Friction deposition additive manufacturing method for continuous fiber grid reinforced metal matrix composites

Abstract

A method for friction deposition additive manufacturing of continuous fiber mesh reinforced metal matrix composite materials, which relates to a method for friction deposition additive manufacturing of metal matrix composite materials. The present invention is intended to solve the problems of the existing method for manufacturing continuous fiber mesh reinforced metal matrix composite materials, such as the difficulty in manufacturing complex structures, excessive interface reaction, and difficulty in ensuring corrosion resistance. The steps of the present invention specifically include: step 1, continuous fiber mesh surface cleaning; step 2, continuous fiber mesh surface roughening; step 3, additive component slicing; step 4, matrix layer friction deposition forming; step 5, laying continuous fiber mesh; step 6, layer-by-layer stacking additive manufacturing; step 7, additive post-processing. The present invention belongs to the technical field of metal matrix composite materials.

Description

Technical Field

[0001] The invention relates to a friction deposition additive manufacturing method for metal-based composite materials, belonging to the technical field of metal-based composite materials. Background Art

[0002] With the advancement of modern engineering technology, traditional alloy materials are difficult to meet the requirements of reliable use in extreme service environments. For example, in order to meet the complex conditions such as impact and collision faced by wheeled extraterrestrial exploration vehicles when serving on various unknown surfaces without being damaged, their wheels must meet the requirements of high strength, impact resistance, wear resistance, corrosion resistance, etc. It is difficult for traditional materials to meet this series of complex working conditions at the same time. As a new type of composite material system, continuous fiber grid reinforced metal matrix composites will bear most of the external load when subjected to external loads, while the main function of the matrix is ​​to transfer and redistribute the load. The mechanical properties of the composite material will be affected by the properties of the fiber, the properties of the matrix, and the interface bonding strength between the two. In addition, it is also related to the weaving method and direction of the fiber grid. For this type of composite material, its fibers mainly include three types of toughening mechanisms: (1) Fiber bridging: Its essence is a crack tail effect, that is, when the two surfaces near the bridging fiber connect the fiber tip, a force is provided to the crack surface to make the cracks approach each other, which prevents the further expansion of the crack and has a strengthening effect; (2) Crack bending and deflection: When the crack extends to the fiber, the crack extension path is bent and deflected, thereby increasing the total surface area of ​​the crack and the total energy absorbed, which has a toughening effect; (3) Fiber desorption: When the interface between the fiber and the matrix is ​​peeled off under the action of external force, the fiber and the matrix are peeled off at the interface, resulting in fiber debonding, consuming a lot of energy, and further improving the toughness of the composite material. Combining the above three points, continuous fiber grid reinforced metal matrix composites can be said to have breakthrough application potential in the application of high-strength and high-toughness structural materials.

[0003] However, the preparation of this type of material currently faces the following difficulties: (1) Complex structures are difficult to manufacture: Existing continuous fiber grid reinforced metal matrix composites are usually prepared by melt infiltration / pressure infiltration or hot pressing sintering of continuous fiber grid preforms, which means that their structural form is relatively limited and can only produce some simple geometric structures. At the same time, considering the structural characteristics of the continuous fiber grid, machining a complex structure from a simple geometric structure directly faces the problem of destroying the fiber continuity; (2) Interfacial overreaction: The molten matrix material is very likely to undergo metallurgical reaction with the continuous fiber grid at high temperature, generating excessive and thick compounds, such as Fe2Al5, Fe4Al 13、Al4C3 and other brittle or easily hydrolyzed phases, which have a very negative impact on the overall load-bearing performance and corrosion resistance of the composite material; (3) Corrosion resistance is difficult to guarantee: Due to the different materials between the matrix and the fiber, there is inevitably a corrosion potential difference in nature, resulting in poor corrosion resistance. However, due to the high temperature characteristics of traditional manufacturing methods, most corrosion protection measures cannot be applied in the manufacturing process, which makes this poor corrosion resistance difficult to effectively control. In view of the above problems, it can be seen that the essential means to break through the difficult manufacturing dilemma of continuous fiber grid reinforced composite materials lies in avoiding melting and re-solidification forming and realizing additive manufacturing mode. Because, if an additive manufacturing method based on the principle of solid phase deposition can be proposed, it will be expected to achieve a revolutionary breakthrough in the reliable manufacturing of continuous fiber grid reinforced metal matrix composite materials. Summary of the Invention

