Copper / nickel electrothermal alloy component and method based on digital modeling and additive manufacturing

Abstract

The application discloses a preparation method of a copper / nickel electrothermal alloy component based on digital modeling and additive manufacturing, and particularly relates to the following steps: step 1, preparing a copper alloy core wire; step 2, 3D modeling of the copper / nickel electrothermal alloy component, establishing a three-dimensional model of the copper / nickel electrothermal alloy component, then carrying out layering and slicing treatment on the three-dimensional model, designing a motion trail in a 3D printing preparation process, and finally converting the above process into a program suitable for operation of an arc welding robot; step 3, additive manufacturing of the copper / nickel electrothermal alloy component; step 4, heat treatment of the copper / nickel electrothermal alloy component prepared in step 3; and surface machining treatment of the copper / nickel electrothermal alloy component after the heat treatment. The component is used for connecting a copper wire and a nickel-chromium electrothermal alloy, and the prepared structural component is compact in structure and excellent in mechanical properties. The application further discloses a preparation method of the copper / nickel electrothermal alloy component.

Description

Technical Field

[0001] This invention belongs to the field of intelligent manufacturing technology, specifically relating to a copper / nickel electrothermal alloy component based on digital modeling and additive manufacturing, and also to a method for preparing the copper / nickel electrothermal alloy component based on digital modeling and additive manufacturing. Background Technology

[0002] Electrothermal alloys are widely used metallic functional materials that convert electrical energy into heat energy. Currently, nickel-based electrothermal alloys are mainly used in the manufacture of electric heating elements, high- and medium-temperature resistance elements, stress-strain elements, and electronic components for special instruments. To achieve the conversion of electrical energy into heat energy, it is necessary to connect highly conductive copper wires and nickel-based alloys to transfer electrical energy to the nickel-based electrothermal alloy. However, copper wires and nickel-based electrothermal alloy wires are relatively small in size. When using fusion welding, due to the large heat input, it is easy to cause uneven composition and large deformation of the weld joint, resulting in energy loss. When using brazing, spot welding, pressure welding, or other welding methods, the strength of the weld joint is relatively low and cannot meet the service performance requirements.

[0003] Traditional electrothermal alloy joining methods tend to result in low interfacial bonding strength, making them unsuitable for applications requiring high interfacial bonding strength. Summary of the Invention

[0004] The first objective of this invention is to provide a copper / nickel electrothermal alloy component based on digital modeling and additive manufacturing for connecting copper wires and nickel-chromium electrothermal alloy. The prepared structural component has a dense structure and excellent mechanical properties.

[0005] The second objective of this invention is to provide a method for preparing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing.

[0006] The first technical solution adopted in this invention is a method for preparing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing, the specific steps of which are as follows:

[0007] Step 1: Prepare the copper alloy flux wire for the copper side of the copper / nickel electrothermal alloy component;

[0008] Step 2: Perform 3D modeling of copper / nickel electrothermal alloy components, establish a three-dimensional model of copper / nickel electrothermal alloy components, then perform layer-by-layer slicing of the three-dimensional model, design the motion trajectory during the 3D printing process, and finally convert the above process into a program suitable for the operation of arc welding robots.

[0009] Step 3: Perform additive manufacturing of copper / nickel electrothermal alloy components;

[0010] Step 4: Heat-treat the copper / nickel electric heating alloy component prepared in Step 3; and perform surface machining on the heat-treated copper / nickel electric heating alloy component.

[0011] The invention is further characterized in that,

[0012] In step 1, the copper alloy core wire includes a core and an outer sheath. The core is composed of the following components by mass percentage: 18%–23% chromium powder, 8%–12% silver powder, 5%–6% boron powder, 2%–3% yttrium oxide powder, and the balance being copper powder. The outer sheath is T2 pure copper strip. The filling rate of the core wire is 15wt%–18wt%.

[0013] In step 1, the preparation method of the copper alloy core wire is as follows:

[0014] Weigh the following flux-cored powders according to their mass percentages: 18%–23% chromium powder, 8%–12% silver powder, 5%–6% boron powder, 2%–3% yttrium oxide powder, and the remainder copper powder; the outer sheath is T2 pure copper strip; all the weighed powders are first mixed using a powder mixer at a speed of 100–120 r / min for 5–6 h; then, flux-cored wire is prepared using a flux-cored wire drawing machine at a drawing speed of 6 mm / s–7 mm / s, with a matching powder filling speed of 5 g / s–6 g / s; the diameter of the flux-cored wire is reduced every 0.2 mm until it reaches a diameter of 1.1 mm to ensure the core powder is compacted, and the filling rate of the flux-cored wire is 15 wt%–18 wt%; the prepared copper alloy flux-cored wire is then stored in a dehumidifying cabinet.

