An electron beam melting electroplating wire integrated composite additive manufacturing device and method

Abstract

The present invention belongs to the field of additive manufacturing and advanced manufacturing technology, and discloses an integrated composite additive manufacturing device and method for electron beam melting and electroplating wires. The integrated composite additive manufacturing device for electron beam melting and electroplating wires includes an electron gun and an electroplating wire supply system; the electron gun is used to ensure the energy density of the electron beam and the precise control of the scanning path; the electroplating wire supply system includes a wire feeding mechanism, a wire guide device, an electroplating chamber, and a current source. These components work together to achieve electroplating processing and precise supply of metal wires. The composite additive device combines the precise heating and melting capabilities of electron beam melting with the diverse material supply characteristics of electroplated metal wires to construct a highly integrated, multi-material compatible, integrated additive manufacturing platform.

Description

Technical Field

[0001] The present invention belongs to the technical field related to additive manufacturing, and more specifically, relates to an electron beam melting and electroplating wire integrated composite additive manufacturing device and method. Background Art

[0002] In the field of additive manufacturing, electron beam fused wire forming technology has become an important technology for the manufacture of high-precision metal parts due to its advantage of using high-energy electron beams to achieve rapid and precise local heating control. The core of this technology is to use solid welding wire or precision-drawn metal wire as raw material, and through the precise control of high-speed electron beams as heat source, directly acting on the surface of the wire, the kinetic energy of the electron beam is efficiently converted into thermal energy, causing the metal wire to melt rapidly locally to form a stable liquid molten pool. As the heat source moves continuously along the preset path, the liquid molten pool cools and solidifies, stacking layer by layer, and ultimately achieving the precise construction of complex three-dimensional metal structures. This technology not only achieves rapid, localized heating and melting of metal wire, but also gives metal parts excellent mechanical properties and structural integrity.

[0003] However, with the rapid development of science and technology and the increasing diversification and complexity of industrial application scenarios, the demand for multi-material composite components with multifunctional characteristics has increased dramatically. Such components require the integration of multiple materials in the same structure to optimize overall performance and meet specific functional requirements. Therefore, the limitations of traditional electron beam fuse manufacturing technology in the supply and combination of multiple materials have gradually become apparent. Specifically, existing electron beam fuse manufacturing devices can only control the supply and melting process of a single or several metal wires, and cannot directly realize the diversified manufacture of more complex multi-material metal parts using multi-material wires.

[0004] To overcome this bottleneck, multi-material composites can be indirectly achieved by pre-processing the metal wires. However, this method not only significantly prolongs the production cycle and increases process complexity, but also comes with a significant increase in energy consumption and a sharp increase in manufacturing costs. Therefore, exploring and developing a new multi-material electron beam fuse forming device that can achieve direct, synchronous supply and precise control of multiple multi-material metal wires has become a key technical issue that needs to be addressed in the current additive manufacturing field. Summary of the Invention

[0005] In response to the above-mentioned defects or improvement needs of the prior art, the present invention provides an electron beam melting and electroplating wire integrated composite additive manufacturing device and method, which solves the technical problem of integrated direct molding of multiple multi-material metal wires, and provides strong support for the application of additive manufacturing technology in the field of multi-material composite component manufacturing.

[0006] To achieve the above-mentioned objectives, according to one aspect of the present invention, an electron beam melting and electroplating wire integrated composite additive manufacturing device is provided, which includes an electron gun 1 and an electroplating wire supply system 2; the electroplating wire supply system 2 is provided with multiple, and the multiple electroplating wire supply systems 2 are evenly distributed with the axis of the electron gun 1 as the center of the circle, and the metal wire 25 is electroplated by the electroplating wire supply system 2 and transported to the bottom of the electron gun 1 for electron beam melting; the electroplating wire supply system 2 includes a wire feeding mechanism, a wire guide device, an electroplating chamber 21 and a current source 27; the wire feeding mechanism is arranged in the electroplating chamber 21, and the side connection end 215 of the electroplating chamber 21 is fixedly connected to the end face 214 of the wire guide device; the current source 27 is arranged below the electroplating chamber to provide power to the electroplating chamber 21.