[0004] The present invention aims to solve the problems of difficult manufacturing of complex structures, excessive interface reaction, and difficulty in ensuring corrosion resistance in existing continuous fiber grid reinforced metal matrix composite material manufacturing methods, and further proposes a friction deposition additive manufacturing method for continuous fiber grid reinforced metal matrix composite materials.

[0005] The technical solution adopted by the present invention to solve the above problems is: the steps of the present invention specifically include:

[0006] Step 1: Cleaning the surface of the continuous fiber mesh: Cleaning the surface of the continuous fiber mesh, including degreasing, pickling and weak etching;

[0007] Step 2: Surface texturing of the continuous fiber mesh: A pulsed electrodeposition process is used to electrochemically texturize the surface of the continuous fiber mesh to create a high-roughness surface structure. A corrosion inhibitor is simultaneously introduced to strengthen the mechanical interlocking effect between the continuous fiber mesh and the matrix, thereby improving the load transfer effect. At the same time, the corrosion inhibitor is introduced to weaken the galvanic corrosion behavior between the continuous fiber mesh and the matrix, thereby improving the overall corrosion resistance of the composite material.

[0008] Step 3: Slicing the additive component: Slice the digital model of the additive component designed using 3D modeling software in the height direction with a slice thickness of 0.5 to 3.0 mm. Cut each layer of continuous fiber mesh using laser cutting or wire EDM according to the slice topography.

[0009] Step 4: Tribo-deposition of the base layer: Deposit a layer of metal base on the substrate or additively manufactured component. The basic device structure used for tribo-deposition includes three parts: a drive component, a set screw, and a restraining ring.

[0010] Step 5: Laying the continuous fiber mesh: Laying the continuous fiber mesh on the surface of the substrate additive manufacturing layer and rolling it flat;

[0011] Step 6: Layer-by-layer additive manufacturing: Repeat steps 4 and 5, and the sum of the thickness of each matrix manufacturing layer and the continuous fiber mesh is equal to the thickness of each layer of the additive component slice in step 3;

[0012] Step 7: Additive post-processing: Remove the additively manufactured component from the substrate by machining and perform fine processing according to the product structure requirements.

[0013] Furthermore, the matrix of the metal matrix composite material is one of aluminum, aluminum alloy, magnesium, magnesium alloy, copper, copper alloy, titanium, and titanium alloy.

[0014] Furthermore, the degreasing step for cleaning the surface of the continuous fiber mesh is to immerse the continuous fiber mesh in a strong alkaline degreasing solution at 70-90° C. for 10-60 minutes, and then rinse it with deionized water. The strong alkaline degreasing solution is 100 g / L NaOH solution.

[0015] Furthermore, the continuous fiber mesh surface is cleaned by pickling and weak etching using a 10% HCl+5% HF mixed solution to remove the surface oxide film and slightly corrode it to expose a fresh metal surface.

[0016] Furthermore, the surface texturing step of the continuous fiber mesh was carried out using 240 g / L CrO3+2.4 g / L H2SO4 (98%)+20.0 g / L Na2MoO4 electrolyte, with the carbon plate as the anode and the continuous fiber mesh as the cathode for electrochemical texturing, with an electrolysis current density of 50~2000 mA / cm 2 , the pulse duty cycle is 0.30~0.75, the electrolyte temperature is 40~90℃, and the duration is 10~120min, so as to prepare a surface roughness layer with high roughness on the surface of the continuous fiber mesh. At the same time, a corrosion inhibitor mainly composed of molybdate is introduced to improve the mechanical interlocking of the interface while weakening the galvanic corrosion effect between the matrix and the continuous fiber mesh, thereby simultaneously improving the mechanical and corrosion resistance of the composite material.