[0015] In step 2, the copper / nickel electrothermal alloy component is modeled using PRO / E modeling software; and slicing is performed using CAM software, with each slice thickness set to 3mm-4mm. When additively manufacturing the copper / nickel electrothermal alloy component, the path is selected to complete the stacking of multiple passes in a spiral path from the outside to the inside, and this process is repeated layer by layer to complete the preparation of the copper / nickel electrothermal alloy component. When performing single-layer multi-pass stacking on the nickel side, the spacing is designed to ensure an overlap rate of 50%-60% between passes; when performing single-layer multi-pass stacking on the copper side, the spacing of the weld passes is designed to ensure an overlap rate of 50%-60%. The above process is then converted into a program and imported into the arc welding robot.

[0016] In step 3, during the additive manufacturing process, the wire used on the nickel side is ENiCrMo3T1-4, and the wire used on the copper side is the copper alloy flux-cored wire prepared in step 1. The process parameters for the nickel side are: voltage: 27V~30V, current: 180A~190A, wire extension length: 12mm-15mm, and the next cladding pass is performed after cooling to 100℃~150℃. The process parameters for the copper side are: voltage: 22V~25V, current: 220A~230A, wire extension length: 12mm-15mm, interpass temperature is measured using thermocouples, and the next cladding pass is performed after cooling to 300℃~350℃. The shielding gas is a mixture of 90vol%Ar + 10vol%CO2, with a gas flow rate of 12L / min~15L / min and a wire filling speed of 280mm~300mm / min.

[0017] In step 4, the specific heat treatment process is as follows: solution treatment at 930℃ for 1 hour, followed by aging at 600℃ for 1.5 hours.

[0018] The second technical solution adopted in this invention is to prepare a copper / nickel electrothermal alloy component based on digital modeling and additive manufacturing using the above method.

[0019] The beneficial effects of this invention are:

[0020] (1) When the method of the present invention is based on digital modeling and additive manufacturing of copper / nickel electrothermal alloy components, the preparation method of the copper-side flux-cored welding wire is simple; the Cr element in the copper-based welding wire of the present invention can play the role of precipitation strengthening, and the Cr element has little effect on the conductivity of copper alloy; in order to avoid the influence of Cr element on the conductivity of copper alloy due to easy growth and coarsening during heat treatment, Ag, B and Y elements are added. These elements all have the effect of refining grains, and these elements themselves have little effect on the conductivity of copper alloy; B element has the effect of removing iron, which can avoid the influence of nickel-side iron element diffusion to copper side on the conductivity of copper alloy; Y element has the effect of removing impurities, which can avoid the influence of impurity elements on the conductivity of copper alloy.

[0021] (2) The method of the present invention is based on digital modeling and additive manufacturing technology, and provides a new way to manufacture copper / nickel electrothermal alloy components. The mechanical properties and electrical conductivity of the manufactured structural components meet the actual working conditions, and at the same time solve the problem of difficult connection between copper wires and electrothermal alloy elements.

[0022] (3) The method of the present invention is based on digital modeling and additive manufacturing technology. The entire process from filament preparation to structural component forming can be fully automated and intelligent, with high production efficiency, low material waste rate, dense structure of the prepared structural components, and excellent mechanical properties.

[0023] (4) The copper / nickel electric heating alloy component prepared by the method of the present invention can be used to connect copper wires and nickel-chromium electric heating alloy. The copper / nickel electric heating alloy component has both the excellent electrical and thermal conductivity of copper and the excellent wear resistance, corrosion resistance and high resistance of nickel, and has high application value.