[0007] Preferably, the wire feeding mechanism includes a wire nut 29, a wire rolling wheel 210, and a wire nut 211. The wire nut 211 is installed at the bottom of the electroplating chamber 21 in a direction perpendicular to the bottom surface of the electroplating chamber 21. The wire nut 29 is fixedly installed on the inner side of the side connection end 215 of the electroplating chamber 21. The wire rolling wheel 210 is installed above the wire nut 211. The metal wire 25 enters the electroplating chamber 21 from the bottom of the electroplating chamber 21 through the wire nut 211, and after the movement direction is changed by the wire rolling wheel 210, it passes through the wire nut 29 and enters the wire guide device.

[0008] Preferably, the wire guide device includes a wire nut three 213, a robotic arm channel 212 and a nozzle 28, wherein the wire nut three 213 is arranged in the robotic arm channel 212, one end of the robotic arm channel 212 is connected to the wire nut one 29, and the other end is connected to the nozzle 28; the metal wire 25 entering the wire guide device is transported to the nozzle 28 at a certain angle and direction through the wire nut three 213 in the robotic arm channel 212.

[0009] Preferably, the electroplating chamber 21 contains electroplating solution, and the thread rolling wheel 210 is located in the electroplating chamber 21 and rotated by a stepping motor to ensure that the metal wire 25 passes through the electroplating solution in the electroplating chamber 21 at a uniform speed.

[0010] Preferably, a platinum rod 22 is installed at the bottom of the electroplating chamber 21 and passes through the electroplating chamber. One end of the wire 1 24 is connected to the platinum rod 22, and the other end is connected to the positive pole of the current source 27. One end of the wire 2 26 is connected to the metal wire 25, and the other end is connected to the negative pole of the current source 27.

[0011] Preferably, a telescopic seat 23 is installed at the bottom of the electroplating chamber 21 , and the height of the electroplating chamber 21 is adjusted by the telescopic seat 23 .

[0012] Preferably, the multiple electroplating wire supply systems 2 select different types of metal wires 25 and electroplating solutions according to usage requirements.

[0013] The diameter of the metal wire 25 ranges from 1 mm to 1.5 mm.

[0014] According to another aspect of the present invention, a method for manufacturing an electron beam melting and electroplating wire integrated composite additive manufacturing device is provided, comprising the following steps:

[0015] S1: Start the electroplating wire supply system 2, adjust the nozzle 28 to a reasonable position and angle, start the stepper motor to drive the rolling wheel 210 to rotate, and the metal wire 25 passes through the wire nut 211, the rolling wheel 210, and the wire nut 1 29 to the nozzle 28. Turn off the stepper motor to stop the rolling wheel 210 from rotating.

[0016] S2: Add plating solution into the plating chamber 21 so that the plating solution covers the metal wire 25. Connect one end of the wire 1 24 to the platinum rod 22 and the other end to the positive electrode of the current source 27. Connect one end of the wire 26 to the metal wire 25 and the other end to the negative electrode of the current source 27.

[0017] S3: Start the current source 27 and start the stepper motor again, so that the metal wire 25 moves at a constant speed in the electroplating solution in the electroplating chamber 21 while being electroplated. When the metal wire 25 passes through the wire nut 29, it has become the multi-material metal wire required for processing.

[0018] S4: When the metal wire 25 that has completed the electroplating process is transported to the nozzle 28 through the wire nut 3 213, the cutting device in the nozzle 28 is activated to remove the unplated portion at the front end of the metal wire 25;

[0019] S5: According to the above steps S1-S4, each electroplating wire supply system is completed to feed the wire simultaneously or in sequence, wherein each electroplating wire supply system can select different types of metal wires according to needs;

[0020] S6: Start the electron gun 1 to emit an electron beam, melt different types of metal wires with specific electron beam process parameters, and complete the preparation and forming of multi-material metal parts.

