Automatic system and method for preparing multi-component metal alloy

Abstract

The invention provides an automatic system and method for preparing multi-component metal alloy, and the system comprises an industrial robot which is used for recognizing and grabbing target block metal from a sample library and then installing the target block metal into machining equipment; the machining equipment is used for carrying out surface treatment on the installed block metal and then cutting the block metal to a target volume; the weighing equipment is used for weighing the cut metal; the mixing and smelting equipment is used for sequentially carrying out melt mixing and casting forming on the weighed metal; and the automatic control system is used for calculating and outputting the required target volume of each metal according to an input metal formula, and then controlling the industrial robot, the machining equipment, the weighing equipment and the mixed smelting equipment to sequentially complete the processes of recognition, grabbing, machining, weighing, melting mixing and casting forming. By the adoption of the automatic system, the proportion of all metal elements can be accurately controlled, and the batching efficiency of the multi-component alloy material is remarkably improved.

Description

Technical Field

[0001] The present invention belongs to the field of metal materials. Specifically, the present invention relates to an automated system and method for preparing a multi-component metal alloy. Background Art

[0002] The development of high-performance metal materials is crucial to the development of human society. Since the industrial age, every technological leap has been inseparable from the development of high-performance metal materials. For example, the development of lightweight and high-strength aluminum alloys, titanium alloys, and high-temperature resistant nickel-based superalloys has enabled humans to transcend geographical and spatial limitations, bringing prosperity to freight and passenger transport. In addition, cemented carbide, as the "teeth" of industry, has solved the problem of metal processing, making it possible to manufacture precise and complex structural components. The development of biocompatible magnesium alloys, stainless steel, and shape memory alloys has brought protection to human life and health. In modern society, with the gradual increase in application scenarios, especially in extreme environment fields such as aerospace, thermal energy conversion, and national defense and military industry, the demand for the development of high-performance new materials has become more urgent.

[0003] However, it is not easy to develop high-performance metal materials. On the one hand, there are many types of metal materials with different properties, and different composition ratios can produce different mechanical and functional properties. On the other hand, the current development method of high-performance metal materials is still based on the traditional trial and error method, which requires a lot of manpower and material resources for inefficient and repetitive metal batching, smelting and characterization. In these repetitive tasks, the key to restricting the speed of new metal material research and development lies in the metal batching link. Unlike industrial production, the new material research and development process often focuses on the purity of raw materials and the accuracy of the ratio, while some active metal raw materials, such as aluminum, magnesium, titanium and zirconium, often produce oxide layers due to long-term exposure to air, thereby affecting the purity of the alloy. In addition, different metal materials have obvious differences in hardness and shape, and it takes a lot of time to cut, crush and polish the metal materials to achieve high-precision weighing and ratio. Generally speaking, an ordinary R&D personnel needs to spend a whole day to mix about 5-10 three- to five-element alloy composition ratios, which is a drop in the bucket for large-scale metal material research and development.

[0004] Therefore, in order to improve the research and development efficiency of high-performance metal materials, it is crucial to develop a method that can realize the automated preparation of multi-component metal alloys. Summary of the invention

[0005] The object of the present invention is to provide an automated system and method for preparing a multi-component metal alloy. The automated system of the present invention can not only accurately control the proportion of each metal element, but also realize efficient and unmanned operation, thereby significantly improving the efficiency of multi-component alloy material batching and smelting. The automated system of the present invention has great application prospects and commercial value in the field of new metal material research and development and industrial production.

[0006] The above-mentioned object of the present invention is achieved through the following technical solutions.