[0024] (5) The method of this invention can solve the problem of low interfacial bonding strength caused by the small size of the wires and the difficulty of connecting dissimilar metals in electrothermal alloy connections. Since copper and nickel have the same face-centered cubic structure, they are infinitely miscible and will form a continuous solid solution throughout the entire composition range, thereby achieving better metallurgical bonding between the cladding layer and the substrate. The copper / nickel electrothermal alloy connector can be used directly as an electrothermal alloy or for connecting copper and nickel wires, transforming the traditional copper / nickel dissimilar connection into a copper-to-copper connection and a nickel-to-nickel connection. Attached Figure Description

[0025] Figure 1 This is a microstructure of the copper / nickel interface of the copper / nickel electrothermal alloy component prepared in Example 1 of this invention;

[0026] Figure 2 This is a macroscopic morphology diagram of the copper / nickel electrothermal alloy component prepared in Example 1 of the present invention. Detailed Implementation

[0027] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0028] This invention provides a method for producing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing, the specific steps of which are as follows:

[0029] Step 1: Prepare the copper alloy flux wire for the copper side of the copper / nickel electrothermal alloy component;

[0030] In step 1, the copper alloy core wire includes a core and an outer sheath. The core is composed of the following components by mass percentage: 18%–23% chromium powder, 8%–12% silver powder, 5%–6% boron powder, 2%–3% yttrium oxide powder, and the balance being copper powder. The outer sheath is T2 pure copper strip. The filling rate of the core wire is 15wt%–18wt%.

[0031] The Cr element in the copper-based welding wire of this invention can play a precipitation strengthening role, and the Cr element has little effect on the conductivity of copper alloys. In order to avoid the influence of Cr element on the conductivity of copper alloys due to easy growth and coarsening during heat treatment, Ag, B and Y elements are added. These elements all have the effect of refining grains, and these elements themselves have little effect on the conductivity of copper alloys. Element B has the effect of removing iron, which can avoid the influence of iron elements from the nickel side on the conductivity of copper alloys. Element Y has the effect of removing impurities, which can avoid the influence of impurity elements on the conductivity of copper alloys.

[0032] In step 1, the preparation method of the copper alloy core wire is as follows:

[0033] Weigh the following flux-cored powders according to their mass percentages: 18%–23% chromium powder, 8%–12% silver powder, 5%–6% boron powder, 2%–3% yttrium oxide powder, and the remainder copper powder; the outer sheath is T2 pure copper strip; all the weighed powders are first mixed using a powder mixer at a speed of 100–120 r / min for 5–6 h; then, flux-cored wire is prepared using a flux-cored wire drawing machine at a drawing speed of 6 mm / s–7 mm / s, with a matching powder filling speed of 5 g / s–6 g / s; the diameter of the flux-cored wire is reduced every 0.2 mm until it reaches a diameter of 1.1 mm to ensure the core powder is compacted, and the filling rate of the flux-cored wire is 15 wt%–18 wt%; the prepared copper alloy flux-cored wire is then stored in a dehumidifying cabinet.

[0034] Step 2: Perform 3D modeling of the additive manufacturing copper / nickel electrothermal alloy component, establish a three-dimensional model of the copper / nickel electrothermal alloy component, then perform layer-by-layer slicing of the three-dimensional model, design the motion trajectory in the 3D printing process, and finally convert the above process into a program suitable for the operation of the arc welding robot.

[0035] In step 2, the copper / nickel electrothermal alloy component is modeled using PRO / E modeling software; and slicing is performed using CAM software, with each slice thickness set to 3mm-4mm. When additively manufacturing the copper / nickel electrothermal alloy component, the path is selected to complete the stacking of multiple passes in a spiral path from the outside to the inside, and this process is repeated layer by layer to complete the preparation of the copper / nickel electrothermal alloy component. When performing single-layer multi-pass stacking on the nickel side, the spacing is designed to ensure an overlap rate of 50%-60% between passes; when performing single-layer multi-pass stacking on the copper side, the spacing of the weld passes is designed to ensure an overlap rate of 50%-60%. The above process is then converted into a program and imported into the arc welding robot.

[0036] Step 3: Perform additive manufacturing of copper / nickel electrothermal alloy components;

[0037] In step 3, during the additive manufacturing process, the wire used on the nickel side is ENiCrMo3T1-4, and the wire used on the copper side is the copper alloy flux-cored wire prepared in step 1. The process parameters for the nickel side are: voltage: 27V~30V, current: 180A~190A, wire extension length: 12mm-15mm, and the next cladding pass is performed after cooling to 100℃~150℃. The process parameters for the copper side are: voltage: 22V~25V, current: 220A~230A, wire extension length: 12mm-15mm, interpass temperature is measured using thermocouples, and the next cladding pass is performed after cooling to 300℃~350℃. The shielding gas is a mixture of 90vol%Ar + 10vol%CO2, with a gas flow rate of 12L / min~15L / min and a wire filling speed of 280mm~300mm / min.