[0021] Preferably, the electron beam process parameters in S6 include voltage, beam current, focusing current, and forming speed.

[0022] In general, the above technical solutions conceived by the present invention have the following beneficial effects compared with the prior art:

[0023] 1. This invention integrates the electron beam emission and electroplating wire supply systems, achieving a seamless transition from wire electroplating to final electron beam melting and forming. This integrated design not only improves manufacturing efficiency and reduces process complexity, but also enhances process stability and part precision by precisely controlling the interaction between the electron beam and the wire, providing strong support for the manufacture of complex multi-material composite components.

[0024] 2. The present invention introduces electroplating pretreatment technology into the electron beam additive manufacturing device, and directly electroplates the required other metal materials onto the surface of the base wire to form an electroplated wire with composite material properties. This not only enhances the surface quality and corrosion resistance of the wire, but also ensures high-strength bonding and good interface compatibility between materials, providing strong support for the application of additive manufacturing technology in the field of multi-material composite component manufacturing.

[0025] 3. The electroplating wire feed system of the present invention is highly flexible and adjustable. Equipped with multiple electroplating chambers and corresponding wire guides, the system can simultaneously process wires of various different materials, enabling continuous or alternating feeds of multiple materials, depending on manufacturing requirements. Furthermore, the height-adjustable design of the electroplating chambers and the multi-directional configuration of the wire guide nuts enable the system to accommodate wires of varying sizes and shapes, as well as electron beam melting requirements at varying angles, thereby enabling precise control and efficient manufacturing of multi-material composite components. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a three-dimensional structural model diagram of an electron beam melting and electroplating wire integrated composite additive manufacturing device;

[0027] Figure 2 This is a front view of the structural model of the electron beam melting electroplating wire integrated composite additive manufacturing device;

[0028] Figure 3 This is a model diagram of the electroplating wire supply system for an electron beam melting electroplating wire integrated composite additive manufacturing device;

[0029] Figure 4 It is a top view of the structure of the electroplating chamber;

[0030] Figure 5 is a partial cross-sectional view of a wire guide;

[0031] In all the drawings, the same reference numerals are used to represent the same elements or structures, wherein: 1-electron beam emission system; 2-electroplating wire supply system; 21-electroplating chamber; 22-platinum rod; 23-telescopic seat; 24-wire one; 25-metal wire; 26-wire two; 27-current source; 28-nozzle; 29-wire nut one; 210-rolling wheel; 211-wire nut two; 212-robotic arm channel; 213-wire nut three, 214-end face, 215-side connection end. DETAILED DESCRIPTION

[0032] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely for the purpose of explaining the present invention and are not intended to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.

[0033] See also Figure 1-5 The present embodiment is described as an electron beam melting electroplating wire integrated composite additive manufacturing device, which includes an electron gun 1 and an electroplating wire supply system 2; the electroplating wire supply system 2 is provided with three groups, and the three groups of electroplating wire supply systems 2 are evenly distributed with the axis of the electron gun 1 as the center of the circle, and the metal wire 25 is electroplated by the electroplating wire supply system 2 and transported to the bottom of the electron gun 1 for electron beam melting; the electroplating wire supply system 2 includes a wire feeding mechanism, a wire guide device, an electroplating chamber 21 and a current source 27; the wire feeding mechanism is arranged in the electroplating chamber 21, and the side connection end 215 of the electroplating chamber 21 is fixedly connected to the end face 214 of the wire guide device; the current source 27 is arranged below the electroplating chamber to provide power to the electroplating chamber 21.

[0034] The wire feeding mechanism includes a wire nut 29, a wire rolling wheel 210, and a wire nut 211. The wire nut 211 is installed at the bottom of the electroplating chamber 21 in a direction perpendicular to the bottom surface of the electroplating chamber 21. The wire nut 29 is fixedly installed on the inner side of the side connection end 215 of the electroplating chamber 21. The wire rolling wheel 210 is installed above the wire nut 211. The metal wire 25 enters the electroplating chamber 21 from the bottom of the electroplating chamber 21 through the wire nut 211, and after the movement direction is changed by the wire rolling wheel 210, it passes through the wire nut 29 and enters the wire guide device.