[0007] In one aspect, the present invention provides an automated system for preparing a multi-component metal alloy, comprising:

[0008] An industrial robot that is used to identify and grab a target piece of metal from a sample library and then install it into a machining device;

[0009] Machining equipment for surface treatment of installed bulk metal and then cutting to target volume;

[0010] Weighing equipment, which is used to weigh the cut metal;

[0011] Mixing and smelting equipment, which is used to melt and mix the weighed metals and then cast them into shape;

[0012] The automatic control system is used to calculate and output the target volume of each metal required according to the input metal formula, and then control the industrial robot, mechanical processing equipment, weighing equipment and mixed smelting equipment to complete the process of identification, grasping, mechanical processing, weighing, melting and mixing, and casting in sequence.

[0013] The inventors of the present invention unexpectedly found that the automated system of the present invention can not only accurately control the proportion of each metal element, but also significantly improve the efficiency of multi-component alloy material batching. Compared with the traditional method, the batching of 10 raw materials per day is improved to the batching of hundreds of raw materials per day, saving labor costs and reducing human errors.

[0014] Preferably, in the automation system described in the present invention, the automatic control system converts the target weight of each metal based on the total weight of all metals input and the molar ratio between the metals, and then calculates and outputs the target volume of each metal using the density of each metal that has been entered.

[0015] Preferably, in the automated system of the present invention, the automated control system outputs the target volume of each metal by outputting the target diameter and the target length of each metal.

[0016] Preferably, in the automation system described in the present invention, the industrial robot is a robotic arm.

[0017] Preferably, in the automation system described in the present invention, the bulk metal is rod-shaped metal.

[0018] Preferably, in the automation system described in the present invention, the mechanical processing equipment is a Swiss-type CNC machine tool.

[0019] Preferably, in the automated system of the present invention, the surface treatment is to remove oxides on the metal surface and process the bulk metal to a target diameter.

[0020] Preferably, in the automation system described in the present invention, the surface treatment is performed by turning and milling.

[0021] Preferably, in the automation system of the present invention, the automation system further comprises:

[0022] Cleaning and drying equipment, which is used to blow, wash and dry the cut metal in sequence;

[0023] Wherein, the cleaning and drying equipment is controlled by an automatic control system to complete the purging, cleaning and drying processes in sequence.

[0024] Preferably, in the automation system described in the present invention, the mixed smelting equipment is selected from one or more of an arc melting furnace, a vacuum casting furnace and a vacuum suction casting machine.

[0025] Preferably, in the automation system of the present invention, the automation system further comprises:

[0026] a data logging system for recording the weight of metal measured by the weighing device; and

[0027] The background monitoring system is used to compare the weighed metal weight with the metal weight calculated by the automatic control system according to the metal formula. When the deviation between the weighed metal weight and the calculated metal weight exceeds the threshold set by the system, the alarm mechanism is triggered.

[0028] In another aspect, the present invention provides a method for preparing a multi-component metal alloy using the automated system of the present invention, comprising the following steps:

[0029] (1) Inputting the metal formula into the automatic control system, the automatic control system calculates and outputs the target volume of each metal required;

[0030] (2) The automatic control system controls the industrial robot to identify and grab the target block metal from the sample library and then install it into the machining equipment;

[0031] (3) The automatic control system controls the machining equipment to perform surface treatment on the installed bulk metal and then cut it to the target volume;

[0032] (4) The automatic control system controls the weighing equipment to weigh the cut metal;

[0033] (5) An automatic control system controls the mixed smelting equipment to sequentially melt, mix and cast the weighed metals to obtain a multi-component metal alloy.

[0034] Preferably, in the method of the present invention, the method further comprises the following steps after step (3) and before step (4):

[0035] The automatic control system controls the cleaning and drying equipment to blow, clean and dry the cut metal in sequence.

[0036] Preferably, in the method of the present invention, the method further comprises the following steps:

[0037] The data recording system records the metal weight measured by the weighing equipment, and then the background monitoring system compares the weighed metal weight with the metal weight calculated by the automatic control system according to the metal formula. When the deviation between the weighed metal weight and the calculated metal weight exceeds the threshold set by the system, the alarm mechanism is triggered.