[0038] Step 4: Heat-treat the copper / nickel electric heating alloy component prepared in Step 3; and perform surface machining on the heat-treated copper / nickel electric heating alloy component.

[0039] In step 4, the specific heat treatment process is as follows: solution treatment at 930℃ for 1 hour, followed by aging at 600℃ for 1.5 hours.

[0040] The present invention also provides a copper / nickel electrothermal alloy component, which is prepared by the above method.

[0041] Example 1

[0042] The specific steps of the preparation method of copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing are as follows:

[0043] Step 1: Prepare the copper alloy flux-cored wire for the copper side of the copper / nickel heating alloy component. The specific method is as follows: Weigh the following flux-cored powders according to their mass percentages: 20% chromium powder, 10% silver powder, 5% boron powder, 2% yttrium oxide powder, and the remainder copper powder. The sum of the mass percentages of the above components is 100%. Mix all the weighed powders using a powder mixer at a speed of 110 r / min for 5 hours. When preparing the flux-cored wire, set the wire drawing speed to 7 mm / s, and the powder filling speed to match the drawing speed to 5 g / s. Reduce the diameter of the flux-cored wire every 0.2 mm until it reaches a diameter of 1.1 mm to ensure the powder core is compacted. The outer sheath is T2 pure copper strip; the filling rate is 16%. Store the prepared copper alloy flux-cored wire in a dehumidifying cabinet.

[0044] Step 2: Model the copper / nickel electrothermal alloy component using PRO / E modeling software, and perform slicing using CAM software, with each slice thickness set to 3-4mm. When additively manufacturing the copper / nickel electrothermal alloy component, the path is selected to complete the multi-pass stacking of one layer from the outside to the inside in a spiral path, and this is repeated layer by layer to complete the preparation of the copper / nickel electrothermal alloy component. When performing single-layer multi-pass stacking on the nickel side, the spacing is designed to ensure an overlap rate of 50%-60%. When performing single-layer multi-pass stacking on the copper side, the spacing of the weld beads is designed to ensure an overlap rate of 50%-60%. The above process is converted into a program and imported into the arc welding robot.

[0045] Step 3: During the additive manufacturing process, the wire used on the nickel side is ENiCrMo3T1-4, and the wire used on the copper side is the copper alloy flux-cored wire prepared in Step 1. Nickel side process parameters: Voltage: 27V, Current: 180A, Wire extension length: 12mm, The next cladding pass is performed after cooling to 100℃~150℃. Copper side process parameters: Voltage: 23V, Current: 220A, Wire extension length: 15mm, Interpass temperature is measured using thermocouples, the next cladding pass is performed after cooling to 300℃~350℃. The shielding gas is a mixture of 90vol%Ar + 10vol%CO2, gas flow rate: 125L / min, and wire filling speed: 280mm / min.

[0046] Step 4: The copper / nickel electric heating alloy component prepared in Step 3 is subjected to heat treatment. The specific heat treatment process is: solution treatment at 930℃ for 1 hour followed by aging at 600℃ for 1.5 hours; and the surface of the heat-treated copper / nickel electric heating alloy component is machined.

[0047] Example 1 employs a method for manufacturing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing. After mechanical property testing, the interfacial bonding strength is 125 MPa at a high temperature of 600°C. After electrical conductivity testing, the copper side conductivity is 74% IACS, the nickel side conductivity is 21.1% IACS, and the overall conductivity of the copper / nickel electrothermal alloy component is 65% IACS. After hardness testing, the average hardness of the copper side is 251 HV. 0.1 The average hardness of the nickel side is 215 HV. 0.1 The average hardness of the copper / nickel transition region is 227 HV. 0.1 The measured mechanical properties and conductivity all meet the requirements of actual working conditions.

[0048] from Figure 1 As can be seen, the copper / nickel electrothermal alloy component achieved good metallurgical bonding, without defects such as incomplete fusion, porosity, or cracks, and the prepared structural component has a dense microstructure; a clear transition region was formed between copper and nickel, indicating that the copper / nickel electrothermal alloy component achieved a gradient transition and has relatively good interfacial mechanical properties;

[0049] from Figure 2 As can be seen from the above, the forming technology provided by the method of the present invention can successfully produce defect-free and well-formed copper / nickel electrothermal alloy components.