[0035] The wire guide device includes a wire nut 3 213, a robotic arm channel 212 and a nozzle 28. The wire nut 3 213 is arranged in the robotic arm channel 212. One end of the robotic arm channel 212 is connected to the wire nut 1 29, and the other end is connected to the nozzle 28. The metal wire 25 entering the wire guide device is transported to the nozzle 28 at a certain angle and direction through the wire nut 3 213 in the robotic arm channel 212.

[0036] The electroplating chamber 21 contains electroplating solution. The wire roller 210 is located in the electroplating chamber 21 and rotated by a stepper motor to ensure that the metal wire 25 passes through the electroplating solution in the electroplating chamber 21 at a uniform speed. A platinum rod 22 is installed at the bottom of the electroplating chamber 21, which runs through the electroplating chamber. One end of the wire 1 24 is connected to the platinum rod 22, and the other end is connected to the positive pole of the current source 27. One end of the wire 2 26 is connected to the metal wire 25, and the other end is connected to the negative pole of the current source 27. A telescopic seat 23 is installed at the bottom of the electroplating chamber 21, and the height of the electroplating chamber 21 is adjusted by the telescopic seat 23. The three sets of electroplating wire supply systems 2 select different types of metal wires 25 and electroplating solutions according to usage requirements. The diameter of the metal wire 25 ranges from 1mm to 1.5mm.

[0037] Example 1

[0038] The present invention provides a method for using an integrated composite additive manufacturing device for forming a single electroplated metal wire, comprising the following steps:

[0039] S1: Start a set of electroplating wire supply systems 2, adjust the nozzle 28 to a reasonable position and angle, start the stepper motor to drive the rolling wheel 210 to rotate, and the metal wire 25 passes through the wire nut 211, the rolling wheel 210, and the wire nut 1 29 to the nozzle 28. Turn off the stepper motor to stop the rolling wheel 210 from rotating.

[0040] S2: Add plating solution into the plating chamber 21 so that the plating solution covers the metal wire 25. Connect one end of the wire 1 24 to the platinum rod 22 and the other end to the positive electrode of the current source 27. Connect one end of the wire 26 to the metal wire 25 and the other end to the negative electrode of the current source 27.

[0041] S3: Start the current source 27 and start the stepper motor again, so that the metal wire 25 moves at a constant speed in the electroplating solution in the electroplating chamber 21 while being electroplated. When the metal wire 25 passes through the wire nut 29, it has become the multi-material metal wire required for processing.

[0042] S4: When the metal wire 25 that has completed the electroplating process is transported to the nozzle 28 through the wire nut 3 213, the cutting device in the nozzle 28 is activated to remove the unplated portion at the front end of the metal wire 25;

[0043] S5: Start the electron gun 1 to emit an electron beam, melt the metal wire with specific electron beam process parameters, and complete the preparation and forming of the multi-material metal part.

[0044] Among them, the metal wire 25 in step S1 is 316 stainless steel wire with a diameter of 1 mm, which is made by a drawing process; in step S2, the electroplating solution added is a CuSO4 solution; in step S3, the wire feeding speed suitable for 316 stainless steel wire is 10 mm / s, ensuring that the 316 stainless steel wire can pass through the electrolyte at a uniform speed to complete the electroplating process, and the parameters of the current source 27 are set to: current of 2 mA, voltage of -5 V; in step S5, the process parameters of the electron beam are set to: voltage of 70 kV, beam current of 30 mA, focusing current of 440 mA, and forming speed of 80 mm / s.