[0038] The present invention has the following beneficial effects:

[0039] 1. The automation system of the present invention utilizes the known density of single metal raw materials (such as iron, copper, aluminum and titanium, etc.) and accurately controls the volume of metal raw materials through high-precision machining methods to prepare a variety of high-purity raw materials of target weight (weight error <1%), and combines industrial robots to complete the transportation and proportional mixing of high-purity raw materials. Among them, the present invention uses a Swiss-type CNC machine tool to descale and cut samples. This method can not only easily dock with industrial robots to complete automatic loading and unloading, but also achieve high-precision turning, milling and cutting. Compared with traditional file grinding or pickling methods, this method can achieve full automation and unmanned operation, and is suitable for most metal materials.

[0040] 2. The automation system of the present invention realizes the automation of each link in the preparation process of multi-metal alloys. Specifically, the present invention is centered on an industrial robot controlled by an automatic control system, and realizes the automation of each link from raw material identification, peeling, cutting, cleaning, drying, weighing to melting and mixing. Compared with traditional methods, the batching of 10 kinds of raw materials per day is improved to the batching of hundreds of raw materials per day, which saves labor costs and reduces human errors.

[0041] 3. The present invention also provides a background monitoring system and a data recording system, which can automatically and completely record the weight of each raw material weighed. When the deviation between the weighed raw material weight and the calculated raw material weight exceeds the threshold set by the system, an alarm mechanism can be triggered. Compared with the traditional manual batching method, the experimental error caused by human factors is eliminated.

[0042] 4. The automation system of the present invention can not only accurately control the proportion of each metal element, but also improve the batching efficiency of multi-component alloy materials, and can complete the batching of large quantities of gradient alloy systems and realize the alternating use of single formula and large number of gradient component formulas. In addition, the automation system of the present invention also solves the batching problems caused by the easy oxidation, hardness and shape differences of metal materials. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The embodiments of the present invention are described in detail below with reference to the accompanying drawings, wherein:

[0044] Figure 1 is a schematic diagram of an automated system for preparing a multi-component metal alloy according to a specific embodiment of the present invention;

[0045] Among them, the figure numbers are: 1-automatic control system; 2-mechanical arm; 3-metal bar sample library; 4-central CNC machine tool; 5-ultrasonic cleaning machine; 6-compressed air pump; 7-high-precision electronic balance; 8-crucible array; 9-mixed smelting equipment.

[0046] Figure 2 It is a schematic diagram of a process for preparing a multi-component metal alloy using a specific embodiment of the present invention.

[0047] Figure 3 It is a schematic diagram of part of the metal bar raw materials in Example 1 of the present invention.

[0048] Figure 4 Schematic diagram of a rod-shaped sample obtained by mechanical processing in Example 1 of the present invention.

[0049] Figure 5 It is a schematic diagram of an alloy ingot obtained by arc melting and an amorphous metal rod with a diameter of 3 mm obtained by copper mold suction casting in Example 1 of the present invention.

[0050] Figure 6 This is the EDS characterization result of the amorphous metal rod with a diameter of 3 mm prepared in Example 1 of the present invention.

[0051] Figure 7 This is the XRD characterization result of the amorphous metal rod with a diameter of 3 mm prepared in Example 1 of the present invention.

[0052] Figure 8This is the EDS characterization result of 120 g of bulk alloy material prepared in Example 2 of the present invention.

[0053] Fig. 9 This is the XRD characterization result of 120 g of bulk alloy material prepared in Example 2 of the present invention. DETAILED DESCRIPTION

[0054] The present invention is further described in detail below in conjunction with specific embodiments. The given examples are only for illustrating the present invention, but not for limiting the scope of the present invention.