[0050] Example 2

[0051] The specific steps of the preparation method of copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing are as follows:

[0052] Step 1: Prepare the copper alloy flux-cored wire for the copper side of the copper / nickel heating alloy component. The specific method is as follows: Weigh the following flux-cored powders according to their mass percentages: 19% chromium powder, 11% silver powder, 6% boron powder, 3% yttrium oxide powder, and the remainder copper powder. The sum of the mass percentages of the above components is 100%. Mix all the weighed powders using a powder mixer at a speed of 120 r / min for 6 hours. When preparing the flux-cored wire, set the wire drawing speed to 6 mm / s, and the powder filling speed to match the drawing speed to 6 g / s. Reduce the diameter of the flux-cored wire every 0.2 mm until it reaches a diameter of 1.1 mm to ensure the powder core is compacted. The outer sheath is made of T2 pure copper strip with a filling rate of 17%. Store the prepared copper alloy flux-cored wire in a dehumidifying cabinet.

[0053] Step 2: Model the copper / nickel electrothermal alloy component using PRO / E modeling software, and perform slicing using CAM software, with each slice thickness set to 3-4 mm. When additively manufacturing the copper / nickel electrothermal alloy component, the path is selected to complete the multi-pass stacking of one layer from the outside to the inside in a spiral path, and this is repeated layer by layer to complete the preparation of the copper / nickel electrothermal alloy component. When performing single-layer multi-pass stacking on the nickel side, the spacing is designed to ensure an overlap rate of 50-60% between passes. When performing single-layer multi-pass stacking on the copper side, the spacing of the weld beads is designed to ensure an overlap rate of 50%-60%. The above process is converted into a program and imported into the arc welding robot.

[0054] Step 3: During the additive manufacturing process, the wire used on the nickel side is ENiCrMo3T1-4, and the wire used on the copper side is the copper alloy flux-cored wire prepared in Step 1. Nickel side process parameters: Voltage: 27V, Current: 185A, Wire extension length: 15mm, The next cladding pass is performed after cooling to 100℃~150℃. Copper side process parameters: Voltage: 23V, Current: 220A, Wire extension length: 12mm, Interpass temperature is measured using thermocouples, the next cladding pass is performed after cooling to 300℃~350℃. The shielding gas is a mixture of 90vol%Ar + 10vol%CO2, gas flow rate: 13L / min, and wire filling speed: 290mm / min.

[0055] Step 4: The copper / nickel electric heating alloy component prepared in Step 3 is subjected to heat treatment. The specific heat treatment process is: solution treatment at 930℃ for 1 hour followed by aging at 600℃ for 1.5 hours; and the surface of the heat-treated copper / nickel electric heating alloy component is machined.

[0056] Example 2 employs a method for manufacturing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing. After mechanical property testing, the interfacial bonding strength is 130 MPa at a high temperature of 600°C. After electrical conductivity testing, the copper side conductivity is 73.5% IACS, the nickel side conductivity is 22.4% IACS, and the overall conductivity of the copper / nickel electrothermal alloy component is 62.3% IACS. After hardness testing, the average hardness of the copper side is 263 HV. 0.1 The average hardness of the nickel side is 232 HV. 0.1 The average hardness of the copper / nickel transition region is 254 HV. 0.1 The measured mechanical properties and conductivity all meet the requirements of actual working conditions.

[0057] Example 3

[0058] The specific steps of the preparation method of copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing are as follows:

[0059] Step 1: Prepare the copper alloy flux-cored wire for the copper side of the copper / nickel heating alloy component. The specific method is as follows: Weigh the following flux-cored powders according to their mass percentages: 20% chromium powder, 11% silver powder, 5% boron powder, 2% yttrium oxide powder, and the remainder copper powder. The sum of the mass percentages of the above components is 100%. Mix all the weighed powders using a powder mixer at a speed of 100 r / min for 5 hours. When preparing the flux-cored wire, set the wire drawing speed to 7 mm / s, and the powder filling speed to match the drawing speed to 5 g / s. Reduce the diameter of the flux-cored wire every 0.2 mm until it reaches a diameter of 1.1 mm to ensure the powder core is compacted. The outer sheath is made of T2 pure copper strip with a filling rate of 18%. Store the prepared copper alloy flux-cored wire in a dehumidifying cabinet.