[0017] The beneficial effects of the present invention are:

[0018] 1. This invention proposes a friction deposition additive manufacturing method for continuous fiber grid reinforced metal matrix composites. By adopting the additive manufacturing concept of slicing and stacking layer by layer, it solves the bottleneck of difficult manufacturing of complex structures of continuous fiber grid reinforced metal matrix composites.

[0019] 2. The friction deposition additive manufacturing method used in this invention is a pure solid-phase process, which avoids the problem of excessive interface reaction in fused additive manufacturing. By combining electrochemical texturing and the introduction of corrosion inhibitors, the overall load-bearing performance and corrosion resistance of the composite material are significantly improved;

[0020] 3. The present invention is suitable for high-performance manufacturing of various continuous fiber grid-reinforced metal matrix composite materials, and has a simple structure, low production cost and good feasibility. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 Schematic diagram of a friction deposition additive manufacturing method for continuous fiber grid reinforced metal matrix composite materials according to the present invention;

[0022] Figure 2 is a schematic diagram of a friction deposition additive manufacturing tool according to the present invention;

[0023] Figure 3 It is an isometric view of a continuous fiber grid reinforced metal matrix composite material according to the present invention;

[0024] Figure 4 is a front view of the semi-rigid constraint body in the round bar mode of the present invention;

[0025] Figure 5 is a top view of the semi-rigid constraint in the square bar mode of the present invention;

[0026] Figures 1 to 5 In the figure, 1-continuous fiber grid reinforced metal matrix composite material, 101-matrix, 102-continuous fiber grid, 2-friction deposited rod-shaped raw material, 3-driving component, 301-mounting end, 30101-side fixed plane, 302-clamping end, 30201-clamping inner hole, 30202-setting screw hole, 4-setting screw, 5-constraint ring, 501-inner hole, 502-chamfer. DETAILED DESCRIPTION

[0027] Specific implementation method 1: Figures 1 to 5 As shown, a friction deposition additive manufacturing method for continuous fiber grid reinforced metal matrix composite materials, the specific steps include:

[0028] Step 1: Cleaning the surface of the continuous fiber mesh: Cleaning the surface of the continuous fiber mesh 102 , including but not limited to degreasing, pickling, and weak etching.

[0029] Step 2, surface texturing of the continuous fiber mesh: A pulse electrodeposition process is used to perform electrochemical texturing on the surface of the continuous fiber mesh 102 to create a high-roughness surface structure and simultaneously introduce a corrosion inhibitor to strengthen the mechanical interlocking effect between the continuous fiber mesh 102 and the matrix 101, thereby improving the load transfer effect. At the same time, the galvanic corrosion behavior between the continuous fiber mesh 102 and the matrix 101 is weakened by the introduction of the corrosion inhibitor, thereby improving the overall corrosion resistance of the continuous fiber mesh reinforced metal matrix composite material 1.

[0030] Step 3: Slicing the additive component: Slice the digital model of the additive component designed by the 3D modeling software in the height direction with a slice thickness of 0.5-3.0 mm. Cut each layer of the continuous fiber mesh 102 by laser cutting or wire electric discharge cutting according to the slice shape.

[0031] Step 4: Forming the substrate layer by friction deposition: On a substrate or base 101, the basic structure of the friction deposition apparatus comprises a drive component 3, a set screw 4, and a restraining ring 5. The mounting end 301 is designed to connect to the rotating spindle rotor of machining equipment, including but not limited to friction stir welding machines, CNC milling machines, and CNC machining centers. It features a side-fixed flat surface 30101 for side-fixed clamping. The clamping end 302 has a clamping inner hole 30201 for clamping the friction deposition rod-shaped raw material 2. The inner hole has a diameter 0.05-0.20 mm larger than the friction deposition rod-shaped raw material 2 and is coaxially fixed and clamped by a set screw installed in the set screw hole 30202. The restraining ring 5 is a cylindrical ring structure with an inner hole 501 0.10-1.50 mm larger in diameter than the friction deposition rod-shaped raw material. A chamfer 502 is provided at the upper end of the inner hole 501 to ensure that the friction deposition rod-shaped raw material 2 can easily pass through the inner hole 501 for friction deposition additive manufacturing. This function prevents the end surface of the deposited rod-shaped raw material 2 from thermally plasticizing and curling during the friction deposition process, which can lead to reduced material utilization. The basic method is as follows: the friction deposition rod-shaped raw material 2 is rotated at high speed by a high-speed driving component 3 and passes through the restraining ring 5. Under a certain axial force or downward pressure, it is thermally plasticized and deposited onto the surface of the substrate or additively manufactured component 1, forming a matrix 101. The thickness of the additively manufactured layer can be controlled by the axial force or downward pressure.