[0055] See also Figure 1 The present invention provides an automated system for preparing a multi-component metal alloy, comprising:

[0056] A robot arm 2, which is used to identify and grab the target metal bar from the metal bar sample library 3, and then install it into the Swiss-type CNC machine tool 4;

[0057] A Swiss-type CNC machine tool 4, which is used to turn and mill the installed metal bars to remove the oxide scale on the surface, and then cut them to a target diameter and a target length;

[0058] Ultrasonic cleaning machine 5, which is used to clean the cut metal;

[0059] A compressed air pump 6 for blowing the metal before and after cleaning, on the one hand to remove debris and on the other hand to remove liquid;

[0060] A high-precision electronic balance 7, which is used to weigh the blow-dried metal;

[0061] A crucible array 8, which is used to store samples before mixed smelting;

[0062] Mixing and smelting equipment 9, which is used to sequentially melt, mix and cast the weighed metals;

[0063] An automatic control system 1 is used to calculate and output the target volume of each metal required according to the input metal formula, and then control the robot arm 2, the Swiss CNC machine tool 4, the ultrasonic cleaning machine 5, the compressed air pump 6, the high-precision electronic balance 7 and the mixed smelting equipment 9 to sequentially complete the processes of identification, grasping, machining, purging (removing debris), cleaning, re-purging (drying), weighing, melting and mixing, and casting; wherein the automatic control system 1 converts the target weight of each metal according to the total weight of all the input metals and the molar ratio between the metals, and then calculates and outputs the target diameter and target length of each metal using the density of each metal that has been entered;

[0064] A data recording system (not shown) for recording the weight of metal measured by the high-precision electronic balance 7;

[0065] The background monitoring system (not shown in the figure) is used to compare the weighed metal weight with the metal weight calculated by the automatic control system 1 according to the metal formula. When the deviation between the weighed metal weight and the calculated metal weight exceeds the threshold set by the system, an alarm mechanism is triggered.

[0066] The method for preparing a multi-component metal alloy using the above multi-automation system is as follows (see Figure 2 ):

[0067] (1) The metal formula is input into the automatic control system 1, and the automatic control system 1 calculates and outputs the target volume of each metal required;

[0068] (2) The automatic control system 1 controls the robot arm 2 to identify and grab the target metal bar from the metal bar sample library 3, and then install it into the Swiss CNC machine tool 4;

[0069] (3) the automatic control system 1 controls the Swiss-type CNC machine tool 4 to turn and mill the installed metal bar to a target diameter, and then cut it to a target length;

[0070] (4) The automatic control system 1 controls the compressed air pump 6 and the ultrasonic cleaning machine 5 to blow and clean the cut metal in sequence;

[0071] (5) The automatic control system 1 controls the compressed air pump 6 to purge the cleaned metal again;

[0072] (6) The automatic control system 1 controls the high-precision electronic balance 7 to weigh the blow-dried metal;

[0073] (7) The automatic control system 1 controls the mixed smelting equipment 9 to sequentially melt, mix and cast the weighed metals, thereby completing the preparation of the multi-component metal alloy.

[0074] Among them, the data recording system records the metal weight weighed by the high-precision electronic balance 7, and then the background monitoring system compares the weighed metal weight with the metal weight calculated by the automatic control system 1 according to the metal formula. When the deviation between the weighed metal weight and the calculated metal weight exceeds the threshold set by the system, the alarm mechanism is triggered.

[0075] Example 1

[0076] The automated system of the present invention is used to prepare Zr with a total weight of 30 g. 52.5 Ti5Al 10 Ni 14.6 Cu 17.9 Bulk metallic glass, comprising the following steps:

[0077] Customize Zr, Ti, Al, Ni and Cu rods with a purity of 99.9 wt% (diameter 12 mm or 10 mm, length 300 mm, such as Figure 3 As shown). The automatic control system 1 calculates the weight of each metal rod required based on the total weight of the metallic glass being 30g and the molar ratio of each metal component being 52.5:5:10:14.6:17.9, wherein Zr is 19.701g, Ti is 0.985g, Al is 1.110g, Ni is 3.525g, and Cu is 4.679g. Then the automatic control system 1 further calculates the volume of each metal rod required based on the density of each elemental metal, wherein Zr is 3025.849mm 3 , Ti is 218.45mm 3 , Al is 411.090mm 3 , Ni is 395.718mm 3 and Cu is 524.569mm 3 Then, the automatic control system 1 controls the Swiss-type CNC machine tool 4 to mill the outer surfaces of the metal bars (Zr, Ti, Ni and Cu bars) with a diameter of 12 mm and the metal bars (Al bars) with a diameter of 10 mm to a diameter of 10 mm and 9 mm respectively to remove the oxide scale on the surface, and then cut the above metal bars to a specified length to meet the volume requirements.

[0078] Figure 4 The metal bars processed by the central CNC machine tool 4 are shown. After being weighed by the high-precision electronic balance 7, their weights are: Zr is 19.863g, Ti is 0.983g, Al is 1.106g, Ni is 3.51g, and Cu is 4.68g. It can be calculated that the maximum mass error of the metal bars cut by the system of the present invention does not exceed 1%. According to calculations, the actual composition of the bulk metallic glass is Zr 52.758 Ti 4.975 Al 9.932 Ni 14.490 Cu 17.845 , which is very close to the target composition.

[0079] In order to further verify the purity and accuracy of the prepared metal bars, the metal bars were purged (to remove debris), ultrasonically cleaned, and purged again (to remove liquid) in sequence, and then melted and mixed in an arc melting furnace to obtain alloy ingots. Subsequently, amorphous bars with a diameter of 3 mm (such as Figure 5 As shown, the button shape is the alloy ingot before suction casting). After EDS composition analysis (such as Figure 6 As shown) and XRD structural analysis (as Figure 7As shown in FIG. 1 , it is demonstrated that bulk amorphous alloys that are highly sensitive to composition and impurities (eg, oxygen) can be prepared using the automated system of the present invention.

[0080] Example 2

[0081] The automated system of the present invention is used to prepare Zr with a total weight of 120 g. 52.5 Ti5Al 10 Ni 14.6 Cu 17.9 Bulk metallic glass, comprising the following steps:

[0082] The method of Example 1 was repeated, and the automatic control system 1 calculated the required weight of each metal element according to the total weight of the metallic glass and the molar ratio of each metal component, which were: Zr was 78.805g, Ti was 3.938g, Al was 4.440g, Ni was 14.100g, and Cu was 18.717g. Then the automatic control system 1 further calculated the required volume of each metal bar according to the density of each elemental metal, where Zr was 12103.397mm 3 , Ti is 873.786mm 3 , Al is 1644.360mm 3 , Ni is 1582.871mm 3 And Cu is 2098.278mm 3 Then, the automatic control system 1 controls the Swiss-type CNC machine tool 4 to perform surface milling on the metal bar to remove the oxide scale on the surface, and then cut it to a specified length to meet the volume requirement.

[0083] The actual mass of the cut metal bar weighed by a high-precision electronic balance 7 is: Zr is 79.461g, Ti is 3.934g, Al is 4.435g, Ni is 14.051g and Cu is 18.726g. The maximum mass error accuracy is within 1%. After calculation, the actual composition of the bulk metallic glass is: Zr 52.737 Ti 4.976 Al 9.952 Ni 14.494 Cu 17.841 , which is very close to the target composition and can better meet the actual needs.

[0084] In order to further verify the purity and accuracy of the prepared metal bars, the metal bars were purged, ultrasonically cleaned and purged again in sequence, and then the dried metal bars were vacuum melted in a vacuum casting machine using induction heating, and then bulk alloy samples were prepared by vacuum casting. Figure 8 As shown) and XRD structural analysis (as Fig. 9As shown in the figure, it is confirmed that the difference between the composition of the prepared alloy and the target composition is within the error range, the oxygen content is low, and the structure is amorphous.