[0060] Step 2: Model the copper / nickel electrothermal alloy component using PRO / E modeling software, and perform slicing using CAM software, with each slice thickness set to 3-4 mm. When additively manufacturing the copper / nickel electrothermal alloy component, the path is selected to complete the multi-pass stacking of one layer from the outside to the inside in a spiral path, and this is repeated layer by layer to complete the preparation of the copper / nickel electrothermal alloy component. When performing single-layer multi-pass stacking on the nickel side, the spacing is designed to ensure an overlap rate of 50-60% between passes. When performing single-layer multi-pass stacking on the copper side, the spacing of the weld beads is designed to ensure an overlap rate of 50%-60%. The above process is converted into a program and imported into the arc welding robot.

[0061] Step 3: During the additive manufacturing process, the wire used on the nickel side is ENiCrMo3T1-4, and the wire used on the copper side is the copper alloy flux-cored wire prepared in Step 1. Nickel side process parameters: Voltage: 28V, Current: 190A, Wire extension length: 13mm, The next cladding pass is performed after cooling to 100℃~150℃. Copper side process parameters: Voltage: 23V, Current: 230A, Wire extension length: 14mm, Interpass temperature is measured using thermocouples, the next cladding pass is performed after cooling to 300℃~350℃. The shielding gas is a mixture of 90vol%Ar + 10vol%CO2, gas flow rate: 12L / min, and wire filling speed: 300mm / min.

[0062] Step 4: The copper / nickel electric heating alloy component prepared in Step 3 is subjected to heat treatment. The specific heat treatment process is: solution treatment at 930℃ for 1 hour followed by aging at 600℃ for 1.5 hours; and the surface of the heat-treated copper / nickel electric heating alloy component is machined.

[0063] Example 3 employs a method for manufacturing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing. After mechanical property testing, the interfacial bonding strength is 130 MPa at a high temperature of 600°C. After electrical conductivity testing, the copper side conductivity is 70.1% IACS, the nickel side conductivity is 20.2% IACS, and the overall conductivity of the copper / nickel electrothermal alloy component is 61.3% IACS. After hardness testing, the average hardness of the copper side is 245 HV. 0.1 The average hardness of the nickel side is 217 HV. 0.1 The average hardness of the copper / nickel transition region is 231 HV. 0.1 The measured mechanical properties and conductivity all meet the requirements of actual working conditions.

[0064] Example 4

[0065] The specific steps of the preparation method of copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing are as follows:

[0066] Step 1: Prepare the copper alloy flux-cored wire for the copper side of the copper / nickel heating alloy component. The specific method is as follows: Weigh the following flux-cored powders according to their mass percentages: 23% chromium powder, 12% silver powder, 5% boron powder, 3% yttrium oxide powder, and the remainder copper powder. The sum of the mass percentages of the above components is 100%. Mix all the weighed powders using a powder mixer at a speed of 110 r / min for 5 hours. When preparing the flux-cored wire, set the wire drawing speed to 7 mm / s, and the powder filling speed to match the drawing speed to 5 g / s. Reduce the diameter of the flux-cored wire every 0.2 mm until it reaches a diameter of 1.1 mm to ensure the powder core is compacted. The outer sheath is T2 pure copper strip with a filling rate of 18%. Store the prepared copper alloy flux-cored wire in a dehumidifying cabinet.

[0067] Step 2: Model the copper / nickel electrothermal alloy component using PRO / E modeling software, and perform slicing using CAM software, with each slice thickness set to 3-4 mm. When additively manufacturing the copper / nickel electrothermal alloy component, the path is selected to complete the multi-pass stacking of one layer from the outside to the inside in a spiral path, and this is repeated layer by layer to complete the preparation of the copper / nickel electrothermal alloy component. When performing single-layer multi-pass stacking on the nickel side, the spacing is designed to ensure an overlap rate of 50-60% between passes. When performing single-layer multi-pass stacking on the copper side, the spacing of the weld beads is designed to ensure an overlap rate of 50%-60%. The above process is converted into a program and imported into the arc welding robot.

