dual welding torch 100 and the second dual welding torch 200 are respectively connected to the positive terminals of two power supplies, and the negative terminals of the power supplies are connected to the substrate 14. The two power supplies are independent of each other.

[0043] The wire feeding device 1 of the first double welding torch 100 and the second double welding torch 200 is configured as required to feed the welding wire 4 from the spool into the welding torch arc to melt and enter the corresponding additive layer area.

[0044] According to the layering path, select the arc starting point on the substrate 14, pre-circulate the shielding gas for 3-5 seconds, then turn on the power, and perform the first layer of overlay welding according to the weld bead layout. Layer by layer, until the last layer of part is printed, turn off the welding power to terminate the arc, and continue to circulate the shielding gas for 2-5 seconds.

[0045] Welding wire 4 is any one of low-carbon steel, copper and copper alloys, aluminum and aluminum alloys, or stainless steel wire, with a diameter of 0.6-1.6mm. The substrate 14 is made of carbon steel or aluminum alloy.

[0046] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A magnetically controlled dual-arc additive manufacturing system, characterized in that, It includes a double welding torch, namely a first double welding torch (100) and a second double welding torch (200); both the first double welding torch (100) and the second double welding torch (200) are controlled by an arc controller (7). The double welding torch is a double independent wire pole parallel arc, which can start the arc simultaneously or separately. The first double welding torch (100) and the second double welding torch (200) are both mounted on the four-axis linkage system (8); The four-axis linkage system (8) includes a Z-axis adjustment slider (82), which is mounted on the four-axis linkage system (8) via a fixed shaft (81); the Z-axis adjustment slider (82) is provided with a welding gun slide plate (83), which is provided with a horizontal slide groove (84) for slidingly connecting the first double welding gun (100) and the second double welding gun (200) to adjust the distance between the two guns; the four-axis linkage system (8) is also provided with a temperature measuring instrument (19); Each welding torch is equipped with a wire feeding device (1), and each welding torch is provided with a coaxially integrated wire through hole (18), a venting ring (16) and a magnetic field coil through hole (17); the welding wire (4) fed by the wire feeding device (1) enters the wire through hole (18); the venting ring (16) is provided with a protective gas path (2), which is controlled by a gas path controller (3); Each welding torch has a pulse magnetic field generator (5) and a rod-shaped magnetic head (15) at the lower end of the magnetic field coil through hole (17); the pulse magnetic field generator (5) is controlled by a magnetic field controller (6); each welding torch also has an electromagnetic protective cover (13) on the outside of the rod-shaped magnetic head (15). It also includes a powder spreading lifting platform (10), which is located below the double welding gun and is equipped with a temperature controller (11). The upper surface is provided with a substrate (14); powder spreading systems (12) are provided at both ends of the substrate (14), and the powder spreading system (12) is controlled by the powder spreading control system (9).

2. The magnetically controlled dual-arc additive manufacturing system according to claim 1, characterized in that, The axis of the wire through hole (18) is perpendicular to the horizontal plane; the magnetic field coil axis of the magnetic field generating device (5) is at an angle of 30°±5° with the axis of the wire through hole (18), the magnetic field coil extends two-thirds of the way out of the magnetic field coil through hole (17) and the horizontal distance between the lowest point and the welding wire (4) is limited to 5-8mm; the thickness between the magnetic field coil through hole (17), the wire through hole (18) and the ventilation ring (16) is 3-5mm and is made of tungsten material; the welding wire (4) rod elongates by 5-10mm during additive forming.

3. A magnetically controlled dual-arc additive manufacturing method, characterized in that, The magnetically controlled dual-arc additive manufacturing system according to claim 1 or 2 is used; the method includes the following steps: The first double welding torch (100) and the second double welding torch (200) are respectively connected to the positive terminals of two power supplies, and the negative terminals of the power supplies are connected to the substrate (14). The two power supplies are independent of each other. The wire feeding device (1) of the first double welding torch (100) and the second double welding torch (200) is configured to feed the welding wire (4) from the spool into the welding torch arc to melt and enter the corresponding additive layer area. According to the layering path, select the arc starting point on the substrate (14), first pre-circulate the protective gas for 3-5s, then turn on the power, and perform the first layer of overlay welding according to the weld bead layout, layer by layer until the last layer of part is printed, turn off the welding power to terminate the arc, and continue to circulate the protective gas for 2-5s.

4. The magnetically controlled dual-arc additive manufacturing method according to claim 3, characterized in that, The welding wire (4) is any one of low carbon steel, copper and copper alloys, aluminum and aluminum alloys, or stainless steel wire, with a diameter of 0.6-1.6 mm.

5. The magnetically controlled dual-arc additive manufacturing method according to claim 3, characterized in that, The substrate (14) is made of carbon steel or aluminum alloy.

Images