[0085] Table 1. Weight and dimensional parameters of bulk metallic glasses prepared in Examples 1 and 2

[0086]

[0087]

[0088] The above are only several exemplary embodiments of the present invention, and are not intended to limit the present invention in any form. Although the present invention is disclosed as above with preferred embodiments, they are not intended to limit the present invention. Any technician familiar with the profession, without departing from the scope of the technical solution of the present invention, can make some changes or modifications to obtain equivalent or equivalent embodiments using the above disclosed technical content, which belong to the scope of the present invention.

Claims

1. An automated system for preparing a multi-component metal alloy, include: An industrial robot that is used to identify and grab a target piece of metal from a sample library and then install it into a machining device; Machining equipment for surface treatment of installed bulk metal and then cutting to target volume; Weighing equipment, which is used to weigh the cut metal; Mixing and smelting equipment, which is used to melt and mix the weighed metals and then cast them into shape; The automatic control system is used to calculate and output the target volume of each metal required according to the input metal formula, and then control the industrial robot, mechanical processing equipment, weighing equipment and mixed smelting equipment to complete the process of identification, grasping, mechanical processing, weighing, melting and mixing, and casting in sequence.

2. The automation system according to claim 1, in, The automatic control system converts the target weight of each metal according to the total weight of all metals input and the molar ratio between the metals, and then calculates and outputs the target volume of each metal using the density of each metal input.

3. The automation system according to claim 1, in, The automatic control system outputs a target volume for each metal by outputting a target diameter and a target length for each metal.

4. The automation system according to claim 1, in, The industrial robot is a robotic arm; Preferably, the bulk metal is a rod-shaped metal.

5. The automation system according to claim 1, in, The mechanical processing equipment is a Swiss-type CNC machine tool; Preferably, the surface treatment is to remove oxides on the metal surface and process the bulk metal to a target diameter; Preferably, the surface treatment is performed by turning and milling.

6. The automation system according to claim 1, in, The automation system further comprises: Cleaning and drying equipment, which is used to blow, wash and dry the cut metal in sequence; Wherein, the cleaning and drying equipment is controlled by an automatic control system to complete the purging, cleaning and drying processes in sequence.

7. The automation system according to claim 1, in, The mixed smelting equipment is selected from one or more of an arc melting furnace, a vacuum casting furnace and a vacuum suction casting machine.

8. The automation system according to claim 1, in, The automation system further comprises: a data logging system for recording the weight of metal measured by the weighing device; and The background monitoring system is used to compare the weighed metal weight with the metal weight calculated by the automatic control system according to the metal formula. When the deviation between the weighed metal weight and the calculated metal weight exceeds the threshold set by the system, the alarm mechanism is triggered.

9. A method for preparing a multi-component metal alloy using the automated system according to any one of claims 1 to 8, comprising the following steps: (1) Inputting the metal formula into the automatic control system, the automatic control system calculates and outputs the target volume of each metal required; (2) The automatic control system controls the industrial robot to identify and grab the target block metal from the sample library and then install it into the machining equipment; (3) The automatic control system controls the machining equipment to perform surface treatment on the installed bulk metal and then cut it to the target volume; (4) The automatic control system controls the weighing equipment to weigh the cut metal; (5) An automatic control system controls the mixed smelting equipment to sequentially melt, mix and cast the weighed metals to obtain a multi-component metal alloy.

10. The method according to claim 9, in, The method further comprises the following steps after step (3) and before step (4): The automatic control system controls the cleaning and drying equipment to blow, clean and dry the cut metal in sequence; Preferably, the method further comprises the following steps: The data recording system records the metal weight measured by the weighing equipment, and then the background monitoring system compares the weighed metal weight with the metal weight calculated by the automatic control system according to the metal formula. When the deviation between the weighed metal weight and the calculated metal weight exceeds the threshold set by the system, the alarm mechanism is triggered.

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