[0068] Step 3: During the additive manufacturing process, the wire used on the nickel side is ENiCrMo3T1-4, and the wire used on the copper side is the copper alloy flux-cored wire prepared in Step 1. Nickel side process parameters: Voltage: 28V, Current: 185A, Wire extension length: 12mm. The next cladding pass is performed after cooling to 100℃~150℃. Copper side process parameters: Voltage: 23V, Current: 230A, Wire extension length: 15mm. Thermocouples are used to test the interpass temperature. The next cladding pass is performed after cooling to 300℃~350℃. The shielding gas is a mixture of 90vol%Ar + 10vol%CO2, with a gas flow rate of 13L / min and a wire filling speed of 300mm / min.

[0069] Step 4: The copper / nickel electric heating alloy component prepared in Step 3 is subjected to heat treatment. The specific heat treatment process is: solution treatment at 930℃ for 1 hour followed by aging at 600℃ for 1.5 hours; and the surface of the heat-treated copper / nickel electric heating alloy component is machined.

[0070] Example 4 employs a method for manufacturing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing. After mechanical property testing, the interfacial bonding strength is 117 MPa at a high temperature of 600°C. After electrical conductivity testing, the copper side conductivity is 75.5% IACS, the nickel side conductivity is 21.5% IACS, and the overall conductivity of the copper / nickel electrothermal alloy component is 63.6% IACS. After hardness testing, the average hardness of the copper side is 245 HV. 0.1 The average hardness of the nickel side is 213 HV. 0.1 The average hardness of the copper-nickel transition region is 235 HV. 0.1 The measured mechanical properties and conductivity all meet the requirements of actual working conditions.

[0071] Example 5

[0072] The specific steps of the preparation method of copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing are as follows:

[0073] Step 1: Prepare the copper alloy flux-cored wire for the copper side of the copper / nickel heating alloy component. The specific method is as follows: Weigh the following flux-cored powders according to their mass percentages: 21% chromium powder, 12% silver powder, 5% boron powder, 3% yttrium oxide powder, and the remainder copper powder. The sum of the mass percentages of the above components is 100%. Mix all the weighed powders using a powder mixer at a speed of 110 r / min for 5 hours. When preparing the flux-cored wire, set the wire drawing speed to 7 mm / s, and the powder filling speed to match the drawing speed to 5 g / s. Reduce the diameter of the flux-cored wire every 0.2 mm until it reaches a diameter of 1.1 mm to ensure the powder core is compacted. The outer sheath is T2 pure copper strip with a filling rate of 17%. Store the prepared copper alloy flux-cored wire in a moisture-proof cabinet.

[0074] Step 2: Model the copper / nickel electrothermal alloy component using PRO / E modeling software, and perform slicing using CAM software, with each slice thickness set to 3-4 mm. When additively manufacturing the copper / nickel electrothermal alloy component, the path is selected to complete the multi-pass stacking of one layer from the outside to the inside in a spiral path, and this is repeated layer by layer to complete the preparation of the copper / nickel electrothermal alloy component. When performing single-layer multi-pass stacking on the nickel side, the spacing is designed to ensure an overlap rate of 50-60% between passes. When performing single-layer multi-pass stacking on the copper side, the spacing of the weld beads is designed to ensure an overlap rate of 50%-60%. The above process is converted into a program and imported into the arc welding robot.

[0075] Step 3: During the additive manufacturing process, the wire used on the nickel side is ENiCrMo3T1-4, and the wire used on the copper side is the copper alloy flux-cored wire prepared in Step 1. Nickel side process parameters: Voltage: 27V, Current: 190A, Wire extension length: 12mm, The next cladding pass is performed after cooling to 100℃~150℃. Copper side process parameters: Voltage: 23V, Current: 220A, Wire extension length: 15mm, Thermocouple is used to test the interpass temperature, the next cladding pass is performed after cooling to 300℃~350℃. The shielding gas is a mixture of 90vol%Ar + 10vol%CO2, gas flow rate: 12L / min, and wire filling speed: 280mm / min.

[0076] Step 4: The copper / nickel electric heating alloy component prepared in Step 3 is subjected to heat treatment. The specific heat treatment process is: solution treatment at 930℃ for 1 hour followed by aging at 600℃ for 1.5 hours; and the surface of the heat-treated copper / nickel electric heating alloy component is machined.