[0032] Step 5: Laying the continuous fiber grid: Lay the continuous fiber grid 102 on the surface of the substrate 101 and roll it flat.

[0033] Step 6, Layer-by-Layer Additive Manufacturing: Repeat steps 4 and 5. Note that the combined thickness of the matrix 101 and the continuous fiber mesh 102 should be equal to the thickness of each additive component slice in step 3. During the deposition of each layer of matrix 101, due to the high-speed rotation of the end face of the friction-deposited rod-shaped raw material 2, frictional heat plasticization and large plastic deformation, the matrix in its thermoplasticized solid state infiltrates into the continuous fiber mesh 102, creating a mechanical interlock and metallurgical reaction with the interface of the continuous fiber mesh 102, forming a metallurgical bond.

[0034] Step 7, additive post-processing: remove the continuous fiber grid reinforced metal matrix composite material 1 from the substrate by machining, and perform fine processing according to product structure requirements.

[0035] The substrate 101 includes but is not limited to aluminum and aluminum alloys, magnesium and magnesium alloys, copper and copper alloys, titanium and titanium alloys, and other materials. Preferred materials include 5A06 deformation-strengthened aluminum alloy, AZ31B magnesium alloy, and the like.

[0036] The strength of the material of the continuous fiber mesh 102 should be significantly higher than that of the matrix 101. For example, for an aluminum alloy matrix, TC4 titanium alloy, 2507 duplex stainless steel, tungsten-molybdenum alloy, and the like can be preferably used.

[0037] Specific implementation method 2: Figures 1 to 5 As shown, the matrix of the metal matrix composite material is one of aluminum, aluminum alloy, magnesium, magnesium alloy, copper, copper alloy, titanium, and titanium alloy.

[0038] Specific implementation method three: Figures 1 to 5 As shown, the degreasing step for cleaning the surface of the continuous fiber mesh is to immerse the continuous fiber mesh in a strong alkaline degreasing solution at 70-90°C for 10-60 minutes, and then rinse it with deionized water. The strong alkaline degreasing solution is 100g / L NaOH solution.

[0039] Specific implementation method four: Figures 1 to 5 As shown, the pickling and weak etching steps for cleaning the surface of the continuous fiber mesh use a 10% HCl+5% HF mixed solution to clean and remove the surface oxide film and slightly corrode it to expose a fresh metal surface.

[0040] Specific implementation method five: Figures 1 to 5 As shown in the figure, the surface texturing step of the continuous fiber mesh adopts 240 g / L CrO3+2.4 g / L H2SO4(98%)+20.0 g / L Na2MoO4 electrolyte, with the carbon plate as the anode and the continuous fiber mesh as the cathode for electrochemical texturing, and the electrolysis current density is 50~2000 mA / cm 2 , the pulse duty cycle is 0.30~0.75, the electrolyte temperature is 40~90℃, and the duration is 10~120min, so as to prepare a surface roughness layer with high roughness on the surface of the continuous fiber mesh. At the same time, a corrosion inhibitor mainly composed of molybdate is introduced to improve the mechanical interlocking of the interface while weakening the galvanic corrosion effect between the matrix and the continuous fiber mesh, thereby simultaneously improving the mechanical and corrosion resistance of the composite material.