[0045] Example 2

[0046] For three different electroplated metal wires: 316 stainless steel wire, copper wire, and 304 stainless steel wire, all with a diameter of 1 mm, the present invention uses an integrated composite additive manufacturing device formed from the three electroplated metal wires, including the following steps:

[0047] S1: Start the electroplating wire supply system 2, adjust the nozzle 28 to a reasonable position and angle, start the stepper motor to drive the rolling wheel 210 to rotate, and the metal wire 25 passes through the wire nut 211, the rolling wheel 210, and the wire nut 1 29 to the nozzle 28. Turn off the stepper motor to stop the rolling wheel 210 from rotating.

[0048] S2: Add plating solution into the plating chamber 21 so that the plating solution covers the metal wire 25. Connect one end of the wire 1 24 to the platinum rod 22 and the other end to the positive electrode of the current source 27. Connect one end of the wire 26 to the metal wire 25 and the other end to the negative electrode of the current source 27.

[0049] S3: Turn on the current source 27 and start the stepper motor again, causing the metal wire 25 to move at a constant speed in the plating solution in the plating chamber 21 while being electroplated. When the metal wire 25 passes through the wire nut 1 29, it has become the multi-material metal wire required for processing. The parameters of the current source 27 are set to: current 2 mA, voltage -5 V.

[0050] S4: When the metal wire 25 that has completed the electroplating process is transported to the nozzle 28 through the wire nut 3 213, the cutting device in the nozzle 28 is activated to remove the unplated portion at the front end of the metal wire 25;

[0051] S5: According to the above steps S1-S4, the three sets of electroplating wire supply systems are used to feed wires simultaneously or in sequence, wherein the metal wires of the three sets of electroplating wire supply systems are respectively selected as 316 stainless steel wire, copper wire, and 304 stainless steel wire;

[0052] S6: Start the electron gun 1 to emit an electron beam, melt different types of metal wires with specific electron beam process parameters, and complete the preparation and forming of multi-material metal parts.

[0053] The electroplating solution, wire feeding speed and electron beam process parameter settings for different metal wire materials are as follows:

[0054] When the metal wire is 316 stainless steel wire, the electroplating solution is set to CuSO4 solution, the wire feeding speed is 10 mm / s, and the electron beam process parameters are: voltage 70 kV, beam current 30 mA, focusing current 440 mA, and forming speed 80 mm / s;

[0055] When the metal wire is copper wire, the electroplating solution is set to NiSO4 solution, the wire feeding speed is 8 mm / s, and the electron beam process parameters are: voltage 65 kV, beam current 25 mA, focusing current 450 mA, and forming speed 80 mm / s;

[0056] When the metal wire is 304 stainless steel wire, the electroplating solution is set to NiSO4 solution, the wire feeding speed is 8 mm / s, and the process parameters of the electron beam are: voltage 75 kV, beam current 30 mA, focusing current 460 mA, and forming speed 90 mm / s.

[0057] In summary, this embodiment can process metal wires of multiple different materials simultaneously according to manufacturing requirements, realize continuous or alternating supply of multiple materials, and achieve seamless connection from electroplating treatment of multiple metal wires to final electron beam melting forming.

[0058] It will be easily understood by those skilled in the art that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An electron beam melting and electroplating wire integrated composite additive manufacturing device, characterized by: The device comprises an electron gun (1) and an electroplating wire material supply system (2); the electroplating wire material supply system (2) is provided with a plurality of electroplating wire material supply systems (2), and the plurality of electroplating wire material supply systems (2) are evenly distributed with the axis of the electron gun (1) as the center of a circle; a metal wire material (25) is electroplated by the electroplating wire material supply system (2) and transported to the bottom of the electron gun (1) for electron beam melting; the electroplating wire material supply system (2) comprises a wire feeding mechanism, a wire material guide device, an electroplating chamber (21) and a current source (27); the wire feeding mechanism is arranged in the electroplating chamber (21), and the side connection end (215) of the electroplating chamber (21) is fixedly connected to the end face (214) of the wire material guide device; the current source (27) is arranged below the electroplating chamber to provide power for the electroplating chamber (21).