[0077] Example 5 employs a method for manufacturing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing. After mechanical property testing, the interfacial bonding strength is 118 MPa at a high temperature of 600°C. After electrical conductivity testing, the copper side conductivity is 75.5% IACS, the nickel side conductivity is 22.1% IACS, and the overall conductivity of the copper / nickel electrothermal alloy component is 63.3% IACS. After hardness testing, the average hardness of the copper side is 243 HV. 0.1 The average hardness of the nickel side is 217 HV. 0.1 The average hardness of the copper / nickel transition region is 232 HV. 0.1 The measured mechanical properties and conductivity all meet the requirements of actual working conditions.

Claims

1. A method for preparing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing, characterized in that, The specific steps are as follows: Step 1: Prepare the copper alloy flux wire for the copper side of the copper / nickel electrothermal alloy component; In step 1, the copper alloy core wire includes a core and an outer sheath. The core is composed of the following components by mass percentage: 18%~23% chromium powder, 8%~12% silver powder, 5%~6% boron powder, 2%~3% yttrium oxide powder, and the balance being copper powder. The outer sheath is T2 pure copper strip. The filling rate of the core wire is 15wt%-18wt%. Step 2: Perform 3D modeling of copper / nickel electrothermal alloy components, establish a three-dimensional model of copper / nickel electrothermal alloy components, then perform layer-by-layer slicing of the three-dimensional model, design the motion trajectory during the 3D printing process, and finally convert the above process into a program suitable for the operation of arc welding robots. Step 3: Perform additive manufacturing of copper / nickel electrothermal alloy components; Step 4: Heat-treat the copper / nickel electric heating alloy component prepared in Step 3; and perform surface machining on the heat-treated copper / nickel electric heating alloy component.

2. The method for preparing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing according to claim 1, characterized in that, In step 1, the preparation method of the copper alloy core wire is as follows: Weigh the following flux-cored powders according to their mass percentages: chromium powder 18%~23%, silver powder 8%~12%, boron powder 5%~6%, yttrium oxide powder 2%~3%, and copper powder as the remainder; the outer sheath is T2 pure copper strip; all the weighed powders are first mixed using a powder mixer at a speed of 100r / min-120r / min for 5h-6h; then, flux-cored wire is prepared using a flux-cored wire drawing machine at a drawing speed of 6mm / s-7mm / s, with a matching powder filling speed of 5 g / s-6g / s; the diameter of the flux-cored wire is reduced every 0.2mm until the diameter reaches 1.1mm, and the filling rate of the flux-cored wire is 15wt%-18wt%; the prepared copper alloy flux-cored wire is stored in a dehumidifying cabinet.

3. The method for preparing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing according to claim 2, characterized in that, In step 2, the copper / nickel electrothermal alloy component is modeled using PRO / E modeling software; and slicing is performed using CAM software, with each slice thickness set to 3mm~4mm; when additively manufacturing the copper / nickel electrothermal alloy component, the path is selected to complete the stacking of multiple passes in a spiral path from the outside to the inside, and this is repeated layer by layer to complete the preparation of the copper / nickel electrothermal alloy component; when performing single-layer multi-pass stacking on the nickel side, the design spacing ensures an overlap rate of 50%-60% between passes; when performing single-layer multi-pass stacking on the copper side, the design spacing of the weld passes ensures an overlap rate of 50%-60%. The above process is converted into a program and imported into the arc welding robot.

4. The method for preparing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing according to claim 2, characterized in that, In step 3, during the additive manufacturing process, the wire used on the nickel side is ENiCrMo3T1-4, and the wire used on the copper side is the copper alloy flux-cored wire prepared in step 1. The process parameters for the nickel side are: voltage: 27V~30V, current: 180A~190A, wire extension length: 12mm-15mm, and the next cladding is performed after cooling to 100℃~150℃. The process parameters for the copper side are: voltage: 22V~25V, current: 220A~230A, wire extension length: 12mm-15mm, the interpass temperature is measured using a thermocouple, and the next cladding is performed after cooling to 300℃~350℃. The shielding gas is a mixture of 90vol%Ar + 10vol%CO2, the gas flow rate is 12L / min~15L / min, and the wire filling speed is 280mm~300mm / min.

5. The method for preparing copper / nickel electrothermal alloy components based on digital modeling and additive manufacturing according to claim 2, characterized in that, In step 4, the specific heat treatment process is as follows: solution treatment at 930℃ for 1 hour, followed by aging at 600℃ for 1.5 hours.

6. A copper / nickel electrothermal alloy component based on digital modeling and additive manufacturing, characterized in that, It is prepared by the method described in any one of claims 1-5.

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