[0041] The above description is merely a preferred embodiment of the present invention and does not constitute any form of limitation to the present invention. Although the present invention has been disclosed as a preferred embodiment as above, it is not intended to limit the present invention. Any technician familiar with the present profession can make some changes or modifications to equivalent embodiments of equivalent changes using the technical content disclosed above without departing from the scope of the technical solution of the present invention. However, any simple modification, equivalent replacement and improvement of the above embodiments made according to the technical essence of the present invention, within the spirit and principles of the present invention, without departing from the content of the technical solution of the present invention, shall still fall within the scope of protection of the technical solution of the present invention.

Claims

1. A method for friction deposition additive manufacturing of continuous fiber grid reinforced metal matrix composite materials, characterized in that: Specifically include: Step 1: Cleaning the surface of the continuous fiber mesh: Cleaning the surface of the continuous fiber mesh, including degreasing, pickling and weak etching; Step 2: Surface texturing of the continuous fiber mesh: A pulsed electrodeposition process is used to electrochemically texturize the surface of the continuous fiber mesh to create a high-roughness surface structure. A corrosion inhibitor is simultaneously introduced to strengthen the mechanical interlocking effect between the continuous fiber mesh and the matrix, thereby improving the load transfer effect. At the same time, the corrosion inhibitor is introduced to weaken the galvanic corrosion behavior between the continuous fiber mesh and the matrix, thereby improving the overall corrosion resistance of the composite material. Step 3: Slicing the additive component: Slice the digital model of the additive component designed using 3D modeling software in the height direction with a slice thickness of 0.5 to 3.0 mm. Cut each layer of continuous fiber mesh using laser cutting or wire-cutting EDM according to the slice topography. Step 4: Tribo-deposition of the base layer: Deposit a layer of metal base on the substrate or additively manufactured component. The basic device structure used for tribo-deposition includes three parts: a drive component, a set screw, and a restraining ring. Step 5: Laying the continuous fiber mesh: Laying the continuous fiber mesh on the surface of the substrate additive manufacturing layer and rolling it flat; Step 6: Layer-by-layer additive manufacturing: Repeat steps 4 and 5, and the sum of the thickness of each matrix manufacturing layer and the continuous fiber mesh is equal to the thickness of each layer of the additive component slice in step 3; Step 7: Additive post-processing: Remove the additively manufactured component from the substrate by machining and perform fine processing according to the product structure requirements.

2. The friction deposition additive manufacturing method for continuous fiber grid reinforced metal matrix composite materials according to claim 1, characterized in that: The matrix of the metal matrix composite material is one of aluminum, aluminum alloy, magnesium, magnesium alloy, copper, copper alloy, titanium and titanium alloy.

3. The friction deposition additive manufacturing method for continuous fiber grid reinforced metal matrix composite materials according to claim 1, characterized in that: The degreasing step for cleaning the surface of the continuous fiber mesh is to immerse the continuous fiber mesh in a strong alkaline degreasing liquid at 70 to 90° C. for 10 to 60 minutes, and then rinse it with deionized water. The strong alkaline degreasing liquid is 100 g / L NaOH solution.

4. The friction deposition additive manufacturing method for continuous fiber grid reinforced metal matrix composite material according to claim 1, characterized in that: The pickling and weak etching steps for cleaning the surface of the continuous fiber mesh use a 10% HCl+5% HF mixed solution to clean and remove the surface oxide film and slightly corrode it to expose a fresh metal surface.

5. The friction deposition additive manufacturing method for continuous fiber grid reinforced metal matrix composite material according to claim 1, characterized in that: The surface texturing step of the continuous fiber mesh adopts 240g / L CrO3+2.4g / L H2SO4(98%)+20.0g / LNa2MoO4 electrolyte, with the carbon plate as the anode and the continuous fiber mesh as the cathode for electrochemical texturing, and the electrolysis current density is 50~2000mA / cm 2 , a pulse duty cycle of 0.30 to 0.75, an electrolyte temperature of 40 to 90°C, and a duration of 10 to 120 minutes are used to prepare a surface hairy layer with high roughness on the surface of the continuous fiber mesh. At the same time, a corrosion inhibitor mainly composed of molybdate components is introduced to improve the mechanical interlocking of the interface while weakening the galvanic corrosion effect between the matrix and the continuous fiber mesh, thereby simultaneously improving the mechanical and corrosion resistance of the composite material.

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