2. The manufacturing device according to claim 1, wherein: The wire feeding mechanism comprises a first wire nut (29), a wire rolling wheel (210), and a second wire nut (211). The second wire nut (211) is installed at the bottom of the electroplating chamber (21) in a direction perpendicular to the bottom surface of the electroplating chamber (21). The first wire nut (29) is fixedly installed on the inner side of the side connection end (215) of the electroplating chamber (21). The wire rolling wheel (210) is installed above the second wire nut (211). The metal wire (25) enters the electroplating chamber (21) from the bottom of the electroplating chamber (21) through the second wire nut (211), and after changing its movement direction by the wire rolling wheel (210), passes through the first wire nut (29) and enters the wire guide device.

3. The manufacturing device according to claim 2, wherein: The wire guide device comprises a wire nut three (213), a robot channel (212) and a nozzle (28), wherein the wire nut three (213) is arranged in the robot channel (212), one end of the robot channel (212) is connected to the wire nut one (29), and the other end is connected to the nozzle (28); the metal wire (25) entering the wire guide device is transported to the nozzle (28) at a certain angle and direction through the wire nut three (213) in the robot channel (212).

4. The manufacturing device according to claim 2, wherein: The electroplating chamber (21) contains electroplating liquid, and the thread rolling wheel (210) is located in the electroplating chamber (21) and is rotated by a stepping motor to ensure that the metal wire (25) passes through the electroplating liquid in the electroplating chamber (21) at a uniform speed.

5. The manufacturing device according to claim 1, wherein: A platinum rod (22) is installed at the bottom of the electroplating chamber (21) and passes through the electroplating chamber. One end of the first wire (24) is connected to the platinum rod (22), and the other end is connected to the positive electrode of the current source (27). One end of the second wire (26) is connected to the metal wire (25), and the other end is connected to the negative electrode of the current source (27).

6. The manufacturing device according to claim 1, wherein: A telescopic seat (23) is installed at the bottom of the electroplating chamber (21), and the height of the electroplating chamber (21) is adjusted by the telescopic seat (23).

7. The manufacturing device according to claim 4, wherein: Multiple electroplating wire material supply systems (2) select different types of metal wire materials (25) and electroplating solutions according to usage requirements.

8. The manufacturing device according to claim 1, wherein: The diameter of the metal wire (25) ranges from 1 mm to 1.5 mm.

9. A method for manufacturing a manufacturing device according to any one of claims 1 to 8, characterized in that: The method comprises the following steps: S1: Start the electroplating wire material supply system (2), adjust the nozzle (28) to a reasonable position and angle, start the stepper motor to drive the rolling wheel (210) to rotate, and the metal wire material (25) passes through the wire nut 2 (211), the rolling wheel (210), and the wire nut 1 (29) to the nozzle (28), and turn off the stepper motor to stop the rolling wheel (210); S2: Add electroplating solution into the electroplating chamber (21) so that the electroplating solution covers the metal wire (25), connect one end of the first wire (24) to the platinum rod (22), and the other end to the positive electrode of the current source (27), and connect one end of the second wire (26) to the metal wire (25) and the other end to the negative electrode of the current source (27); S3: Start the current source (27) switch and start the stepper motor again, so that the metal wire (25) moves at a constant speed in the electroplating solution of the electroplating chamber (21) while being electroplated. When the metal wire (25) passes through the wire nut (29), it has become the multi-material metal wire required for processing; S4: When the metal wire (25) that has completed the electroplating process is transported to the nozzle (28) through the wire nut three (213), the cutting device in the nozzle (28) is activated to remove the unplated portion of the front end of the metal wire (25); S5: According to the above steps S1-S4, each electroplating wire supply system is completed to feed the wire simultaneously or in sequence, wherein each electroplating wire supply system can select different types of metal wires according to needs; S6: Start the electron gun (1) to emit an electron beam, melt different types of metal wires with specific electron beam process parameters, and complete the preparation and forming of multi-material metal parts.

10. A method for manufacturing a manufacturing device according to claim 9, characterized in that: The electron beam process parameters in S6 include voltage, beam current, focusing current, and forming speed.

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